FLUSH MOUNT INSTALLATION MANUAL INSTALLATION MANUAL © 2022 IRONRIDGE, INC. VERSION 3.
Contents DISCLAIMER 1 RATINGS 2 MARKINGS 2 ATTACHMENTS 3 COMPONENTS 4 1. ATTACH BASES 5 2. PLACE RAILS 5 3. SECURE LUGS 6 4.
RATINGS UL 2703 LISTED #5003807 Conforms to STD UL 2703 Standard for Safety First Edition: Mounting Systems, Mounting Devices, Clamping/ Retention Devices, and Ground Lugs for Use with Flat-Plate Photovoltaic Modules and Panels • Max Overcurrent Protective Device (OCPD) Rating: 40A • Max Module Size: 30.
ATTACHMENTS PRE-INSTALLATION ATTACHMENTS ☐ Verify module compatibility. See Page 21 for info.
COMPONENTS COMPONENTS PRE-INSTALLATION ☐ Verify module compatibility. See Page 21 for info.
1. PLACE ATTACHMENTS The general installation method for attachments is to locate a rafter, drill a pilot hole and install the attachment. For composition roof attachments installation instructions refer to page 10. For tile roof attachments refer to page 12. For low slope roof attachments refer to page 14. When using approved third party attachments, refer to manufacturer's install instructions.
3. SECURE LUGS Grounding Lugs Rail Grounding Lug Only one Grounding Lug (Rail or Module) required per continuous subarray, regardless of subarray size (Unless frameless modules are used, see Page 20). Terminal Screw (20 in-lbs) ➢ Grounding Lugs are intended to for use with one solid or stranded copper wire, conductor size 10-4 AWG. Rail Grounding Lug Insert T-bolt in Top Rail slot and torque Hex Nut to 80 in-lbs. Install a minimum 10 AWG solid copper or stranded grounding wire.
CAMO A. SLIDE INTO RAIL Slide CAMO into rail channel far enough to clear the module frame. CAMO requires 6" of clearance from end of rail. A 6" Cle ara B. PLACE MODULE Place module on rails (module cells not shown for clarity). When installing CAMO the module can overhang the rail no more than 1/4". B nc e C. PULL TOWARDS END Pull CAMO towards rail ends, at 45 degree angle, so the bonding bolt contacts the module flange edge. C D.
8 EXPANSION JOINTS 7 6 5 4 3 2 F Expansion Joints are required every 100' of continuous rail to allow for thermal expansion and contraction of the system. ➢ Do not install modules over expansion joint. E BOSS Insert BOSS into first Rail up to the Alignment Circle, Slide second Rail over BOSS to the second Alignment Circle, D leaving a 1" gap between the Rails.
End Caps (Optional) ELECTRICAL DIAGRAM UFO or UFO or CAMO CAMO Rail Grounding Lug* * Grounding Lug Module Grounding Lug* Bonded Splice (Rail Connection) Fault Current Ground Path Minimum 10 AWG * Copper Wire 8" Bonding Jumper (Alternative row to row bond)** *One Module Grounding Lug or Rail Grounding lug is required per row of a system. ** The use of the 8" Bonding Jumper eliminates the need for row to row bonding. A minimum of one grounding lug per continuous array is required for earth ground.
COMPOSITION SHINGLE FLASHFOOT2 Locate roof rafters and mark locations on roof. Drill 1/4" pilot holes perpendicular to the roof and back fill with roofing manufacturers' approved sealant. Slide flashing between 1st and 2nd course of shingles, ensuring both that the flashing reaches under the 3rd shingle course and doesn't overhang the downhill shingle course. Line up with pilot hole and insert supplied lag bolt with washer through flashing. With a 7/16" Socket fully seat lag bolt.
COMPOSITION SHINGLE QM L-MOUNT Locate roof rafters and mark locations on roof. Drill 7/32”(Lag) or 1/8"(ST) pilot holes perpendicular to the roof and back fill with roofing manufacturers' approved sealant. Slide flashing between 1st and 2nd course of shingles, ensuring both that the flashing reaches under the 3rd shingle course and doesn't overhang the downhill shingle course. Place L-foot on flute and rotate into desired position. Prepare lag bolt or structural screw with sealing washer.
