UNIRAC GRIDFLEX Rail-Based Flat Roof System Installation Guide

INSTALLATION GUIDE

UNIRAC Code-Compliant Installation Manual
© 2021 by Unirac, Inc. All rights reserved.
Document No. PUB19JAN2022

UNIRAC welcomes input concerning the accuracy and user-friendliness of this publication. Please write to publications@unirac.com.

TOOLS & SPECIFICATIONS

TECHNICAL SPECIFICATIONS:
Material Types: A380 cast aluminum and mill finish extruded aluminum (6005A-T61 or 6061-T6), G180 steel, Galvalume, PC/ASA Hardware: Stainless steel
Bonding and Grounding: UL2703 Listed Continuous Bonding Path

TOOLS REQUIRED OR RECOMMEND FOR LAYOUT, ATTACHMENTS,
AND INSTALLATION:

•  Drill (Do Not Use an Impact Driver)
• 1/2” Socket
• Torque Wrench
•  Tape Measure
• Chalk Reel
• Optional Spacers

All applicable OSHA safety guidelines should be observed when working on a PV installation job site. The installation and handling of PV solar modules, electrical installation and PV racking systems involves handling components with potentially sharp metal edges. Rules regarding the use of gloves and other personal protective equipment should be observed.

SYSTEM COMPONENTS

SOUTH RAIL:
The rail is made of Galvalume steel, preassembled with 5/16” SS Riv-Hex nuts. Module width scale is marked on rail, for overlap alignment.

MID RAIL:
The rail is made of Galvalume, pre-assembled with 5/16” Riv-Hex nuts, SS. This rail is bulged at one end for overlapping rail connection.

Two module width scales each corresponding 8” and 11” row spacing are printed on rail, so that rails are overlapped to achieve accurate module width.
NORTH RAIL:
The rail is made of Galvalume, pre-assembled with 5/16” Riv-Hex nut, SS. This rail is bulged at one end for overlapping rail connection.

BALLAST TRAY:
Ballast Trays made of G180 galvanized steel hold standard ballast blocks. Multiple lengths are available to accommodate different module lengths.

BALLAT TRAY NOTE:
Ballast tray can fit up to 4 standard 4”x8”x16” solid concrete cap blocks. See “Complete Ballast Placement” page of this document for more information. Block weight can range from 26 – 38lbs. The weight of the block will have a major impact on how many will be required for the project so be sure to verify your block weights before using the U-builder online tool.
SOUTH CLAMP: The south stanchion assembly is made of a mill finish Aluminum and engages the return flange underneath the panel to secure and electrically bond the module. This unique design attaches to the return flange and outside of the module frame creating a universal connection.

NORTH CLAMP: The north stanchion assembly is made of a mill finish Aluminum and engages the return flange underneath the panel to secure the module. This unique design takes advantage of the design of the module frame, attaching to the return flange of the frame creating a universal connection.

WIND DEFLECTORS: Wind deflectors are made of G180. Multiple lengths are available to accommodate different module lengths
IMPORTANT : WIND DEFLECTORS ARE REQUIRED ON NORTH EDGES OF ARRAYS TO MAINTAIN CLASS A FIRE RATING.

ROOF PAD: The Roof Pad provides a protective interface between the Rails and roofing material to protect the roof membrane.

HARDWARE:
1. 5/16-18″ X 1.25″ Hex Head Bolt
2a. 5/16” Flat Washer 0.75” OD
2b. 5/16” Flat Washer, 1” OD, .125 thk.

SNAP ROOF PAD ON TO RAILS

INSTALL ROOF PADS ON RAILS
Roof Pads snap onto Rails. Install a Roof Pad under every North Stanchion location and under every South Stanchion located at a south edge of an array. Ensure the stanchion bolt above each roof pad goes into the protruding boss in the roof pad.

