u.s. des. patent no. d496,248s, d496,249s. other patents ...projected area, or may be perpendicular...

© 2004 by UniRac, Inc. All rights reserved.

Pub 040316-1iiMarch 2004

UniRac welcomes input concerning the accuracy and user friendliness of this publication. Please write to [email protected].

Code-Compliant Planning and Assemblywith California Building Code Certifi cation

Installation Manual 214

ContentsLetter of certifi cation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Part I. Scope, certifi cation, and installer responsibility. . . . . . . . 3

Part II. Procedures for code-compliant installationsusing the SolarMount® Module Mounting System. . . . . . 4

Part III. Installing SolarMount® with top mounting clamps . . . . . 9

Part IV. Installing SolarMount® with bottom mounting clips . . . 15

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

U.S. Des. Patent No. D496,248S, D496,249S. Other patents pending.

Installation Manual 214 SolarMount Code-Compliant Planning and Assembly

Part I. Scope, certifi cation, and installer responsibilityPlease review this manual thor-oughly before installing your SolarMount system.

This manual provides (1) sup-porting documentation for building permit applications relating to UniRac’s Solar-Mount™ Universal PV Module Mounting system, and (2) plan-ning and assembly instructions for SolarMount.

SolarMount products, when installed in accordance with this bulletin, will be structur-ally adequate and will meet the 2001 California Building Code and the Uniform Building Code, 1997, hereafter UBC 1997. UniRac also provides a limited warranty on SolarMount prod-ucts (see p. 20).

The installer is solely responsible for:

• Complying with all applicable local or national building codes, including any that may supercede this manual;

• Ensuring that UniRac and other products are appropri-ate for the particular installation and the installation environment;

• Ensuring that the roof, its rafters, connections, and other structural support members can support the array under building live load conditions (this total assembly is hereafter referred to as the roof rafter assembly);

• Using only UniRac parts and installer-supplied parts as specifi ed by UniRac (substitution of parts may void the warranty and invalidate the letter of certifi cation on page 2);

• Ensuring that lag screws have adequate pullout strength and shear capacities as installed;

• Maintaining the waterproof integrity of the roof, includ-ing selection of appropriate fl ashing; and

• Ensuring safe installation of all electrical aspects of the PV array.


Part II. Procedures for code-compliant installationsusing the SolarMount Module Mounting SystemThis bulletin is designed to support applications for build-ing permits for installations using SolarMount™ PV Module Mounting System, manufactured by UniRac, Inc.

Follow the six steps below and the installation instructions on pages 9 –20 to install SolarMount in com pli ance with the 2001 California Building Code and the UBC 1997.

Before proceeding, note the following:

• This bulletin addresses only wind loads on the assump tion that wind produces the max i mum load factor af fect ing an installation. Verify that other local factors, such as snow loads and earth quake effects, do not ex-ceed the wind loads. Give pre ce dence to any factor that does. Wind loads are considered to act on the entire projected area, or may be perpendicular to any surface.

• The roof on which the SolarMount will be installed must have the capacity to resist the combined Design Dead Load and Live Load per footing listed in Tables 2 and 3 on pages 6 –7.

Figure 1. Minimum Basic Wind Speeds. Reproduced from UBC, Vol. 2, Structural Engineering Design Provisions, Chap. 16, Div. III, Wind Design, Fig. 16.1, “Min i mum Basic Wind Speeds in Miles per Hour,” p. 36. The map has been adopted by the 2001 California Building Code (Fig. 16-1, vol 2. p. 36).

1. Determine the Basic Wind Speedat your in stal la tion site

For the United States, see “Minimum Basic Wind Speeds in Miles per Hour,” reproduced below.

If your installation is outside the United States or if you need further assistance, consult a local professional engineer or your local building authority.


2. Determine the exposure categoryof your in stal la tion site

The California Building Code* defi nes wind exposure catego-ries as follows:

exposure b has terrain with buildings, forests or sur-face irregularities, covering at least 20 percent of the ground level area extending 1 mile (1.61 km) or more from the site.

exposure c has terrain that is fl at and gen er al ly open, extending ½ mile (0.81 km) or more from the site in any quadrant or having scattered obstructions extending one-half mile or more from the site in any full quadrant. This category includes fl at or gently rolling open country and grasslands. Sites normally considered as Exposure B, but which are subject to topographic amplifi cation or channelization, such as ridgetops or draws, shall be considered as Exposure C.†

exposure d represents the most severe exposure in ar-eas with basic wind speeds of 80 miles per hour (mph) (129 km/h) or greater and has terrain that is fl at and un ob struct ed facing large bodies of water over 1 mile (1.61 km) or more in width relative to any quadrant of the building site. Exposure D extends inland from the shoreline ¼ mile (0.40 km) or 10 times the building height, whichever is greater.

3. Determine Design Wind Pressurerequired for your installation

Design Wind Pressure is the amount of wind pressure that a structure is designed to withstand, expressed here in pounds per square foot (psf). To de ter mine the Design Wind Pressure required for your installation, apply the following factors using Table 1:

• your Basic Wind Speed (determined in step 1),

• your exposure category (determined in step 2), and

• the height of your roof above the ground.

