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 Regulatory Information...3 1.5 Safety...4 2. Technical Description...5 2.1 System Overview...5 2.2 QRail Components...6 2.3 Technical Data...7 2.4 System Electrical Bonding...8 2.5 System Electrical Grounding...12 3. Important Mounting Information...14 3.1 Conditions of Use...14 3.2 Mounting Preparations...14 3.3 Mounting Aids and Required Tools...15 3.4 Fastener Torque Settings...15 4.
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, and to attach the modules to the rails; it also includes other various accessories, such as module level power electronic (MLPE) attachments.
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 Regulatory Information ANSI / UL 2703 The QRail system is ETL listed to UL 2703, Edition 1. Listing documents are available from the website: www.quickmountpv.com. For additional information, contact Quick Mount PV. UL 2703 requires that listed PV systems be labeled to indicate their compliance with UL 2703. The QRail system includes labels affixed to the QRail as shown in image 1.4.1.
1.5 Safety All generally applicable safety regulations for Quick Mount PV products can be viewed in the General Installation Manual. Please read this document carefully and adhere to the instructions and procedures therein – use the system only for its intended purpose and follow both the general and specific safety instructions. In addition, please observe the specific safety instructions which precede the process steps in the present product-specific Mounting Instructions. Safety Ratings: BI 7.2.
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 7.2.3-46 5 Jul-2019, Rev 4.
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2.3 Technical Data Application Low and Steep Slope Roofs Roofing type Suitable for most types of roofing Roof slope Up to - 45°1 (upto 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 2.4.2 and 2.4.3 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 complementary, 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 Heavy, Standard, and Light rails. QRail The Internal QSplice has a bonding plate that pierces any paint or aluminum oxide layer on the rails. This forms a electrical bind from rail-to-rail through the bonding plate.
Roof Attachment Bonding The QRail is attached to the roof by roof attachments with L-feet. 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 2.4.11-2). Image 2.4.11-2 T-bolt Full engagement of T-bolt is confirmed when the alignment indicator line on the end of the T-bolt is vertical. INCORRECT CORRECT WARNING Image 2.4.
2.5 System Electrical Grounding Array Grounding Lug The QRail system is listed to UL 2703 with the Burndy/Wiley WEEB-Lug 8.0 as the means to connect the QRail array to the system ground electrode. It is the system installer’s responsibility to determine the appropriate wire size for grounding the array. To ease and facilitate the process of bonding and grounding the array, it is recommended that these steps are accomplished after the roof attachments and rails are in place prior to module installation.
WEEB-Lug Installation The QRail WEEB-Lug 8.0 is preassembled with a M8-T-bolt, serrated flange nut, and a WEEB bonding plate. The lug is installed in the side channel of the QRail rail. AWG Wire Size WEEB- Lug 8.0 Capacity 14 - 6 1 wire 10 2 wires 12 2 wires Insert T-head bolt head into the rail’s side channel. Be sure to Table 2.5.1 allow the bolt head to rotate as far as possible in the T-bolt WEEB-Lug 8.
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 standards: IBC/IRC 2015 IBC/IRC 2012 ICC-AC428 2012 ASCE 7-05 ASCE 7-10 CBC/CRC 2016 ANSI/ UL 2703 Ed.
3.3 Mounting Aids and Required Tools In addition to standard hand tools, you will need the following tools: 5 mm Allen key / 5 mm Allen key power driver 13 mm hex socket / 13 mm box or open-end wrench 7/16" (11mm) box end wrench Drill driver Metric socket set Torque wrench Reciprocating saw and/or band saw Chalk line Spirit level Tape measure 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 layout should be verified using the QDesign tool or a project-related structural analysis by a qualified professional.
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 fasteners depends on several factors and must be calculated specifically for each project, e.g. with the QDesign Tool. 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 external and internal QSplices are used to join two rail sections to provide a single rail section of a desired length. External QSplice Installation For the Heavy or Standard rails, join the rail sections together by sliding the QSplice onto the end of the rail, leaving half the length of the splice protruding from the end of the rail. Tighten the splice bolt onto the rail end. Tighten to 12 ft-lbf (16 N-m).
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 rivet head comes into contact with the end of the rail. Slide the other rail onto the splice until the end of the rail comes into contact with the rivet head. When re-installing the QRail Internal QSplices, insert the splice backwards for optimal performance. Image 5.2.