ROOF PAD PROVISION FOR GRAVEL AND MINERAL CAP SHEET ROOFS
Systems installed on gravel or MCS roofs require Santoprene stickers be added to the Roof Pads. 2 for gravel and 4 for MCS as shown below.

LOCATE ARRAY & CONNECT RAILS

MARK ROOF WHERE ARRAY WILL START : Use chalk line to mark distances from roof edge as called out in construction documents.

LOCATE ARRAY ON ROOF: Align South Rails with previous chalk lines. Rail Spacing center to center = Module Length + .25”. East and west side rails may be tucked in, under the module.

ATTACH SOUTH RAIL TO MID RAIL: Overlap Mid-Rails on top of South Rails, use the measurement scale printed on the rail to determine the overlap length. Match the value on scale to the module width. Insert hex bolt with 1″ OD washer into riv-nut FOR HARDWARE CALL OUTS REFER TO PAGE 3 TORQUE VALUE – 10 FT-LBS

ATTACH MID-RAIL TO MID-RAIL/ MIDRAIL TO NORTH-RAIL :
Overlap next Rail bulge on top of Rail laid on roof, use the measurement scale (8” or 11” row spacing) printed on the rail to determine the overlap length. Match the value on scale to the module width. Insert hex bolt into riv-nut through a 1″ OD washer TORQUE VALUE – 10 FT-LBS

LAY BALLAST TRAY: With rails spaced apart the module length + .25”, align the slots in the Ballast Tray with the holes on the Base Rail. Secure the Ballast Tray south direction with a hex head bolt with 0.75″ OD washer and screw in the riv-nut FOR  HARDWARE CALL OUTS REFER TO PAGE 3 TORQUE VALUE – 10 FT-LBS

IMPORTANT:
TO MEET THE SYSTEM’S MECHANICAL DESIGN LOAD RATINGS, THE MAXIMUM CANTILEVER FROM THE EDGE OF A MODULE TO THE CENTER OF A TUCKED STANCHION CLAMP IS 8″

CLAMPS & MODULE CONNECTION

ATTACH NORTH STANCHION: Insert the front tab of the North Stanchion into the slot of the base rail and together. Secure with a hex head bolt with .75″ OD washer through the rear hole into the riv-nut FOR HARDWARE CALL OUTS REFER TO PAGE 3
TORQUE VALUE – 10 FT-LBS

ATTACH SOUTH STANCHION: Depending on the row to row spacing (8in or 11in), place the south stanchion over the hole provided on the base rail and secure with a hex head bolt with .75″ OD washer in to the riv-nut. FOR HARDWARE CALL OUTS REFER TO PAGE 3 TORQUE VALUE – 10 FT-LBS

LAY BALLAST BLOCKS: Lay ballast blocks into ballast trays. Quantity of blocks to be placed should be as per appropriate engineering and U-Builder.

MODULE CONNECTION, STEP 1 : Rotate the keeper perpendicular to saddle and pull it completely towards the hex bolt.

MODULE CONNECTION, STEP 2 : Now keep the south clamp at 75 deg, and place one end of module into the clamp.

MODULE CONNECTION, STEP 3 : Now rotate the keeper towards the module and tighten the hexagonal bolt such that the keeper touches the wall of vertical return flange.

ADDITIONAL BALLAST TRAY

HIGHER BALLAST REQUIREMENT: An additional Ballast Tray can be installed in the connection between North rail to Mid rail /Mid rail to Mid rail to support for higher uplift. The Additional Ballast tray can only fit half blocks.

Align the smaller slots in Ballast Tray with the hole used for the rail overlap connection. Secure the ballast tray using the hex bolt and 1″ OD washer provided for the rail overlap connection. For Hardware Call OUTS Refer to page 3.
TORQUE VALUE: 10 FT-LBS

Place up to 4 half ballast blocks as needed.

