Flush Mount SunEarth Flush Mount Installation Manual Thank you for choosing the SunEarth flush mount method. It provides a strong durable solution for mounting SunEarth collectors parallel to the roof surface. The flush mount components consist of 6063-T6 anodized aluminum Solar Strut, collectors clips and stainless steel fasteners that can withstand the harshest weather conditions. SunEarth s flush mount method has been designed for composition shingle style roofs, cedar shake style roofs, standing seam style roofs and flat/barrel tile style roofs with a minimum roof pitch of 2/12 or 10. Collectors must be installed parallel to the roof surface. The flush mount method should not be used in areas that experience positive panel loading (snow) greater than 40 psf or negative panel loading (wind) greater than 60 psf. If expected loading exceeds these values please contact SunEarth for other mounting options. Photo Courtesy of Lend Lease LLC. SunEarth Flush Mount Asphalt Shingle Roofing The use of mounting systems that do not conform to the materials and methods detailed in this or any of SunEarth s other published installation manuals, guidelines, and technical bulletins is not recommended and may void your collector warranty. 1 May 2013
Flush Mount Location The optimal siting of the solar collector is facing true south. If this is not possible the annual performance will suffer very little if the collector is oriented no more than 45 east or west of true south. S GABLE ROOF 10 <ROOF PITCH<45 Warning: The SunEarth flush mount method is inappropriate for any roof pitch less than 2/12 or 10, or for tilting (racking) the solar collectors to an angle greater than the pitch of the roof. The solar collector should be placed on the roof in an area and orientation that minimizes wind and snow loading. It is not advisable to install solar collectors in locations 2 (yellow) and 3 (red) on the plan view shown on the left. Note: If either the roof length or width is less than 30 feet then a is equal to 3 feet. Otherwise dimension a is 10% of the least horizontal dimension LHD or 40% of the mean roof height MRH whichever is smaller, but not less that either 4% of the least horizontal dimension of the building or 3 feet as stated in Minimum Design Loads for Buildings and Other Structures, American Society of Civil Engineers (ASCE) 7-05. Example: If the installation site has a roof that is 35 feet wide, 60 feet long and has a mean roof height of 30 feet. HIP ROOF 10 <ROOF PITCH<27 10% of LHD = 0.10 X 35 = 3.5 4% of LHD = 0.04 X 35 = 1.4 40% of MRH = 0.40 X 30 = 12 a = 3.5 feet since 1.4<3<3.5<12 Therefore collectors should be installed at least 3.5 feet away from any roof peak or edge. 2 May 2013
Flush Mount Layout Portrait Configuration Select either a portrait or landscape collector(s) orientation. Portrait is generally recommended for arrays of two or more collectors, or if moderate annual snow loads are anticipated. Landscape Configuration The flush mount method is not an appropriate mounting solution for locations that experience positive panel loading (snow) greater than 40 psf or negative panel loading (wind) greater than 60 psf. If expected loading exceeds these values please contact SunEarth for other mounting options. 3 May 2013
Flush Mount Portrait Layout Table 1 provides detail on the proper placement of the flush mount offset components for various SunEarth collectors mounted in a portrait orientation. Portrait Layout Dimensions Rafter Spacing Layout Dimension "A" Dimension "B" Dimension "C" Collector Model 16" 24" 16" 24" 16" 24" EP/EC 21 45 1/2 45 1/2 15 1/4 15 1/4 32 24 EP/EC 24 59 59 19 1/2 19 1/2 32 24 EP/EC 32 59 59 19 1/2 19 1/2 48 48 EP/EC 40 73 1/4 73 1/4 24 1/2 24 1/2 48 48 Table 1 If the rafter spacing is not 16 or 24 on center, position the flush mount offset components such that the spacing between offset components is plus or minus 3 of Dimension C. 4 May 2013
Flush Mount Landscape Layout Table 2 provides detail on the proper placement of the flush mount offset components for various SunEarth collectors mounted in a landscape orientation. If the rafter spacing is not 16 or 24 on center, position the flush mount offset components such that the overhang (Dimension B ) is plus or minus 1 of the shown in Table 1. Landscape Layout Dimensions Rafter Spacing Layout Dimension "A" Dimension "B" Dimension "C" Collector Model 16" 24" 16" 24" 16" 24" EP/EC 21 48 48 11 11 40 40 EP/EC 24 64 72 17 1/8 13 1/8 36 36 EP/EC 32 64 72 17 1/8 13 1/8 48 48 EP/EC 40 80 96 21 1/8 13 1/8 48 48 Table 2 5 May 2013