If your values fall signifi cantly outside the range of the table, or if your Design Wind Pressure requirement exceeds 50 psf, consult UniRac, a pro fes sion al engineer, or your local building authority.

Table 1. Design Wind Pressure (psf)by Wind Speed and Ex po sure Cat e go ryDesign force applies to surface pressure and/or uplift (withdrawal).

Basic Wind Speed (mph)

70 80 90 100 110 120 130

Category B15' roof height 10 13 17 21 25 30 3520' roof height 11 14 18 22 27 32 3825' roof height 12 15 19 24 29 35 4130' roof height 12 16 21 25 31 36 43

Category C15' roof height 17 23 29 35 43 51 6020' roof height 19 24 31 38 46 54 6425' roof height 19 25 32 40 48 57 6730' roof height 20 26 33 41 50 59 69

Category D15' roof height 23 30 38 46 56 67 7820' roof height 24 31 39 48 58 70 8225' roof height 25 32 41 50 60 72 8430' roof height 25 33 42 51 62 74 87

Source: These Design Wind Pressure (P) values are based on the formula P = Ce * Cq * qs * Iw ( 2001 California Building Code, vol. 2, chap. 16, Structural Engineering Design Provisions, Div. III, Wind Design, p. 38.10). Assump-tions: Iw = 1 and Cq = 1.3.

* 2001 California Building Code, vol. 2, chap. 16, Structural Engineer-ing Design Provisions, Div. III, Wind Design, p. 38.10.

†Emphasis in the original, indicating material inserted by California into defi nitions adopted from the UBC.

4a. De ter mine Minimum Design Dead and Live Loads for standard rafter spacing . . .

Foot spacing refers to the space between L-feet (or stand offs, if applicable) along the same SolarMount rail (see Fig. 2, p. 8). If you are spacing feet to match a standard rafter spacing, con-sult Table 2 to de ter mine your Minimum Design Live and Dead Loads per footing. (If you prefer to maximize foot spacing to minimize roof penetrations, skip to Step 4b on p. 8.)

Locate the make and model of the PV module that you plan to install and the rafter spacing at your installation site. Read the Minimum Design Dead Load and read or extrapolate the Mini-mum Design Live Load for the Maximum Foot Spacing and the Design Wind Pressure you de ter mined in step 3.

To meet code, you must verify that the roof rafter assembly at your installation site has the capacity to resist the sum of the Design Dead and Live Loads.

If they do not, try smaller footer spacing. (In this case, you may elect to use the procedures outlined in Step 4b.) If the result is still not acceptable, relocate the array to a stronger area of the roof or strengthen the inadequate framing elements. For assistance, consult a local pro fes sion al engineer.

Go to step 5 on page 8.


Minimum

Minimum Design Live Load as a

Design Function of Design Wind Pressure

Dead Load 20psf 30 psf 40 psf 50 psf

Minimum

Minimum Design Live Load as a

Design Function of Design Wind Pressure

Dead Load 20 psf 30 psf 40 psf 50 psf

AstroPower AP65, AP7548" rafter (foot) spacing 33 157 236 315 39364" rafter (foot) spacing 43 210 315 420 52472" rafter (foot) spacing 49 236 354 472 590

AstroPower APi110, APi12048" rafter (foot) spacing 33 194 291 387 48464" rafter (foot) spacing 44 258 387 516 64672" rafter (foot) spacing 50 291 436 581 726

AstroPower APi16548" rafter (foot) spacing 31 194 291 387 48464" rafter (foot) spacing 41 258 387 516 64672" rafter (foot) spacing 46 291 436 581 726

BP Solar 375, 380, 580, 58548" rafter (foot) spacing 31 158 237 316 39564" rafter (foot) spacing 41 211 316 421 52772" rafter (foot) spacing 46 237 356 474 593

BP Solar 312548" rafter (foot) spacing 33 198 297 396 49564" rafter (foot) spacing 44 264 396 528 66072" rafter (foot) spacing 50 297 446 594 743

BP Solar 3160, 4150, 4160, 417048" rafter (foot) spacing 33 209 314 418 52364" rafter (foot) spacing 44 279 418 557 69772" rafter (foot) spacing 50 314 470 627 784

Evergreen EC102, EC110, EC11548" rafter (foot) spacing 35 208 312 416 52064" rafter (foot) spacing 46 277 416 555 69372" rafter (foot) spacing 52 312 468 624 780

First Solar FS50D48" rafter (foot) spacing 35 158 236 315 39464" rafter (foot) spacing 47 210 315 420 52572" rafter (foot) spacing 52 236 354 473 591

Kyocera KC8048" rafter (foot) spacing 29 128 192 256 32064" rafter (foot) spacing 39 171 256 341 42772" rafter (foot) spacing 44 192 288 384 480

Kyocera KC120, KC125G48" rafter (foot) spacing 34 187 281 374 46864" rafter (foot) spacing 45 249 374 499 62372" rafter (foot) spacing 51 281 421 561 701

Kyocera KC158G, KC167G48" rafter (foot) spacing 28 169 254 339 42364" rafter (foot) spacing 37 226 339 452 56472" rafter (foot) spacing 42 254 381 508 635