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 1" thermal break with Internal QSplice Install the internal splice 1" of 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 surface be flashed in accordance with the appropriate local codes and roofing best practices. Installing Two-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 gauge by laying two rails on a flat surface. Lay one of the modules on the rails as shown. Be sure the rails are parallel with the edges of the module and with each other. a Carefully measure distance “a” as shown in Image 5.3.3. This is the critical N-S distance between L-foot rail attachment points for shared rails. Carefully cut a dowel, PVC pipe, or other rigid length of material to distance “a.
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 5mm Allen key 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.
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 will work on any module 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 (Using Ratchet or right angel tool). 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 plates. Mid clamps are designed to fit modules within a particular range. Mid clamps are available in either mill finish or black in the following size ranges: Part Number Finish Clamping Range (mm) Clamping Range (inches) 900 mill 30-45 1.30-1.77 877 902 black 30-45 1.30-1.77 873 901 mill 38-50 1.50-1.97 878 903 black 38-50 1.50-1.
NOTE! The bonding mid clamps with bonding plates are supplied with the bonding plates preassembled under the clamp head If not already so positioned, slide the bonding plate and clamp head to the bolt head. This will hold the bonding plate above the module frames until you are ready to tighten the clamp into place. 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.
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Manufacturer Model Jinko JKMxxxP-60, 60 JKMxxx-P-60, 60 JKMxxx-P-60B, 60 JKMxxxPP-60, 60 JKMxxxPP-60B, PERC 60 JKMxxxM-60, Plus JKMxxxPP-60(Plus), JKMxxxP-60-J4, JKMxxxP60B-J4, Black JKMxxxPP-60-J4, JKMxxxPP60B-J4, 1500V 60 JKMxxxPP-60-V, 1500V 60 JKMxxxM-60-V, Jinko MX60 JKMSxxxP, MX JKMSxxxPP-60, JKMxxxM-60B, JKMxxxM-60-J4, JKMxxxM60B-J4, JKMSxxxP-60, JKMSxxxP-60-J4, JKMSxxxM-60, JKMSxxxM-60-J4, JKMSxxxPP-60-J4, JKMSxxxPP-60, JKMSxxxM-60B-EP, 72 cell modules model: JKMXxxP-72, JKMxxxP-72B, JKMxxxP-72-J
Manufacturer Model SunSpark Technology SMX-xxxw, SST-xxxw Trina TSM-PD05.08-xxx, TSM-PD14-xxx, ALLMAX-PD05.05, ALLMAX M Plus-DD05A.05 (II)-, ALLMAX-PD05A.08, TSM-DD14A(II)-, TSM-DE14A(II)- Yingli YL-xxx-35B, YL-xxx-29B, YLxxxP29b, YLxxxP-35b Note: xxx refers to the power class in watts (W) of the module. The QRail system is to be used only with modules on this list or with those which include the QRail system in their respective installation manuals.
9. CAD Part Drawings ITEM NO. DESCRIPTION QTY. 1 QRAIL, HEAVY, AL, MILL 1 2.047 1.470 TITLE: NOTES: 1. AVAILABLE IN 14' AND 17' - 4" LENGTHS 2. AVAILABLE IN MILL FINISH AND BLACK FINISH QMR-RH: QRAIL HEAVY UNLESS OTHERWISE SPECIFIED: PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF QUICK MOUNT PV. ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF QUICK MOUNT PV IS PROHIBITED.
ITEM NO. DESCRIPTION QTY. 1 QRAIL, LIGHT, AL, MILL 1 1.567 1.056 TITLE: QMR-RL: QRAIL LIGHT NOTES: 1. AVAILABLE IN MILL FINISH AND BLACK FINISH UNLESS OTHERWISE SPECIFIED: PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF QUICK MOUNT PV. ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF QUICK MOUNT PV IS PROHIBITED.
ITEM NO. 2 4 3 QTY. 2 3 4 WASHER, STAR, M6, 18-8 SS 2 2 1 DESCRIPTION QSPLICE EXTERNAL, QRAIL, STANDARD, 6.3", AL, MILL NUT, SQUARE, THIN, M6 X 1.0, DIN 562, 18-8 SS CAP SCREW, SOCKET HEAD, M6 X 1.0 X 25MM, DIN 912, A2-70 SS 1 1 2 1.890 1.468 6.299 TITLE: QMR-ESS: QSPLICE EXTERNAL, QRAIL, STANDARD QRAIL NOT INCLUDED UNLESS OTHERWISE SPECIFIED: PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF QUICK MOUNT PV.