Flush Mount Composition Shingle Standoff 1. Trim shingles allowing Standoff to be place directly on Paper. 2. Drill pilot holes that are 75% of the lag bolt diameter through the flashing, paper, and decking 75% of the full embedded depth into the rafter. 3. Fill pilot holes with roof sealant. 4. Apply roof sealant between the standoff and paper 5. Drive stainless steel lag bolts with flat washers a minimum of 2 inches into roof beam. 6. Apply roof sealant over lag bolts. 7. Apply roof sealant to underside of flashing 8. Tuck flashing under upper shingle 9. Apply roof sealant to underside of upper shingle Standoff Detail 10. Fill void between flashing and standoff with roof sealant 6 May 2013
Flush Mount Composition Shingle Hanger Bolt 1. Drill pilot holes that are 75% of the lag bolt diameter through the flashing, paper, and decking 75% of the full embedded depth into the rafter. 2. Fill pilot holes with roof sealant. 3. Drive stainless steel hanger bolts with flat washers a minimum of 2 inches into roof beam. 4. Apply roof sealant to underside of flashing 5. Tuck flashing under upper shingle 6. Apply roof sealant to underside of upper shingle 7. Fill void between flashing and hanger bolt with roof sealant Hanger Bolt Detail 7 May 2013
Flush Mount Composition Shingle Quick Mount 1. Drill pilot holes that are 75% of the lag bolt diameter through the flashing, paper, and decking 75% of the full embedded depth into the rafter. 2. Fill pilot holes with roof sealant. 3. Apply roof sealant to underside of flashing. 4. Tuck flashing under upper shingle. 5. Apply roof sealant to underside of upper shingle 6. Drive hanger bolt with stainless steel and EPDM sealing washer torque to 13 foot pounds. 7. Insert EPDM sealing washer Quick Mount Detail 8 May 2013
Flush Mount Composition Shingle Flush Foot 1. Position galvanized roof flashing by tucking flashing under nearest upper shingle. 2. Drill pilot holes that are 75% of the lag bolt diameter through the flashing, shingles, and decking 75% of the full embedded depth into the rafter. 3. Apply roof sealant between the flashing and shingles on both sides. 4. Fill pilot holes with roof sealant. 5. Apply sealant to underside of flush mount foot and position flush mount foot. 6. Drive stainless steel lag bolts with flat washers a minimum of 2 inches into roof rafter. 7. Apply roof sealant over lag bolts. 8. Apply roof sealant around parameter of fastened flush mount foot. Flush Foot Detail 9 May 2013
Flush Mount Barrel Tile Standoff 1. Remove tile. 2. Place standoff above roof rafter. 3. Drill pilot holes that are 75% of the lag bolt diameter through the flashing, paper, and decking 75% of the full embedded depth into the rafter. 4. Fill pilot holes with roof sealant. 5. Apply roof sealant between the standoff and paper 6. Drive lag bolts with flat washers a minimum of 2 inches into roof rafter. 7. Apply roof sealant over lag bolts. 8. Apply roof sealant to underside of base flashing 9. Tuck base flashing under upper paper seam. 10. Fill void between flashing and standoff with roof sealant. 11. Drill hole in tile. 12. Reinstall Tile. Standoff Detail 13. Install flexible tile flashing. 10 May 2013
Flush Mount Barrel Tile Hanger Bolt 1. Remove tile. 2. Position hanger bolt above roof rafter. 3. Drill pilot holes that are 75% of the lag bolt diameter through the flashing, paper, and decking 75% of the full embedded depth into the rafter. 4. Fill pilot holes with roof sealant. 5. Drive stainless steel hanger bolts with flat washers a minimum of 2 inches into roof rafter. 6. Apply roof sealant to underside of base flashing 7. Tuck base flashing under upper paper seam. 8. Fill void between flashing and hanger bolt with roof sealant. 9. Drill hole in tile. 10. Reinstall Tile. 11. Install flexible tile flashing. Hanger Bolt Detail 11 May 2013
Flush Mount Cedar Shake / Flat Tile Standoff 1. Remove cedar shake / roof tile. 2. Place standoff above roof rafter. 3. Drill pilot holes that are 75% of the lag bolt diameter through the decking and 75% of the full embedded depth into the rafter. 4. Fill pilot holes with roof sealant. 5. Apply roof sealant between the standoff and paper 6. Drive lag bolts with flat washers a minimum of 2 inches into roof rafter. 7. Apply roof sealant over lag bolts. 8. Drill hole in cedar shake / flat tile. 9. Reinstall cedar shake / flat tile. 10. Apply roof sealant to underside of flashing 11. Tuck flashing under upper cedar shake / flat tile 12. Fill void between flashing and standoff with roof sealant Standoff Detail 12 May 2013
