QRail System ® QClick Technology ® Rail Mounting System RESPECT THE ROOF Installation Manual
Table of Contents 1. Introduction...1 1.1 Short Description...1 1.2 About this Manual...1 1.3 Warnings...1 1.4 Ratings...3 2. Technical Description...4 2.1 System Overview...4 2.2 QRail Components...5 2.3 Technical Data...6 2.4 System Electrical Bonding...7 2.5 System Electrical Grounding...11 3. Important Mounting Information...13 3.1 Conditions of Use...13 3.2 Mounting Preparations...13 3.3 Mounting Aids and Required Tools...14 3.4 Fastener Torque Settings...14 4. Planning the Module Area...15 5.
1. Introduction 1.1 Short Description The QRail PV mounting system is a strong, versatile system for mounting PV modules on low and steep-sloped roofs. The system consists of aluminum module support rails and includes all necessary components in order to attach the rails to each other, to attach the rails to the roof attachment, and to attach the modules to the rails; it also includes other various accessories, such as module level power electronic (MLPE) attachments and a skirt system.
Installation Personnel The QRail system and these instructions are intended for use by qualified personnel. Qualified personnel are those who have skills, knowledge, and training in the installation of photovoltaic mounting systems necessary to follow these instructions in order to safely use the required tools and to carry out the required procedures. Intended Use The QRail system is intended for use only as a mounting system for photovoltaic panels and certain associated hardware and components.
1.4 Ratings ANSI / UL 2703 Conforms to STD UL 2703 (2015) Standard for Safety First Edition: Mounting Systems, Mounting Devices, Clamping/ Retention Devices, and Ground Lugs for Use with FlatPlate Photovoltaic Modules and Panels. • Maximum size of modules: 25.6 ft². • Maximum system voltage is 1500 VDC • Maximum Fuse Rating: 40A • Module orientation: Portrait and landscape.
2. Technical Description 2.1 System Overview The following is an overview of the major QRail system components as shown in Image 2.1.1. Note that the actual configuration of each individual system can vary depending on: • Type of roof (substructure and roofing) • Type of module • Number of modules and configuration • Local conditions b e c a d Image 2.1.1 a Roof attachment b QRail c Mid clamp d End clamp e Internal QSplice (not visible) BI 7.2.
2.
2.3 Technical Data Application Low and steep slope roofs Roofing type Suitable for most types of roofing Roof slope Up to - 45°1 (up to 12:12) Building height Up to 60 ft / 18.
2.4 System Electrical Bonding The QRail system, when properly assembled and installed, provides an integrated electrical bonding path, ensuring that all exposed metal parts and the PV module frames are electrically connected. The QRail employs a number of features to ensure reliable electrical connectivity. Bonding and Fault Path Images 2.4.1 and 2.4.2 show the available current path(s) in the QRail system for standard (2 or more rails per row of modules) and shared rail configurations, respectively.
Bonding with QClick Technology® As shown in Image 2.4.4 and 2.4.5, the QRail Clamps with QClick Technology and rails are designed with sharp hooks. When the clamp is installed in the rail and the bolt is tightened, the bolt forces the hooks into the rail.
Rail Bonding with Internal QSplice All QRails can be spliced into longer units by means of the QRail Internal QSplice (Image 2.4.11). The bonding splice joins the two rail segments mechanically and electrically for the Standard and Light rails. The Internal QSplice has a bonding plate that pierces any paint or aluminum oxide layer on the rails. This forms an electrical bond from rail-to-rail through the bonding plate.
Roof Attachment Bonding The QRail is attached to the roof by roof attachments. Image 2.4.12-1 T-bolt The connection from the attachment device to the rail is made via a stainless steel T-bolt and a stainless steel, serrated flange nut (Image 2.4.12-1 and 2.4.122). When secured to the rail [192 in-lbs (22 N-m)], the T-bolt crushes and pierces the aluminum oxide or paint and forms an electrical bond with the rail.
2.5 System Electrical Grounding Array Grounding Lug The QRail system is listed to UL 2703 with the QMR-GLQ-A-50 Grounding Lug as the means to connect the QRail array to the Equipment Grounding Conductor (EGC). It is the system installer’s responsibility to determine the appropriate wire size for grounding the array.