Photowatt PW75048" rafter (foot) spacing 30 162 244 325 40664" rafter (foot) spacing 40 216 325 433 54172" rafter (foot) spacing 45 244 365 487 609



RWE Schott ASE 30048" rafter (foot) spacing 58 248 373 497 62164" rafter (foot) spacing 77 331 497 662 82872" rafter (foot) spacing 87 373 559 745 NA

RWE Schott SAPC165 (See Sharp NE-165U1)

Sanyo HIT19048" rafter (foot) spacing 29 173 260 347 43364" rafter (foot) spacing 39 231 347 462 57872" rafter (foot) spacing 44 260 390 520 650

Sharp NE-80U148" rafter (foot) spacing 33 158 237 315 39464" rafter (foot) spacing 44 210 315 420 52672" rafter (foot) spacing 49 237 355 473 591

Sharp ND-123U148" rafter (foot) spacing 38 197 295 393 49264" rafter (foot) spacing 50 262 393 525 65672" rafter (foot) spacing 56 295 443 590 738

Sharp ND-NOECU (140W)48" rafter (foot) spacing 26 153 230 306 38364" rafter (foot) spacing 34 204 306 408 51072" rafter (foot) spacing 39 230 344 459 574

Sharp NE-165U1, NT-175U1, NT-185U148" rafter (foot) spacing 35 207 310 413 51764" rafter (foot) spacing 47 276 413 551 68972" rafter (foot) spacing 53 310 465 620 775

Sharp ND-167UI48" rafter (foot) spacing 28 174 262 349 43664" rafter (foot) spacing 37 232 349 465 58172" rafter (foot) spacing 41 262 392 523 654

Shell SM11048" rafter (foot) spacing 32 173 259 345 43264" rafter (foot) spacing 43 230 345 460 57672" rafter (foot) spacing 49 259 389 518 648

Shell SQ70, SQ75, SQ8048" rafter (foot) spacing 31 157 236 315 39364" rafter (foot) spacing 41 210 315 420 52472" rafter (foot) spacing 46 236 354 472 590

Shell SQ140, SQ150, SQ16048" rafter (foot) spacing 36 213 320 426 53364" rafter (foot) spacing 48 284 426 568 71072" rafter (foot) spacing 54 320 479 639 NA

SunWize SW85, SW90, SW9548" rafter (foot) spacing 35 190 285 380 47464" rafter (foot) spacing 46 253 380 506 63372" rafter (foot) spacing 52 285 427 569 712

SunWize SW115, SW12048" rafter (foot) spacing 34 190 285 380 47464" rafter (foot) spacing 45 253 380 506 63372" rafter (foot) spacing 51 285 427 569 712

UniSolar 6448" rafter (foot) spacing 25 179 269 359 44864" rafter (foot) spacing 33 239 359 478 59872" rafter (foot) spacing 37 269 403 538 672

Table 2. SolarMount™ Loads (lbs) per Footing at Standard Rafter SpacingsTo meet code, your Design Loads must be at or above those indicated. You, the installer, are solely responsible for verifying that the roof can withstand these design loads. For specifi cations based on Design Wind Pressure values greater than 50 pounts per square foot, contact UniRac.


Table 3. SolarMount™ Loads per Footing at Maximum Foot SpacingTo meet code, your Design Loads must be at or above the Design Wind Pressure indicated. You, the installer, are solely responsible for verifying that the roof can withstand these design loads. For specifi cations based on Design Wind Pressure values greater than 50 pounds per square foot, contact UniRac,

Design Wind Pressure

20 psf 30 psf 40 psf 50 psf

AstroPower AP65, AP75Maximum Foot Spacing (inches) 131 107 93 83Minimum Foot Design Live Load (lbs) 429 526 610 680Minimum Foot Design Dead Load (lbs) 89 73 63 56

AstroPower APi110, APi120Maximum Foot Spacing (inches) 118 96 83 75Minimum Foot Design Live Load (lbs) 476 581 670 757Minimum Foot Design Dead Load (lbs) 82 67 58 52

AstroPower APi165Maximum Foot Spacing (inches) 118 96 83 75Minimum Foot Design Live Load (lbs) 476 581 670 757Minimum Foot Design Dead Load (lbs) 75 61 53 48

BP Solar 375, 380, 580, 585Maximum Foot Spacing (inches) 131 107 92 83Minimum Foot Design Live Load (lbs) 431 528 606 683Minimum Foot Design Dead Load (lbs) 84 68 59 53

BP Solar 3125Maximum Foot Spacing (inches) 117 95 82 74Minimum Foot Design Live Load (lbs) 483 588 677 763Minimum Foot Design Dead Load (lbs) 81 65 56 51

BP Solar 3160, 4150, 4160, 4170Maximum Foot Spacing (inches) 114 93 80 72Minimum Foot Design Live Load (lbs) 496 607 697 784Minimum Foot Design Dead Load (lbs) 79 64 55 50

Evergreen EC102, EC110, EC115Maximum Foot Spacing (inches) 114 93 80 72Minimum Foot Design Live Load (lbs) 494 605 693 780Minimum Foot Design Dead Load (lbs) 82 67 58 52