Flush Mount Cedar Shake / Flat Tile Hanger Bolt 1. Remove cedar shake / roof tile. 2. Place standoff above roof rafter. 3. Drill pilot holes that are 75% of the lag bolt diameter through the decking and 75% of the full embedded depth into the rafter. 4. Fill pilot holes with roof sealant. 5. Drive hanger bolts with flat washers a minimum of 2 inches into roof rafter. 6. Drill hole in cedar shake / flat tile. 7. Reinstall cedar shake / flat tile. 8. Apply roof sealant to underside of flashing 9. Tuck flashing under upper cedar shake / flat tile 10. Fill void between flashing and standoff with roof sealant Hanger Bolt Detail 13 May 2013
Flush Mount Standing Seam S-5 1. Position S-5! clamp on seam. 2. Tighten set screws. 3. Torque set screws to 170 in. lbs. for 22 gauge material and 140 in. lbs. for thinner material. S-5 Detail Note: Refer to S-5! specifications for quantity and positioning details www.s-5.com 14 May 2013
Flush Mount Corrugated Roof Hanger Bolt 1. Position hanger bolt above roof rafter. 2. Drill pilot holes that are 75% of the hanger bolt diameter through the roofing, decking and 75% of the full embedded depth into the rafter. 3. Fill pilot holes with roof sealant. 4. Drive stainless steel hanger bolts with flat washers a minimum of 2 inches into roof rafter. 5. Apply roof sealant to underside of master flashing 6. Secure flashing to roofing with sheet metal screws around parameter. 7. Fill any void between flashing and hanger bolt with roof sealant. Hanger Bolt Detail 15 May 2013
Flush Mount Corrugated Roof Standoff 1. Position standoff above roof rafter. 2. Drill pilot holes that are 75% of the lag bolt diameter through the roofing, decking and 75% of the full embedded depth into the rafter. 3. Fill pilot holes with roof sealant. 4. Drive stainless steel lag bolts with flat washers a minimum of 2 inches into roof rafter. 5. Apply roof sealant to underside of master flashing 6. Secure flashing to roofing with sheet metal screws around parameter. 7. Fill any void between flashing and standoff with roof sealant. Standoff Detail 16 May 2013
Flush Mount Collector Placement and Anchoring Position the collector(s) on the solar strut as shown on pages 6 thru 16. Insert four (4) collector clip assemblies (C-SSN) per collector and tighten to specification shown in Table 3. C-SSN Torque Specifications FASTENER SIZE IN*LB FT*LB 3/8 X 16 230 19 Table 3 Note: Do NOT over tighten the mounting hardware. Over tightening can damage the fasteners and affect mounting stability. There should be no visible deflection of the mounting clip attached to the collector after tightening. 17 May 2013
Flush Mount Components SunEarth Part # Extension SunEarth Part Number Index Description 10110-383 3/8" X 3" Stainless Steel Lag Bolt 384 3/8" X 4" Stainless Steel Lag Bolt 385 3/8" X 5" Stainless Steel Lag Bolt 5163.5 5/16" X 3.5" Stainless Steel Lag Bolt 10 5/16" Stainless Steel Flat Washer 10130-2 3/8" Stainless Steel Flat Washer LEXEL Clear Roof Sealant C-SSN Mounting Clip with attachment hardware 10070-158- 042 42 of 1-5/8 Solar Strut LA-SF104 Sf-1/2 052 52 of 1-5/8 Solar Strut 082 82 of 1-5/8 Solar Strut 104.5 104.5 of 1-5/8 Solar Strut 120 120 of 1-5/8 Solar Strut 158 158 of 1-5/8 Solar Strut 240 240 of 1-5/8 Solar Strut Lead Flashing for Standoff Post Lead Flashing for Hanger Bolts TSM- 4 4 Black Painted Standoff 8 8 Black Painted Standoff TSMSS- 4 4 Stainless Steel Standoff 8 8 Stainless Steel Standoff SunEarth Part # Extension Example: PN 10110-385 = 3/8 X 5 Stainless Steel Lag Bolt Description 11070- -158-004 1-5/8 Solar Strut Mounting Foot -250-004 2-1/2 Solar Strut Mounting Foot HBA- 0386 3/8 X 6 Stainless Steel Hanger Bolt QMSC B 12 0388 3/8 X 8 Stainless Steel Hanger Bolt 0126 1/2 X 6 Stainless Steel Hanger Bolt 0128 1/2 X 8 Stainless Steel Hanger Bolt 1210 1/2 X 10 Stainless Steel Hanger 1212 1/2 X 12 Stainless Steel Hanger Bolt QuickMount Bronze Flashing The stainless steel lag bolts should be no less than 5/16 diameter for standard 2 rafters. The lag bolts should be sufficiently long to ensure that no less than two (2) inches of the lag is embedded into the rafter. Note: The pilot hole for the lag bolt should be 75% of the bolt diameter and 75% of the embedded depth. Example: The pilot hole for a 5/16 lag bolt to be embedded 2-1/2 into the rafter should be 15/64 X 1-7/8 in depth. 18 May 2013