QMR-GLQ-A-50 Grounding Lug Installation The QMR-GLQ-A-50 Grounding Lug is preassembled with a M8-T-bolt, serrated flange nut, and a wire capture bolt. The lug can be installed in the top or side channel of the QRail rail in any orientation. AWG Wire Size QMR-GLQ-A-50 Capacity 12 - 6 1 wire 10 2 wires 12 2 wires • Insert T-head bolt head into the rail’s top or side channel. Be sure Table 2.5.
3. Important Installation Information 3.1 Conditions of Use The QRail on-roof system is available with different rail and roof attachment types designed in accordance to and/or compliance with the following codes and standards¹: • IBC/IRC 2018 • IBC/IRC 2015 • IBC/IRC 2012 • ICC-AC428 2012 • ASCE 7-05 • ASCE 7-10 • ASCE 7-16 • CBC/CRC 2016 • CBC/CRC 2019 • ANSI/ UL 2703 Ed. 1 • FBC/FRC 2017 • Aluminum Design Manual 2010, 2015 • SEAOC PV2 - 2012, 2017 ¹Check code-compliance letters for applicable approvals.
3.3 Mounting Aids and Required Tools In addition to standard hand tools, you will need the following tools: • 1/2" or 13mm socket / 1/2" or 13mm box or open-end wrench • Drill driver • Torque wrench (0-200 in-lbs.) • Reciprocating saw and/or band saw • Chalk line • Tape measure • 5 mm Allen key / 5 mm Allen key power driver (for fixed end clamps only) Please adhere to the mounting steps listed and be sure to follow the safety instructions. DO NOT use an impact gun.
4. Planning the Module Area For installation, the QRails are fastened to the building structure with roof attachments (e.g. flashed roof attachments). The roof attachments must be mounted at defined distances, depending on the spacing of the supporting structure, the position on the roof, and the site conditions. The design should be verified using QRail Code Compliance letters or site-specific engineering.
5. Installation of Roof Attachments and QRails The roof attachments are attached to the roof structure and support the QRails. The permissible distance between the roof attachments depends on several factors and must be calculated specifically for each project. Roof attachments are available for a wide variety of roof types. In many cases, additional items may be required to accomplish flashing or other weather sealing. Suitable products are available from a number of sources.
5.2 QRail Preparation The QRail internal QSplices are used to join two rail sections to provide a single rail section of a desired length. Internal QSplice Installation • The internal QSplice is a floating splice, no attachments necessary. • To join any rail using the Internal QSplice, join the rail sections by sliding the splice into the end of the rail until the bonding plate tabs come into contact with the end of the rail.
Thermal Break In cases where a thermal break is necessary it is recommended to use the splices in conjunction with the Wiley WEEBBNDJMP8.0 to insure continuous bonding across the thermal break. Internal Splice: Images 5.2.11 3/4" thermal break with Internal QSplice • Install the internal splice with a 3/4" gap between the rails. • After installing the rails install the WEEB-BNDJMP8.0 across the gap with T-bolts.
5.3 QRail Installation on Roof-top Installation of the QRail system on most roof-types requires that any penetrations of the roof system be flashed in accordance with the appropriate local codes and roofing best practices. Installing Standard Rail Configuration • After determining the location of the array on the roof, mark the rail locations with chalk lines or other suitable method. • Determine the rafter locations and mark them on the E-W chalk lines.
Installing Shared QRail Configuration Optional gauge fabrication: • Fabricate an installation jig shown in image 5.3.3 Rail Spacing = module - 13/16 in Image 5.3.3 Shared rail distance gauge Array Installation: • After determining the location of the array on the roof, mark the location of the lower rail with a chalk line or other suitable method. • Determine the rafter locations and mark them on the E-W chalk lines.
• At this point, it is recommended to install the rail at the opposite side of the array and level it at both ends with respect to the first rail. That is, if the lower-most rail was installed first, the uppermost rail should be installed second and leveled N-S with the first rail and E-W. • Stretch strings from each corner of the upper and lower rails. • Position the next rail and attach it as described above, leveling it both E-W and N-S using the strings installed above as reference.
6. Module Installation 6.1 Module Level Power Electronic Installation If module level power electronics (MLPE) are to be used with the array and mounted on the rails, they should be installed prior to installing the PV modules. There are two methods for attaching these components, either the Rail / MLPE Attachment or the Rail/ Low Mount MLPE Attachment. The two options should be selected by the installer based on site conditions, panel clearance, and system configuration.