First Solar FS50DMaximum Foot Spacing (inches) 131 107 92 83Minimum Foot Design Live Load (lbs) 430 527 604 681Minimum Foot Design Dead Load (lbs) 95 78 67 60

Kyocera KC80Maximum Foot Spacing (inches) 145 118 103 92Minimum Foot Design Live Load (lbs) 387 472 549 613Minimum Foot Design Dead Load (lbs) 88 72 63 56

Kyocera KC120, KC125GMaximum Foot Spacing (inches) 120 98 85 76Minimum Foot Design Live Load (lbs) 468 573 662 740Minimum Foot Design Dead Load (lbs) 85 69 60 54

Kyocera KC158G, KC167GMaximum Foot Spacing (inches) 126 103 89 80Minimum Foot Design Live Load (lbs) 445 545 628 706Minimum Foot Design Dead Load (lbs) 73 60 52 46

Photowatt PW750Maximum Foot Spacing (inches) 129 105 91 81Minimum Foot Design Live Load (lbs) 436 533 616 685Minimum Foot Design Dead Load (lbs) 80 65 57 50



RWE Schott ASE 300Maximum Foot Spacing (inches) 104 85 74 66Minimum Foot Design Live Load (lbs) 538 660 766 854Minimum Foot Design Dead Load (lbs) 126 103 89 80

RWE Schott SAPC165 (See Sharp NE-165U1)

Sanyo HIT190Maximum Foot Spacing (inches) 125 102 88 79Minimum Foot Design Live Load (lbs) 451 553 636 713Minimum Foot Design Dead Load (lbs) 76 62 54 48

Sharp NE-80U1Maximum Foot Spacing (inches) 131 107 92 83Minimum Foot Design Live Load (lbs) 430 527 604 682Minimum Foot Design Dead Load (lbs) 90 73 63 57

Sharp ND-123U1Maximum Foot Spacing (inches) 117 96 83 74Minimum Foot Design Live Load (lbs) 480 590 680 758Minimum Foot Design Dead Load (lbs) 92 75 65 58

Sharp ND-NOECU (140W)Maximum Foot Spacing (inches) 133 108 94 84Minimum Foot Design Live Load (lbs) 424 516 599 669Minimum Foot Design Dead Load (lbs) 72 58 51 45

Sharp NE-165U1, NT-175U1, NT-185U1Maximum Foot Spacing (inches) 114 93 81 72Minimum Foot Design Live Load (lbs) 491 601 698 775Minimum Foot Design Dead Load (lbs) 83 68 59 53

Sharp ND-167UIMaximum Foot Spacing (inches) 124 102 88 79Minimum Foot Design Live Load (lbs) 450 556 639 717Minimum Foot Design Dead Load (lbs) 71 58 50 45

Shell SM110Maximum Foot Spacing (inches) 125 102 88 79Minimum Foot Design Live Load (lbs) 450 550 633 710Minimum Foot Design Dead Load (lbs) 84 69 59 53

Shell SQ70, SQ75, SQ80Maximum Foot Spacing (inches) 131 107 93 83Minimum Foot Design Live Load (lbs) 429 526 610 680Minimum Foot Design Dead Load (lbs) 84 69 60 53

Shell SQ140, SQ150, SQ160Maximum Foot Spacing (inches) 112 92 80 71Minimum Foot Design Live Load (lbs) 497 612 710 788Minimum Foot Design Dead Load (lbs) 84 69 60 53

SunWize SW85, SW90, SW95Maximum Foot Spacing (inches) 119 97 84 75Minimum Foot Design Live Load (lbs) 470 575 664 741Minimum Foot Design Dead Load (lbs) 86 70 61 54

SunWize SW115, SW120Maximum Foot Spacing (inches) 119 97 84 75Minimum Foot Design Live Load (lbs) 470 575 664 741Minimum Foot Design Dead Load (lbs) 84 69 59 53

UniSolar 64Maximum Foot Spacing (inches) 123 100 87 78Minimum Foot Design Live Load (lbs) 459 560 650 728Minimum Foot Design Dead Load (lbs) 64 52 45 40

Design Wind Pressure

20 psf 30 psf 40 psf 50 psf


4b. . . . Or verify Maximum FootSpacing and De ter mine Minimum Design Dead and Live Loads

To minimize roof penetrations, consult Table 3 (p. 7) to deter-mine Maximum Foot Spacing allowable for the Design Wind Pressure that you determined in Step 3.

Find the make and model of the PV module you plan to install, then read or extrapolate Foot Design Live Loads and Dead Loads at the maximum spacing.

To meet code, you must verify that foot spacing is at or below the dimension listed and that the roof rafter assembly at your installation site has the capacity to withstand the sum of the Design Dead Load and Design Live Load for the speci-fi ed spacing.

If they do not, try smaller footer spacing. If the result is still not acceptable, relocate the array to a stronger area of the roof or strengthen the inadequate framing elements. For assistance, consult a local pro fes sion al engineer.

5. Verify acceptable Rail End OverhangRail End Overhang (Fig. 2) must equal 50 percent or less of foot spacing. Thus, if foot spacing is 72 inches, the Rail End Over hang can be up to 36 inches. In this case, two feet can support a rail of as much as 144 inches (72 inches between the feet and 36 inches of overhang at each end).