MODULE CONNECTION

MODULE CONNECTION, STEP 4: Tighten the South Stanchion bolts and rotate the module down to rest on the North Stanchion as shown.
SOUTH STANCHION CLAMP TORQUE VALUE – 8 FT-LBS

MODULE CONNECTION, STEP 5: Rest the north end of the module on the North Stanchion Clamp. Install the adjacent module and tighten the hexagonal bolt so the clamp engages the return flange of both modules firmly.
NORTH STANCHION CLAMP TORQUE VALUE – 2 FT-LBS

WIND DEFLECTOR

INSTALL WIND DEFLECTOR: Thread the bolts through the included 0.75″ OD washer, then wind deflector, and into the threaded hole provided in north stanchion.

TIGHTEN BOLTS TO TORQUE:
Narrow side of the deflector will be on the bottom.
TORQUE VALUE: 6-8 FT-LBS

NOTE: Wind deflectors will overlap where modules meet.

NOTE: For perimeter modules, align outside edge of wind deflectors with the exposed edge of module.

MODULE REPLACEMENT

STEP 1: Locate the module to be replaced. Loosen the hexagonal bolt in both the north stanchions to which the module is connected.

STEP 2: Now lift the module from north edge and rotate it 75deg towards south. Loosen the bolt in the south stanchion and rotate the keeper 90deg.

STEP 3 : Remove the module and place the new module by following module attaching steps from page 5 and 6.

IMPORTANT : ANY LOOSE COMPONENTS OR FASTENERS SHALL BE RE-TIGHTENED IN ACCORDANCE WITH THESE INSTRUCTIONS. ANY COMPONENTS SHOWING SIGNS OF DAMAGE THAT COMPROMISE SAFETY SHALL BE REPLACED  MMEDIATELY.

CERTIFICATION

UL2703 System Label: To document the UL2703 system rating, Installers must apply a label to each array during installation. The label should be applied to the easternmost North Rail at each array’s north edge. Below is an example of the label and a diagram of where to place it.

MECHANICAL LOAD TEST QUALIFICATION
The GridFlex™ system has been tested to the mecanical load provisions of UL2703 and covers the following basic parameters:

• PV module may have reduced load rating, independent of the GridFlex™ 5 rating. please consult the PV module manufacturer’s installation guide for more information.
• Load rating may vary based on PV module area. Please Contact Unirac for more information.

Module Manufacturer| Model / Series| Area [sqft]| Design Load [PSF]
---|---|---|---
Hyundai| HiS-M305TI| 21.06| 16.7 up / 36 down
Q Cells| Q.PEAK DUO L-G8.3| 23.06| 17.3 up / 21.05 down
SunPower| P-19-330-COM| 22.20| 18.45 up / 36.5 down

Note: North Rail may be stamped by the manufacturer with the system label in the location shown in the diagram. If label is stamped on part there is no need to apply the sticker label

SYSTEM LEVEL FIRE CODE COMPLIANCE

SYSTEM LEVEL FIRE CLASSIFICATION: The system fire class rating is only valid when the installation is conducted in accordance with the assembly instructions contained in  this manual over a fire resistant roof covering rated for the application. GridFlex™ has been classified to the system level fire portion of UL2703. It has achieved Class A performance for low sloped roofs when used in conjunction with type 1, 2, 3 with a metal frame, 19, 22, and type 25 module constructions. Please see the specific conditions for mounting details described within this document required to maintain the Class A fire rating. Minimum and maximum roof slopes are restricted through the system design and layout rules. The fire classification rating is only valid on roof pitches less than 2:12 (slopes < 2 inches per foot, or 9.5 degrees).
Refer to page 9 for proper installation of wind deflectors for fire mitigation.
NOTE: Fire Type information can be found on back of modules or through manufacturers documentation. Some building codes and fire codes require minimum clearances around such installations, and the installer should check local building code requirements for compliance.
CLASS A FIRE RATING MOUNTING ORIENTATION
GridFlexT™ has achieved Class A system level fire performance for type 1, 2, 3 with a metal frame, 19, 22, and type 25 module constructions. In order to maintain the fire rating, the module J-Box must be oriented away from the array east-west edges.