6.2 Installing Clamps w/ QClick Technology® Quick Mount PV’s patented QClick Technology is a special clip with which the module clamps are fastened in the QRail. You need only a 1/2" or 13mm socket for the installation. The QClick is inserted from above into the top channel of the QRail. Installation Steps: • Insert the QClick at a slight angle into the rail channel. • While holding it firmly in place, rock the QClick upright until it clicks into place.m (Do not squeeze the QClick.
6.3 Installing the End Modules The end modules of the PV system are fastened on the outer side with two module end clamps each. Three types of module end clamps are available from Quick Mount PV. Fixed end clamps are sized to fit a particular module thickness and will not work on modules of other thicknesses. Hidden End Clamps (P/N QMR-HEC-A-20) will work on almost all modules with a flange in the acceptable clamping zone. Universal end clamps are designed to fit 2 ranges of module thicknesses.
Mounting Steps, Hidden End Clamps: • After installation of rails and prior to installation of the modules slide the Hidden End Clamp into both sides approximately 4 inches from the end of the rail. See Image 6.3.4 • Install first module insuring the module frame is flush with the end of the rails. See Image 6.3.5 • Slide Hidden End Clamp over until it fully engages with the module flange. See Image 6.3.6 • Tighten Hidden End Clamp bolt to 9 ft-lbs (12 N-m). See Image 6.3.
6.4 Installing the Inner Modules Inner modules of the array are secured with mid clamps. All mid clamps are provided with integral bonding. Mid clamps are designed to fit modules within a particular range. Mid clamps are available in either mill or black finish in the following size ranges: Part Number Finish Clamping Range (mm) QMR-UMC3045BP1.2 A 20 mill 30-45 QMR-UMC3045-B-20 black 30-45 Table 6.4.1 Mounting steps: • Insert the QClick of the mid clamp into the QClick channel of the rail.
6.5 Installing Additional Module Rows Mounting steps: • Additional module rows are by repeating steps in sections 6.1-6.4. NOTE! Use of a spare module clamp QClick or other item as a spacing gauge between the top of one row of modules and the bottom of another can help provide a neat, aesthetically pleasing array. Image 6.4.1 Inner module installation step 1 Material damage due to incorrect mounting Incorrectly fastened modules can fall and become damaged.
7. Maintenance When properly assembled, the QRail is a reliable and trouble-free system and should require little in the way of ongoing maintenance or repair. Nevertheless, Quick Mount PV recommends maintaining a regular inspection and maintenance schedule. Such a program can detect and address potential problems before they become serious and help ensure the system’s excellent long-term durability and reliability. The following procedure pertains only to the QRail mounting system structure.
8. List of UL Tested and/or Evaluated PV Modules The Qrail system may be used to ground and/or mount UL1703 or UL 61730 listed PV module only when the specific module has been evaluated for grounding and/or mounting under UL 2703 and in compliance with the included instructions. Unless otherwise noted, “xxx” refers to the module power rating and both black and silver frames are included in the certification.
Manufacturer BYD Canadian Solar CertainTeed CSUN Dehui Ecosolargy ET Solar Flex GCL GigaWatt Solar BI 7.2.
Manufacturer Hansol Hanwha Solar Hanwha Q CELLS Heliene HT-SAAE Hyundai Itek JA Solar BI 7.2.
Manufacturer Jinko Kyocera LG Longi Mission Solar Mitsubishi Motech Next Energy Alliance Neo Solar Power Panasonic (HIT) BI 7.2.
Manufacturer Panasonic (EverVolt) Peimar Philadelphia Solar Phono Solar Recom REC Solar Renesola Renogy Risen S-Energy SEG Solar BI 7.2.
Manufacturer Seraphim USA Sharp Silfab Solaria Solarcity (Tesla) SolarTech SolarWorld AG SolarWorld Americas Sonali Stion SunEdison BI 7.2.
Manufacturer Suniva Sunpower Sunspark Suntech Talesun Tesla Trina URE Vikram BI 7.2.
VSUN Waaree Winaico Yingli ZN Shine BI 7.2.
RESPECT THE ROOF 925-478-8269 | 2700 Mitchell Dr. | Walnut Creek, CA 94598 www.quickmountpv.com | tech@quickmountpv.com Conforms to UL STD 2703 BI 7.2.3-46 ©2020 by Quick Mount PV. All rights reserved.