Figure 2. SolarMount foot spacing refers to the distance between feet on the same rail. Over-hang, the distance from end of the rail to the fi rst foot, may be no more than half the foot spacing.

6. Ensure that Live Loads do not exceed Pull-Out Capacities

Based on the characteristics of your roof rafter or truss lumber and the lag screws, consult Table 4 to determine the lag pull-out capacity per 1-inch thread depth. Compare that value to

the minimum design live load per footing determined in Step 4a or 4b. Based on these values, determine the length of the lag-screw thread depth you require to resist the design live load. To ensure code compliance, the lag pull-out capacity per footing must be greater than the footing design live load.

If your SolarMount requires standoffs, always use at least two lag screws to secure the standoff to the rafter.

Table 4. Lag pull-out (withdrawal) capacities (lbs) in typical roof truss lumber

Lag screw specifi cations

Specifi c 5⁄16˝ shaft,* 5⁄16˝ shaft,* 3⁄8˝ shaft,* gravity 2½˝ thread depth per 1˝ thread depth per 1˝ thread depth

Douglas Fir, Larch 0.50 665 266 304

Douglas Fir, South 0.46 588 235 269

Engelmann Spruce, Lodgepole Pine(MSR 1650 f & higher) 0.46 588 235 269

Hem, Fir 0.43 530 212 243

Hem, Fir (North) 0.46 588 235 269

Southern Pine 0.55 768 307 352

Spruce, Pine, Fir 0.42 513 205 235

Spruce, Pine, Fir(E of 2 million psi and highergrades of MSR and MEL) 0.50 665 266 304

Sources: Uniform Building Code; American Wood Council.

Notes: (1) Thread must be embedded in a rafter or other structural roof member. (2) Pull-out values incorporate a 1.6 safety factor recommended by the American Wood Council. (3) See UBC for required edge distances.

*Use fl at washers with lag screws.

Threaddepth

SolarMount

foot spacing Overhang


This section covers SolarMount assembly where the installer has elected to use top mount-ing clamps to secure modules to the rails. It details the procedure for fl ush mounting SolarMount to a pitched roof.

Part III. Installing SolarMount with top mounting clamps

Figure 3. Exploded view of a low-profi le installation mounted fl ush to the roof with L-feet.

ContentsLaying out theinstallation area . . . . . . . . . . 10

Laying out L-feet . . . . . . . . . 11

Installing L-feet . . . . . . . . . . 11

Laying out standoffs . . . . . . 12

Installing standoffs . . . . . . . 12

Installing SolarMountrails . . . . . . . . . . . . . . . . . . . . 13

Installing the modules . . . . . 14

Table 6. Wrenches and torque

Wrench Recommended size torque (ft-lbs)

¼˝ hardware 7⁄16˝ 153⁄ 8˝ hardware 9⁄16˝ 30

Table 5. Part quantities

SMR Series SolarMount Rail Sets (model no. = rail length in inches)

3⁄ 8˝ footing 3⁄ 8˝ fl ange Rails L-feet bolts nuts

SMR48 thru 106 2 4 4 4SMR120 thru 180 2 6 6 6SMR192 thru 216 2 8 8 8

CT Series Clamp Sets (model no. = modules ac com mo dat ed)

End Mid ¼˝ module ¼˝x 5⁄8˝ ¼˝ fl ange clamps clamps clamp bolts safety bolts nuts

CT2 4 2 6 2 8CT3 4 4 8 2 10CT4 4 6 10 2 12CT5 4 8 12 2 14

CT6 4 10 14 2 16CT7 4 12 16 2 18CT8 4 14 18 2 20

Stainless steel hardware can seize up, a process called galling. To sig nifi cant ly reduce its like li hood, (1) apply lubri-

cant to bolts, preferably an anti-seize lu bri cant, available at auto parts stores, (2) shade hardware prior to installation, and (3) avoid spinning on nuts at high speed. See Installation Supplement 910, Galling and Its Prevention, at www.unirac.com.


Laying out the in stal la tion areaThe installation can be laid out with rails parallel to the rafters (high-profi le mode) or per pen dic u lar to the rafters (low-pro-fi le mode). Note that Solar Mount rails make excellent straight edges for doing layouts.

Center the installation area over the rafters as much as pos-sible.

Leave enough room to safely move around the array during installation.

Figure 4. Rails may be placed parallel or perpendicular to rafters.

The width of the installation area is equal to the length of one module.

The length of the installation area is equal to:

• the total width of the mod ules,

• plus 1 inch for each space be tween modules (for mid-clamp),

• plus 3 inches (1½ inches for each set of end clamps).

High-profi lemode

Low-profi lemode


Laying out L-feetL-feet (Fig. 5) are used for installation through existing roofi ng ma te ri al, such as asphalt shingles or sheet metal.

Use Figure 6 or Figure 7 below to locate and mark the L-feet lag bolt holes within the installation area.

To meet code, you must use the foot spacing deter-mined in procedural steps 4a or 4b (pp. 5, 8).

Figure 6. Low-profi le layout

Installing L-feetDrill pilot holes through the roof into the center of the rafter at each L-foot lag bolt hole location.