BONDING & GROUNDING ELECTRICAL DIAGRAM

NOTE: Ground bond path can be established by installing the ground lug and copper wire connection to either the South Stanchion, North Stanchion, Rail, Wind Deflector, or Ballast Tray

BONDING AND GROUNDING

GROUNDING LUG MOUNTING DETAILS AS REQUIRED BY CODE & ENGINEER OF RECORD: The Ilsco lug has a green colored set screw for grounding indication purposes. One lug is recommended per continuous array, not to exceed 150ft X 150ft.
Unirac GridFlex™ is intended to be used with PV modules that have a system voltage less than or equal to that allowable by the National Electric Code (NEC). It is the installer’s responsibility to check adherence to local codes.
NOTE: The installation must be conducted in accordance with the National Electric Code ANSI / NFPA 70.

NOTE: In order to prevent corrosion induced by dissimilar metals, it is important to verify that the bare copper wire does not come into contact with aluminum or galvanized steel. These metals must be kept separate.
Although conformance with UL2703 was demonstrated without the use of oxide inhibitor material, it is recommended by Ilsco to provide an optimized bonding solution for their lay-in-lug.

Ilsco SGB.4 Solar Grounding & Bonding

TERMINAL TORQUE:
Install conductor and torque to the following: 4-14 AWG: 35 in-lbs
Ilsco GBL-4 Solar Grounding & Bonding

TERMINAL TORQUE:
Install conductor and torque to the following: 4-6 AWG: 35 in-lbs, 8 AWG: 25 in-lbs
Wiley WEWB-Lug 6.7 Solar Grounding & Bonding

TERMINAL TORQUE:
Install conductor and torque to the following: 4-6 AWG: 10 ft-lbs, 6-14 AWG: 7 ft-lbs

BONDING & GROUNDING SYSTEM CERTIFICATION

Electrical Bonding and Grounding Test Modules
The list below is not exhaustive of compliant modules but shows those that have been evaluated and found to be electrically compatible with the GridFlex™ system.

Astronergy

| CHSM6612 M, M/HV CHSM6612P Series CHSM6612P/HV Series CHSM72M-HC,

Auxin

| AXN6M610T, AXN6P610T, AXN6M612T AXN6P612T
Axitec| AC-xxxMH/120(S/V/SB/VB) AC-xxxMH/144(S/V/SB/VB)
Boviet| BVM6610, BVM6612
BYD| P6K & MHK-36 Series
Canadian Solar| CS1(H/K/U/Y)-MS
CS3K-(MB/MB-AG/MS/P/P HE/PB-AG) CS3L-(MS/P)
CS3U-(MB/MB-AG/MS/P/P HE/PB/PB-AG) CS3W-(MS/P/P-PB-AG)
CS5A-M
CS6K-(M/MS/MS AllBlack/P/P HE)
Centrosolar America| C-Series & E-Series
CertainTeed| CT2xxMxx-01, CT2xxPxx-01,
CTxxxMxx-01, CTxxxPxx-01, CTxxxMxx-02, CTxxxMxx-03
CTxxxMxx-04, CTxxxHC11-04
Eco Solargy| Orion 1000 & Apollo 1000
ET Solar| ET AC Module, ET Module

Manufacture

|

Module Model / Series

---|---
Flextronics| FXS-xxxBB
GCL| GCL-P6 & GCL-M6 Series
Hanwha SolarOne| HSL 60
Hansol| TD-AN3, TD-AN4, UB-AN1, UD-AN1
Heliene| 36M, 36P 60M, 60P, 72M & 72P Series

