UNIRAC SolarMount User manual

© 2005 by UniRac, Inc.
All rights reserved.
Pub 050304-1ii
March 2005
UniRac welcomes input concerning the accuracy and user friendliness of
this publication. Please write to [email protected].
U.S. Des. Patent No. D496,248S. Other patents pending.
This manual details the
procedure for flush mounting
SolarMount to a pitched roof.
If your installation includes tilt
legs, see also the instructions
shipped with the leg kit.
Contents
Installer reponsibility . . . . . . 2
Laying out the
installation area . . . . . . . . . . . 2
Laying out L-feet . . . . . . . . . . 3
Installing L-feet . . . . . . . . . . . 3
Laying out standoffs . . . . . . . 4
Installing standoffs . . . . . . . . 4
Installing SolarMount
rails . . . . . . . . . . . . . . . . . . . . . 5
Installing the modules . . . . . 6
Wrenches and torque
Wrench Recommended
size torque (ft-lbs)
¼˝ hardware 7⁄16˝ 15
3⁄8˝ hardware 9⁄16˝ 30
Figure 3. Exploded view of a low-profile installation
mounted flush to the roof with L-feet.
Mid
clamp
End
clamp
T-bolt slot
for module
mounting
Footing
bolt slot
L-foot
Part quantities
SolarMount®Rail Sets
No. of 3⁄8˝ footing 3⁄8˝ flange
Rail length (inches) rails L-feet bolts nuts
48 – 106 2 4 4 4
120 – 180 2 6 6 6
192 – 216 2 8 8 8
226 – 288 (w/ splice) 2 10 10 10
300 – 336 (w/ splice) 2 12 12 12
348 – 408 (w/ splice) 2 14 14 14
420 – 432 (w/ splice) 2 16 16 16
Top Mounting Clamp Sets, Sizes A –F, G*, H†, and J
Modules End Mid ¼˝ module ¼˝x 5⁄8˝ ¼˝ flange
per row clamps clamps T-bolts safety bolts nuts
2 4 2 6 2 8
3 4 4 8 2 10
4 4 6 10 2 12
5 4 8 12 2 14
6 4 10 14 2 16
7 4 12 16 2 18
8 4 14 18 2 20
9 4 16 20 2 22
10 4 18 22 2 24
11 4 20 24 2 26
12 4 22 26 2 28
* In size G, end clamps and mid clamps are identical, except that end clamps
include spacers. For illustration, see page 14.
† In size H, end clamps and mid clamps are identical. Hexhead bolts replace
T-bolts. For illustration, see page 14.
Stainless steel hardware can seize up, a
process called galling.To significantly re-
duce its likelihood, (1) apply lubricant to
bolts, preferably an anti-seize lubricant, 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.
Installation with Top Mounting Clamps
Installation Manual 201.1

Page
2
Installation Manual 201.1 SolarMount®Top Mounting
10 year limited Product Warranty, 5 year limited Finish Warranty
UniRac, 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 finish, which finish
shall be free from visible peeling, or cracking or
chalking under normal atmospheric conditions
for a period of five (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 finish. All
installations in corrosive atmospheric conditions
are excluded.The Finish Warranty isVOID if
the practices specified 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 modified, 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 specified 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 flashings, may provide written
warranties of their own. UniRac’s limited
Warranty covers only its Product, and not any
related items.
Installer responsibility
Figure 4. Rails may be placed parallel or perpendicular to rafters.
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 ap-
propriate for the particular installation and the
installation environment;
• Ensuring that the roof, its rafters, connections,
and other structural support members can sup-
port the array under building live load conditions.
• Using only UniRac parts and installer-supplied
parts as specified by UniRac (substitution of parts
may void the warranty);
• Ensuring that lag screws have adequate pullout
strength and shear capacities as installed;
• Maintaining the waterproof integrity of the roof,
including selection of appropriate flashing; and
• Ensuring safe installation of all electrical aspects of
the PV array.
High-profile
mode
Low-profile
mode
Lower roof edge
Laying out
the installation area
The installation can be laid out with rails
parallel to the rafters (high-profile mode)
or perpendicular to the rafters (low-profile
mode). Note that SolarMount rails make ex-
cellent straight edges for doing layouts. Center
the installation area over the rafters as much
as possible.
Leave enough room to safely move around the
array during installation.
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 modules,
• plus 1 inch for each space between
modules (for mid-clamp),
• plus 3 inches (1½ inches for each set
of end clamps).