Consult procedural step 6 and Table 4 (p. 8) to select the lag bolts that you must use to meet building code wind load requirements. Lag bolts are not pro vid ed with SolarMount rail sets.

Squirt sealant into the hole, and on the shafts of the lag bolts. Seal the underside of the L-feet with a suitable weatherproof sealant.

Securely fasten the L-feet to the roof with the lag bolts. Ensure that the L-feet face as shown in Figure 6 or Figure 7. The single-slotted square side of the L-foot must always lie against the roof with the double-slotted side perpendicular to the roof.

Figure 7. High-profi le layout

Figure 5

When determining the distance be-tween the rails in high-profi le mode, keep in mind that the center of each rail will be offset from the L-foot lag bolt holes by 1¾ inches.

If multiple high-profi le rows are to be installed adjacent to one another, it will not be possible for each row to be centered above the rafters. Adjust as needed, following the guidelines in Figure 7 as closely as possible.

1¾"

1¾"

1¾"

Lower roof edge

OverhangFoot spacing

Rafters

25% typicaleach end

50% typical

25% maximum typical each end 50% minimum typical

Lower roof edge Overhang

Rafters

Footspacing


Laying out standoffsStandoffs (Fig. 8) are used for fl ashed installations, such as those with tile and shake shingles.

Use Figure 9 or Figure 10 to locate and mark the standoff lag bolt holes within the installation area.

To meet code, you must use the foot spacing determined in procedural steps 4a or 4b (pp. 5, 8).

Remove the tile or shake underneath each standoff location, exposing the roofi ng underlayment. Ensure that the standoff base lies fl at on the underlayment, but remove no more material than required for the fl ashings to be installed properly.

Use the standoff base as a template to mark lag bolt hole locations on underlayment above the center of the rafters (Fig. 9 or Fig. 10).

When determining the distance be-tween the rails in high-profi le mode, keep in mind that the center of each rail will be offset from the standoff lag bolt holes by 7⁄16 of an inch.

If multiple high-profi le rows are to be installed adjacent to each other, it will not be possible for each row to be centered above the rafters. Adjust as needed following the guidelines in Figure 10 as closely as possible.

Installing standoffsDrill 3/16 -inch pilot holes through the underlayment into the center of the rafters at each standoff location. Securely fasten each standoff to the rafters with the two 5/16" x 3 1/2" lag bolts provided with it.

Note: You must verify that the lag bolts you use are adequate for your installation by following proce-dural steps 4A or 4B (pp. 5, 8).

Ensure that the standoffs face as shown in Figure 9 or Figure 10.

SolarMount steel standoffs (15/8" O.D.) are designed for collared fl ashings available from UniRac. Aluminum two-piece standoffs (11/8" O.D.) take all-metal fl ash-ings, also available from UniRac.

Install and seal fl ashings and standoffs using standard building practices.

Figure 8. Raised fl ange standoff (left) and fl at top standoff used in con-junction with an L-foot.

Figure 10. High-profi le layout

Figure 9. Low-profi le layout

OverhangFoot spacing 25% typical

each end

50% minimum typical

RaftersLower roof edge

13/4"

Overhang

Footspacing

25% typicaleach end

50% minimum typical

Rafters

Lower roof edge

7/16"

7/16"


Installing SolarMount railsKeep rail slots free of roofi ng grit or other debris. Foreign matter will cause bolts to bind as they slide in the slots.

Installing Splices. If your installation uses SolarMount splice bars, attach the rails together (Fig. 11) before mounting the rails to the foot-ings. Use splice bars only with fl ush installations or those that use low-profi le tilt legs.

If using more than one splice per rail, contact UniRac concerning thermal expansion issues.

Mounting Rails on Footings. Rails may be attached to either of two mounting holes in the footings (Fig. 12). Mount in the lower hole for a low profi le, more aesthetically pleasing in stal -la tion. Mount in the upper hole for a higher profi le, which will maximize airfl ow under the modules. This will cool them more and may enhance performance in hotter climates.

Slide the 3⁄8-inch mounting bolts into the footing bolt slots. Loosely attach the rails to the footings with the fl ange nuts.

Ensure that the rails are oriented to the footings as shown in Figure 6, 7, 9, or 10, whichever is appropriate.

Aligning the Rail Ends. Align one pair of rail ends to the edge of the in stal -la tion area (Fig. 13 or Fig. 14).

The opposite pair of rail ends will overhang the side of the installation area. Do not trim them off until the installation is complete.

In low-profi le mode (Fig. 13), either end of the rails can be aligned, but the fi rst module must be installed at thealigned end.

For the safest high-profi le installation (Fig. 14), the aligned end of the rails must face the lower edge of the roof. Securely tighten the fl ange nuts on the mounting bolts after align ment is complete (28–32 ft lbs).

Mount modules to the rails as soon as possible. Temperature changes may bow the rails within a few hours if module placement is delayed.

Figure 11. Splice bars slide into the footing bolt slots of SolarMount rail sections.

Figure 12. Foot-to-rail splice attachment

Figure 13. Low-profi le mode Figure 14. High-profi le mode

Edge of installation area Edge of installation area

Clampingbolt slot

Footingbolt slot

Mountingslots


Installing the modulesPrewiring Modules. If modules are the Plug and Play type, no prewiring is required, and you can proceed directly to “Installing the First Module” below.