HT Solar

| HT72-156(M/P),
HT72-156P-C, HT72-156P(V)-C
HT72-156M(PDV)-BF, HT72-156M(PD)-BF HT60-156M-C,
HT60-156M(V)-C
Hyundai| KG, MG, RW, TG, RI, RG, TI, KI, HI Series
HiA-SxxxHG, HiD-SxxxRG(BK), HiS-S400PI
ITEK| iT-SE Series
Japan Solar| JPS-60 & JPS-72 Series

JA Solar

| JAP6 60-xxx,
JAM6(K)-60/xxx, JAP6(k)-72-xxx/4BB, JAP72SYY-xxx/ZZ,
JAP6(k)-60-xxx/4BB, JAP60SYY-xxx/ZZ, JAM6(k)-72-xxx/ZZ, JAM72SYY-xxx/ZZ, JAM6(k)-60-xxx/ZZ, JAM60SYY-xxx/ZZ. i. YY: 01, 02, 03, 09, 10
ii. ZZ: SC, PR, BP, HiT, IB, MW
YY = Backsheet, ZZ Cell technology
Jinko| JKM & JKMS Series JKMxxxM-72HL-V
Kyocera| KD-F & KU Series

Manufacture

|

Module Model / Series

---|---
LG Electronics| LGxxx(E1C/E1K/N1C/N1K/N2T/N2W/S1C/ S2W/Q1C/Q1K)-A5 LGxxx(A1C/M1C/M1K/N1C/N1K/Q1C/Q1K/ QAC/QAK)-A6
LGxxxN2W-B3 LGxxxN2T-B5 LGxxxN1K-B6
LGxxx(N1C/N1K/N2T/N2W)-E6 LGxxx(N1C/N1K/N2W/S1C/S2W)-G4 LGxxxN2T-J5 LGxxx(N1K/N1W/N2T/N2W)-L5 LGxxx(N1C/Q1C/Q1K)-N5
LGxxx(N1C/N1K/N2W/Q1C/Q1K)-V5
LONGi| LR4-60(HPB/HPH) LR4-72(HBD/HPH) LR6-60
LR6-60(BK/HPB/HPH/HV/PB/PE/PH) LR6-72
LR6-72(BK/HBD/HV/PB/PE/PH)
RealBlack LR4-60HPB RealBlack LR6-60HPB
Mission Solar Energy| MSE Mono, MSE Perc
Mitsubishi| MJE & MLE Series
Neo Solar Power Co.| D6M Series
Panasonic| VBHNxxxSA06/SA06B/SA11/SA11B VBHNxxxSA15/SA15B/SA16/SA16B, VBHNxxxKA, VBHNxxxKA03/04, VBHNxxxSA17/SA17G/SA17E/SA18/SA18E, VBHNxxxZA01/ZA02/ZA03/VBHNxxxZA04
Peimar| SGxxxM (FB/BF) SMxxxM

• The frame profile must not have any feature that might interfere with the bonding devices that are integrated into the racking system
• Use with a maximum over current protection device OCPD of 30A
• Please see GridFlex™ information at Unirac.com to ensure the exact solar module selected is approved for use with GridFlex™
• Listed models can be used to achieve a Class A fire system rating, for low slope applications, only when modules fire typed 1, 2, 3 with a metal frame, 19, 22, or 25.

Electrical Bonding and Grounding Test Modules
The list below is not exhaustive of compliant modules but shows those that have been evaluated and found to be electrically compatible with the GridFlex™ system.