Page
3
Installation Manual 201.1 SolarMount®Top Mounting
Laying out L-feet
L-feet (Fig. 5) are used for installation through existing
roofing material, 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.
Consult UniRac’s SolarMount Code-Compliant
Planning and Assembly to determine foot spacing
that will meet code. Download the version for
Figure 6. Low-profile layout
Installing L-feet
Drill 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) in SolarMount Code Compliant
Planning and Assembly to select the lag bolts that meet building code wind load
requirements. Lag bolts are not provided with SolarMount rail sets.
Apply 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-profile layout
Figure 5
the applicable building code at
www.unirac.com.
In low-profile layouts, stagger feet on
rafters (Fig. 7) to distribute the load.
If multiple high-profile 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.
Overhang
Rafters
1
3/4″
1
3/4″
50% typical
25% typical
each end
Foot
spacing
Overhang
Lower roof edge
Rafters
1
3/4″
Foot
spacing 25% typical
each end
50% typical
Lower roof edge
1
3/4″
Overhang
Stagger feet on rafters

Page
4
Installation Manual 201.1 SolarMount®Top Mounting
Laying out standoffs
Standoffs (Fig. 8) are used for flashed 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.
Consult UniRac’s SolarMount Code-Compliant Planning
and Assembly to determine foot spacing that will meet code.
Download the version for the applicable building code at
www.unirac.com.
Remove the tile or shake underneath each standoff location, exposing
the roofing underlayment. Ensure that the standoff base lies flat on
the underlayment, but remove no more material than required for the
flashings 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).
In low-profile layouts, stagger standoffs on rafters (Fig. 9) to distrib-
ute the load.
When determining the distance between the rails in high-profile
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-profile 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 standoffs
Drill 3/16 -inch pilot holes
through the underlayment into
the center of the rafters at each
standoff location. Securely fas-
ten each standoff to the rafters
with the two 5/16" x 3 1/2" lag
bolts provided with it.
Verify that the lag bolts you use
are adequate for your installa-
tion by following procedural
steps 4A or 4B (pp. 5, 8) in
SolarMount Code-Compliant
Planning and Assembly.
If you are using raised-flange
standoffs, ensure that they face
as shown in Figure 9 or Figure
10. Steel flattop standoffs
should also be lagged at oppo-
site corners.
SolarMount steel standoffs are
designed for installation with
collared flashings available from
UniRac. Aluminum flashings
take all metal flashings, also
available from UniRac.
Install and seal flashings and
standoffs using standard build-
ing practices.
Figure 8. SolarMount standoff choices: alumi-
num 2-piece (left), steel flat-top (center), and
steel raised flange. Two-piece standoffs allow
flashings to be precisely placed over bases pri-
or to installation of the standoff itself. Raised
flange standoffs do not require L-feet.
Figure 9. Low-profile layout
Figure 10. High-profile layout
Overhang Foot
spacing
Stagger standoffs on rafters
25% typical each end
50% typical
Lower roof edge
1
3/4″
7/16″
50% typical
25% typical
each end
Foot
spacing
Overhang
Lower roof edge
Rafters
7/16″

Page
5
Installation Manual 201.1 SolarMount®Top Mounting
Installing SolarMount rails
Keep rail slots free of roofing 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 flush installations
or those that use low-profile tilt legs.
If using more than one splice per rail, con-
tact UniRac concerning thermal expan-
sion 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 profile, more aesthetically pleasing instal-
lation. Mount in the upper hole for a higher
profile, which will maximize airflow 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 flange 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 instal-
lation 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-profile mode (Fig.
13), either end of the
rails can be aligned, but
the first module must be
installed at the
aligned end.
For the safest high-profile installation (Fig. 14), the aligned end of the rails must
face the lower edge of the roof. Securely tighten the flange nuts on the mounting
bolts after alignment 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-profile mode Figure 14. High-profile mode
Clamping
bolt slot
Footing
bolt slot
Mounting
slots
Edge of installation area Edge of installation area

UniRac, Inc.
www.unirac.com
3201 University Boulevard SE, Suite 110
Albuquerque NM 87106-5635 USA
505.242.6411
505.242.6412 Fax
Page
6
Installation Manual 201.1 SolarMount®Top Mounting
Installing the modules
Prewiring 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 performed 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-profile installations, the safety bolt and
flange 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 first module. Close the
J-box cover. Secure the first 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 flange nuts, center and align the module as needed, and
securely tighten the flange nuts (15 ft lbs).
Installing the Other Modules. Lay the second module face down (glass to
glass) on the first 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 flange nuts, secure the adjacent sides of the first and second
modules. Align the second module and securely tighten the flange 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 flange nuts on T-bolts are securely fastened.
Figure 18. Size G clamps (for modules with high lips)
include a spacer for the end clamps but are otherwise
identical. Size H mid clamps and end clamps (for mod-
Figure 15
Figure 16
Figure 17
High-lipped module
(cross section)
SolarMount rail with Size H clamps
Low-lipped module
(cross section)
SolarMount rail with G clamps and spacer
Spacer
ules with low lips) are identical and employ hexhead
bolts in place of T-bolts; their heads slide into Solar-
Mount®rails.
1/2" minimum
1/4" module bolt
and flange nut
Rail
End clamp
Module
frame
J-boxes
Module frames
1/4" module bolt
and flange nut
Mid clamp