If modules have standard J-boxes, each module should be prewired with one end of the intermodule cable for ease of installation. For safety reasons, module prewiring should not be per formed on the roof.

Leave covers off J-boxes. They will be installed when the modules are installed on the rails.

Installing the First Module. In high-profi le installations, the safety bolt and fl ange nut must be fastened to the module bolt slot at the aligned (lower) end of each rail. It will prevent the lower end clamps and clamping bolts from sliding out of the rail slot during installation.

If there is a return cable to the inverter, connect it to the fi rst module. Close the J-box cover. Secure the fi rst module with T-bolts and end clamps at the aligned end of each rail. Allow half an inch between the rail ends and the end clamps (Fig. 15). Finger tighten fl ange nuts, center and align the module as needed, and securely tighten the fl ange nuts (15 ft lbs).

Installing the Other Modules. Lay the second module face down (glass to glass) on the fi rst module. Connect intermodule cable to the second module and close the J-box cover. Turn the second module face up (Fig. 16). With T-bolts, mid clamps, and fl ange nuts, secure the adjacent sides of the fi rst and second modules. Align the second module and securely tighten the fl ange nuts (Fig. 17).

For a neat installation, fasten cable clamps to rails with self-tapping screws.

Repeat the procedure until all modules are installed. Attach the outside edge of the last module to the rail with end clamps.

Trim off any excess rail, being careful not to cut into the roof. Allow half an inch between the end clamp and the end of the rail (Fig. 15).

Check that all fl ange nuts on T-bolts are securely fastened.

Figure 18. Mid clamps and end clamps for lipped-frame modules are identical. A spacer for the end clamp is necessary only if lips are located high on the module frame.

Figure 15

Figure 16

Figure 17

High-lipped module

(cross section)Low-lipped module

(cross section)

SolarMount rail SolarMount rail

Spacer

J-boxes

½" minimumModuleframe

RailEnd clamp

¼" module boltand flange nut

Rail

Module frames

Mid clamp

¼" module boltand flange nut


Part IV. Installing SolarMount with bottom mounting clips

Figure 19. SMR and CB components

This section covers SolarMount assembly where the installer has elected to use bottom mounting clips to secure modules to the rails. It de-tails the procedure for fl ush mount-ing SolarMount to a pitched roof.

ContentsPlanning the installation area. . . . 16

Laying out and installing L-feet . . 17

Attaching modules to the rails . . . 18

Installing module-rail assembly . . 19

Table 8. Wrenches and torque

Wrench Recommended size torque (ft-lbs)

¼˝ hardware 7⁄16˝ 153⁄8˝ hardware 9⁄16˝ 30

Table 7. Part quantities

SMR Series SolarMount Rail Sets (model no. = rail length in inches)

3⁄8˝ footing 3⁄8˝ fl ange Rails L-feet bolts nuts

SMR48 thru 106 2 4 4 4SMR120 thru 180 2 6 6 6SMR192 thru 216 2 8 8 8

CB Series Clip Sets (model no. = modules ac com mo dat ed)

¼˝ module ¼˝ fl ange Clips bolts nuts

CB2 8 8 8CB3 12 12 12CB4 16 16 16CB5 20 20 20

CB6 24 24 24CB7 28 28 28CB8 32 32 32

Stainless steel hardware can seize up, a process called galling. To sig nifi cant ly reduce its like li hood, (1) apply lubri-

cant to bolts, preferably an anti-seize lu bri cant, available at auto parts stores, (2) shade hardware prior to installation, and (3) avoid spinning on nuts at high speed. See Installation Supplement 910, Galling and Its Prevention, at www.unirac.com.


Planning the installation areaDecide on an arrangement for clips, rails, and L-feet (Fig. 20).

Use Arrangement A if the full width of the rails contact the module. Oth er wise use Ar range ment B. Caution: If you choose Ar range ment B, either(1) use the upper mounting holes of the L-feet or(2) be certain that the L-feet and clip positions don’t confl ict.

If rails must be parallel to the rafters, it is unlikely that they can be spaced to match rafters. In that case, add structural supports—either sleepers over the roof or mounting blocks beneath it. These additional members must meet code; if in doubt, consult a pro-fessional engineer.

Never secure the footings to the roof decking alone. Such an arrangement will not meet code and leaves the installation and the roof itself vulnerable to severe damage from wind. Secure the footings in accordance with “Installing L-feet” (p. 11).

Leave enough room to safely move around the array during installation. The width of a rail-module as-sembly equals the length of one module. Note that L-feet may extend beyond the width of the assembly by as much as 2 inches on each side. The length of the assembly equals the total width of the modules.

Figure 20. Clip Arrangements A and B


Figure 21. Rails laid out per pen dic u lar to the rafters.

Laying out and installing L-feetL-feet are used for installation through existing low profi le roofi ng material, such as asphalt shingles or sheet metal. They are also used for most ground mount installations. To ensure that the L-feet will be easily accessible during fl ush installation:

• Use the PV module mount ing holes nearest the ends of the mod ules.