TILE KNOCKOUT TILE Remove tile and mark rafter. Use base as guide to drill 1/4” pilot hole and fill with roofing manufacturer’s approved sealant. Install optional Roof Flashing and seal appropriately. Insert lag bolt with bonded washer through base (and flashing if used) and drive until fully seated. Insert Tile Replacement Flashing, lower onto base and apply pressure over the threaded post until it dimples the flashing.
TILE ALL TILE HOOK Remove tile and mark rafter. Position base over rafter, adjust arm if necessary and torque hardware to 132 in-lbs (11 ft-lbs). Use base as guide to drill 1/4" pilot holes, back fill with roofing manufacturer’s approved sealant, then insert lag bolts and tighten until fully seated. Replace tiles and notch as necessary to ensure proper fit. Attach rails to either side of slot using Bonding Hardware and torque to 250 in-lbs (21-ft-lbs).
TILE QM QBASE UNIVERSAL TILE MOUNT Remove tile and mark rafter. Measure up 6 5/8" from bottom of tiles and mark horizontally. Align QBase over rafter center and drill two 7/32" pilot holes, back fill with roofing manufacturers' approved sealant. Place grade-8 Cap Screw under QBase, lag QBase into rafter location. Install Sub-flashing, waterproof at underlayment level according to roofing manufacturers' instructions and the Tile Roofing Industry Alliance guidelines.
LOW SLOPE ROOFS FLAT ROOF ATTACHMENT Flat Roof Attachment can be used with an L-foot for flush mounting modules on low sloped roofs. Mark locations for Flat Roof Attachment. Screws should be installed symmetrically to each other. If using a membrane flashing, remove the silicone washer's protective liner prior to attaching the membrane. Attach L-foot with washers and 3/8” hardware torqued to 250 in-lbs (21 ft-lbs). Seal attachment and/or membrane per roofing manufacturer’s requirements.
CONDUIT End CapsPENETRATION (Optional) FLASHINGS QM CONDUIT PENETRATION FLASHING - COMP SHINGLE Mark a drill point so that the flashing reaches up to the 3rd shingle course. Drill your conduit hole next to the rafter so you can secure the conduit below the roof surface. Cut shingle and remove nails as needed to center the drilled hole and flashing hole. Apply roofing manufacturer's approved sealant on the underside of the flashing in a Upside down U and to top of flashing.
CONDUIT MOUNT QM CONDUIT MOUNT - COMPOSITION SHINGLE Place conduit mounts along path of conduit. Lift shingle above mount location and insert flashing into position. Mark center for drilling, remove flashing and drill pilot hole with 1/8" bit. Clean area, fill hole with roofing manufacturer's approved sealant. Lift shingle and slide Conduit Mount into place. Prepare the lag bolt with sealing washer and pipe clamp (not included).
END CAPS WIRE CLIPS Wire Clips offer a simple wire management solution. Press Clip into Slot Snap Clip Closed Firmly press Wire Clip into top rail slot. Run electrical wire through open clip. Snap closed once all wires have been placed. Ru nW ire JAYBOX A. Prior to installation, use step drill bit to place pass through holes for conduits or water-tight connectors. Drill bit starter locations are provided on the sides and front of enclosure. ➢ Do not install conduit facing up roof. B (Rail).
MICROINVERTER KITS Use IronRidge's Microinverter Kit to bond compatible microinverters and power optimizers to the racking system. Insert Microinverter Kit T-bolt into top rail slot. Place compatible microinverter or power optimizer into position and tighten hex nut to 80 in-lbs.
SYSTEMS USING MICROSTORAGE PRODUCTS PHAZR Use IronRidge's Microinverter Kit to bond compatible microstroage devices to the racking system. Insert Microinverter Kit T-bolt into top rail slot. Place compatible microstorage into position and tighten hex nut to 80 in-lbs. COMPATIBLE PRODUCTS Microinverter Kit (80 in-lbs) PHAZR PHAZR Devices PHAZR-X, where X is 6-12.