ITEM NO. DESCRIPTION QTY. 1 QSPLICE INTERNAL, QRAIL, STANDARD, 8", AL, MILL 1 BONDING PLATE, QSPLICE INTERNAL, QRAIL, SS, MILL 1 RIVET, DOMED HEAD, BLIND, 3/16 X .450, AL, MILL 1 WASHER, RIVET, 3/16" ID X 3/8" OD, ALUMINUM, MILL 1 1 1.26 1.42 4.00 8.00 QRAIL NOT INCLUDED TITLE: QMR-ISS: QSPLICE INTERNAL, QRAIL, STANDARD UNLESS OTHERWISE SPECIFIED: PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF QUICK MOUNT PV.
ITEM NO. DESCRIPTION QTY. 1 QCLICK, 17MM, AL, MILL 1 2 UNIVERSAL END CLAMP, QRAIL, LOWER, 40MM, AL, MILL 1 3 RUBBER O-RING, 5MM ID X 2MM THK, BUNA-N 1 4 STICKER, ETL, QRAIL, END CLAMP 1 5 UNIVERSAL END CLAMP, QRAIL, UPPER, 40MM, AL, MILL 1 6 WASHER, STAR, M6, 18-8 SS 1 7 CAP SCREW, SOCKET HEAD, M6 X 1.0 X 45MM, DIN 912, A2-70 SS 1 8 WEEB BMC, 304 SS 1 7 6 5 8 2 4 3 1.575 1.
ITEM NO. DESCRIPTION QTY. HIDDEN END CLAMP, QRAIL, LOWER, 0.75", AL, MILL HIDDEN END CLAMP, QRAIL, UPPER, 1.5", AL, MILL NUT, SQUARE, THIN, M6 X 1.0, DIN 562, 18-8 SS CAP SCREW, SOCKET HEAD, M6 X 1.0 X 25MM, DIN 912, A2-70 SS, NYLON PATCH 1 5 WASHER, STAR, M6, 18-8 SS 1 6 SPRING, QRAIL, HIDDEN END CLAMP, SS, MILL 1 7 STICKER, ETL, QRAIL, END CLAMP 1 1 2 3 4 7 3 1 1 1 2 6 1.500 1 5 4 2.
ITEM NO. DESCRIPTION QTY. 1 QCLICK, 17MM, AL, MILL 1 2 BONDING PLATE, MID CLAMP, V1.2, QRAIL, SS 1 3 UNIVERSAL MID CLAMP, QRAIL, 40MM, AL, MILL 1 4 WASHER, STAR, TIGHT-GRIP, M6, 18-8 SS 1 5 CAP SCREW, SOCKET HEAD, M6 X 1.0 X 45MM, DIN 912, A2-70 SS 1 5 4 1.575 1.575 3 1 2 1 TITLE: QMR-UMC: UNIVERSAL MID CLAMP, V1.2, QRAIL NOTES: 1 AVAILABLE IN TWO SIZE RANGES: 30-45MM AND 38-50MM 2.
ITEM NO. DESCRIPTION QTY. 1 END CAP, QRAIL, HEAVY, BLACK 1 QRAIL NOT INCLUDED 2.05 1 1.47 TITLE: QMR-CPH: END CAP, QRAIL, HEAVY UNLESS OTHERWISE SPECIFIED: PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF QUICK MOUNT PV. ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF QUICK MOUNT PV IS PROHIBITED.
ITEM NO. DESCRIPTION QTY. 1 END CAP, QRAIL, LIGHT, BLACK 1 1.57 1.04 1 QRAIL NOT INCLUDED TITLE: QMR-CPL: END CAP, QRAIL, LIGHT UNLESS OTHERWISE SPECIFIED: PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF QUICK MOUNT PV. ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF QUICK MOUNT PV IS PROHIBITED.
3 1 ITEM NO. DESCRIPTION QTY. 1 GROUNDING LUG, WEEB 8.0, COPPER, TIN PLATED, ASSY. 1 2 T-BOLT, M8 X 1.25 X 20MM, A2-70 SS, NYLON PATCH 1 3 NUT, SERRATED FLANGE, M8 X 1.25, DIN 6923, A2-70 SS 1 2 RAIL NOT INCLUDED TITLE: QMR-GL: WEEB LUG, QRAIL, W/TBOLT QMR-GL MUST BE INSTALLED PARALLEL TO RAIL PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF QUICK MOUNT PV.
BI 7.2.3-46 44 Jul-2019, Rev 4.
RESPECT THE ROOF 925-478-8269 | 2700 Mitchell Dr. | Walnut Creek, CA 94598 www.quickmountpv.com | tech@quickmountpv.com UL STD 2703 BI 7.2.3-46 ©2019 by Quick Mount PV. All rights reserved. 45 Jul-2019, Rev 4.