• Situate the rails so that foot-ing bolt slots face outward.

Use Figure 20 to determine spacing between feet on opposite rails.

Foot spacing (along the same rail) and rail overhang depend on design wind loads.

To meet code, you must use the foot spacing determined in procedural steps 4a or 4b (pp. 5, 8).

Install half the L-feet:

• If rails are perpendicular to rafters (Fig. 21), install the feet closest to the lower edge of the roof.

• If rails are parallel to rafters (Fig 22), install the feet for one of the rails, but not both.

For the L-feet being installed now, drill pilot holes through the roof into the center of the rafter at each lag bolt hole location. Consult Table 4 (p. 8) to select lag bolts to meet design wind loads.

Squirt sealant into the hole and onto the shafts of the lag bolts. Seal the underside of the L-feet with a weath-erproof sealant. Securely fasten the L-feet to the roof with the lag bolts. Ensure that the L-feet face as shown in Figure 21 or Figure 22.

Hold the rest of the L-feet and fasten-ers aside until the panels are com-plete and ready for installation.

Figure 22. Rails laid out parallel to the rafters.


Attaching modules to the railsLay the modules for a given panel face down on a surface that will not damage the module glass. Align the edges of the modules and snug them together (Fig. 19, p. 15).

Trim the rails to the total width of the modules to be mounted. Place a rail adjacent to the outer mounting holes. Orient the footing bolt slot outward. Place a clip slot adjacent to the mounting holes, following the arrangement you selected earlier (Fig. 20a or 20b, p. 16).

Assemble the clips, mounting bolts, and fl ange nuts. Torque the fl ange nuts to 15 foot-pounds.

Wire the modules as needed. For safety reasons, module wiring should not be performed on a roof. For a neat installation, fasten cable clamps to rails with self-tapping screws.


Installing the module-rail assemblyBring the module-rail assembly to the installation site. Keep rail slots free of debris that might cause bolts to bind in the slots.

Consider the weight of a fully assembled panel. UniRac rec om -mends safety lines whenever lifting one to a roof.

Align the panel with the previously installed L-feet. Slide 3⁄8-inch L-foot mounting bolts onto the rail and align them with the L-feet mounting holes. Attach the panel to the L-feet and fi nger tighten the fl ange nuts.

Rails may be attached to either of two mounting holes in the footings (Fig. 23).

Figure 23. Leg-to-rail at tach ment

• Mount in the lower hole for a low, more aes thet i cal ly pleasing installation.

• Or mount in the upper hole to maximize a cooling airfl ow under the modules. This may enhance perfor-mance in hotter climates.

Adjust the position of the panel as needed to fi t the in stal -la tion area. Slide the remaining L-feet bolts onto the other rail, attach L-feet, and fi nger tighten with fl ange nuts. Align L-feet with mount ing holes pre vi ous ly drilled into roof. Install lag bolts into remaining L-feet as described in “Laying out and installing L-feet” above.

Torque all footing fl ange nuts to 30 foot-pounds. Verify that all lag bolts are securely fastened.


UniRac, Inc.www.unirac.com

1411 Broadway NEAlbuquerque NM 87102-1545 USA

505.242.6411505.242.6412 Fax

Page

20

10 year limited Product Warranty, 5 year limited Finish WarrantyUniRac, Inc., warrants to the original purchaser (“Purchaser”) of product(s) that it manufactures (“Product”) at the original installation site that the Product shall be free from defects in material and workmanship for a period of ten (10) years, except for the anodized fi nish, which fi nish shall be free from visible peeling, or cracking or chalking under normal atmospheric conditions for a period of fi ve (5) years, from the earlier of 1) the date the installation of the Product is completed, or 2) 30 days after the purchase of the Product by the original Purchaser (“Finish Warranty”).

The Finish Warranty does not apply to any foreign residue deposited on the fi nish. All installations in corrosive atmospheric conditions are excluded. The Finish Warranty is VOID if

the practices specifi ed by AAMA 609 & 610-02 – “Cleaning and Maintenance for Architecturally Finished Aluminum” (www.aamanet.org) are not followed by Purchaser. This Warranty does not cover damage to the Product that occurs during its shipment, storage, or installation.

This Warranty shall be VOID if installation of the Product is not performed in accordance with UniRac’s written installation instructions, or if the Product has been modifi ed, repaired, or reworked in a manner not previously authorized by UniRac IN WRITING, or if the Product is installed in an environment for which it was not designed. UniRac shall not be liable for consequential, contingent or incidental damages arising out of the use of the Product by Purchaser under any circumstances.

If within the specifi ed Warranty periods the Product shall be reasonably proven to be defective, then UniRac shall repair or replace the defective Product, or any part thereof, in UniRac’s sole discretion. Such repair or replacement shall completely satisfy and discharge all of UniRac’s liability with respect to this limited Warranty. Under no circumstances shall UniRac be liable for special, indirect or consequential damages arising out of or related to use by Purchaser of the Product.

Manufacturers of related items, such as PV modules and fl ashings, may provide written warranties of their own. UniRac’s limited Warranty covers only its Product, and not any related items.

u.s. des. patent no. d496,248s, d496,249s. other patents ...projected area, or may be perpendicular...

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