Phono Solar

| PSxxxM1-20/U PSxxxM1H-20/U PSxxxM1-20UH PSxxxM1H-20UH
PSxxxM1-20/UH PSxxxM1H-20/UH
PSxxxM-24/T PSxxxMH-24/T PSxxxM-24/TH
PSxxxMH-24/TH
Prism Solar| P72 Series
Q.Cells| Q.PEAK L G4(.2)(.5) Q.PEAK DUO L – G4.2 Q.PLUS L G4.2
Q.PEAK DUO L – G5(.1)(.2)(.3)
Q.PLUS DUO L – G5(.1)(.2)(.3) Q.PEAK DUO (BLK) – G5(SC) Q.PEAK DUO BLK-G6+/TS
Q.PEAK DUO (BLK) – G6(+)(AC)(SC)
Q.PEAK DUO L – G6(.1)(.2)(.3) Q.PEAK DUO (BLK) – G7
Q.PEAK DUO L – G7(.1)(.2)(.3)(.4)(.7) Q.PEAK DUO (BLK) – G8(+)
Q.PEAK DUO L – G8(.1)(.2)(.3)(.3/BFF) Q.PEAK DUO (BLK) – ML (BLK) G9(+) Q.PEAK DUO XL-(G9/G9.2/G9.3)
Q.PEAK DUO (BLK) ML-G10(+)
Manufacture| Module Model / Series
---|---

REC

| RECxxxAA (BLK/Pure) RECxxxNP (N-PEAK)
RECxxxNP2 (Black) RECxxxPE, RECxxxPE72 RECxxxTP, RECxxxTP72 RECxxxTP2(M/BLK2) RECxxxTP2S(M)72
RECxxxTP3M (Black)
RECxxxTP4 (Black)
Renesola| All 60-cell modules
Risen| RSM Series
S-Energy| SN72 & SN60 Series

Seraphim

| SEG-6 & SRP-6 Series SEG-XXX-6MA-HV SRP-XXX-6MB-HV SRP-XXX-BMA-HV SRP-XXX- BMB-HV SRP-XXX-BMC-HV SRP-XXX-BMD-HV SRP-XXX-BMZ-HV
Sharp| NU-SA & NU-SC Series
Silfab| SLA-M, SLA-P, SLG-M, SLG-P & BC Series
SILxxx(BL/NL/NT/HL/ML/BK/NX/NU/HC)
|
Solaria| PowerXT
Solartech| STU HJT, STU PERC & Quantum PERC
SolarWorld| Sunmodule Protect, Sunmodule Plus/Pro
Suntech| STP
Suniva| MV Series & Optimus Series (35mm)

Manufacture

|

Module Model / Series

---|---
Sun Edison| F-Series, R-Series
SunPower| AC, X-Series, E-Series & P-Series
Talesun| TP572, TP596, TP654, TP660,
TP672, Hipor M, Smart, TD6I72M
Tesla| SC, SC B, SC B1, SC B2
TxxxS

Trina

| PA05, PD05, DD05, DD06, DE06 DE15H(II), DE15M(II) PD14, PE14, DD14, DE14
TSMC| TS-150C2 CIGSw
Upsolar| UP-MxxxP, UP-MxxxM(-B)

URECO

| D7Kxxx(H7A/H8A), D7Mxxx(H7A/H8A) FAKxxx(C8G/E8G), FAMxxxE7G-BB FAMxxxE8G(-BB)
Vikram| Eldora, Somera, Ultima

Vina

| VNS-72M1-5-xxxW-1.5, VNS-72M3-5-xxxW-1.5, VNS-144M1-5-xxxW-1.5, VNS- 144M3-5-xxxW-1.5, VNS-120M3-5-xxxW-1.0
VSUN| VSUN315-60M-BB, VSUN390-72MH VSUN415-144BMH, VSUN450-144BMH
Winaico| WST & WSP Series
Yingli| YGE & YLM Series
ZNShine Solar| ZXM6-72 Series

• The frame profile must not have any feature that might interfere with the bonding devices that are integrated into the racking system
• Use with a maximum over current protection device OCPD of 30A
• Please see GridFlex™ information at Unirac.com to ensure the exact solar module selected is approved for use with GridFlex™
• Listed models can be used to achieve a Class A fire system rating, for low slope applications, only when modules fire typed 1, 2, 3 with a metal frame, 19, 22, or 25.

References

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