CONTOUR Install Contour A. Install Contour on a completed array. 12.00 Clamping Zones 12.00 A. Start by placing Contour Clamp on module frame within 12 inches of the down roof corner of the array. Each piece of 84" Contour Trim must be suppported by two Clamps. Clamps must be installed in the 12" clamping zones at edge of trim. Once trim is placed and in position, secure trim by tightening Clamp set screw to 80 in-lbs. B. Multiple Contour pieces can be joined using Contour Splice.
MODULE COMPATIBILITY The Flush Mount System may be used to ground and/or mount a PV module complying with UL 2703 only when the specific module has been evaluated for grounding and/or mounting 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.
MODULE COMPATIBILITY Ecosolargy Ecosolargy modules with 35 and 40 mm frames ECOxxxYzzA-bbD Where “Y” can be A, H, S, or T; “zz” can be 125 or 156; “A” can be M or P; “bb” can be 60 or 72; and “D” can be blank or B ET Solar ET Solar modules with 30, 35 and 40 mm frames ET-YZZZxxxAA Where "Y" can be P, L, or M; "ZZZ" can be 660, 660BH, 672, 672BH, 754BH, 766BH, 772BH; and "AA" can be GL, TB, TW, WB, WW, BB, WBG, WWG, WBAC, WBCO, WWCO, WWBCO or BBAC Flex Flex modules with 35 and 40 mm frames FXS-xxxYY-ZZ;
MODULE COMPATIBILITY JA Solar JA Solar modules with 30, 35 and 40 mm frames JAyyzz-bbww-xxx/aa Where “yy” can be M, P, M6 or P6; “zz” can be blank, (K), (L), (R), (V), (BK), (FA), (TG), (FA)(R), (L)(BK), (L) (TG), (R)(BK), (R)(TG), (V)(BK), (BK)(TG), or (L)(BK)(TG); “bb” can be 48, 54, 60, 66, 72 or 78; "ww" can be D09, D10, D20, D30, S01, S02, S03, S06, S09, S10, S12, S17, S20, S30 or S31; and “aa” can be BP, MB, MR, SI, SC, PR, 3BB, 4BB, 4BB/RE, 5BB Jinko Jinko modules with 35 and 40 mm frames JKMYxxx
MODULE COMPATIBILITY Philadelphia Solar Philadelphia modules with 35 and 40 mm frames PS-YzzAA-xxx Where "Y" can be M or P; "zz" can be 60, 72 or 144; and "AA" can be blank, (BF), (HC) or (HCBF) Phono Solar Phono Solar modules with 35 and 40 mm frames PSxxxY-ZZ/A Where "Y" can be M, M1, MH, M1H, M4, M4H or P; "ZZ" can be 20 or 24; and "A" can be F, T, U, UH, or TH Prism Solar Prism Solar modules with 35mm frames PST-xxxW-M72Y Where "Y" can be H, HB or HBI Recom Recom modules with 35 and 40 mm frames
Module Compatibility SolarWorld AG SolarWorld Sunmodule Plus, Protect, Bisun, XL, Bisun XL, may be followed by mono, poly, duo, black, bk, or clear; modules with 31 and 33 mm frames SW-xxx SolarWorld Americas SolarWorld Sunmodule Plus, Protect, Bisun, XL, Bisun XL, may be followed by mono, poly, duo, black, bk, or clear; modules with 33 mm frames SWA-xxx Sonali Sonali Modules with 35 and 40 mm frames SS-M-xxx Where "M" can be blank or M Stion Stion Thin film modules with 35 mm frames STO-xxx or STO-x
Module Compatibility Waaree Waaree modules with 40 mm frames WSyy-xxx where “yy” can be blank, M, or MB Winaico Winaico modules with 35 and 40 mm frames Wsy-xxxZa Where "y" can be either P or T; "Z" can be either M, P, or MX; and "a" can be blank or 6 Yingli Yingli modules with 35 and 40 mm frames YLxxxZ-yy Where "Z" can be D or P; "yy" can be 29b, 30b, 34d, 35b, 36b or 40d ZN Shine ZN Shine modules with 35 mm frames ZXMY-AAA-xxx/M Where "Y" can be 6 or 7, "AAA" can be 72, NH120, NH144, NHDB144, NHLD
