PRODUCT TECHNICAL INFORMATION
This informational page will take you through the
steps of how the Professional Solar Product line of mounting systems were
developed and why the design is so efficient. The information on this page
refers to the RoofTrac, SolarWedge and GroundTrac mounting systems
SECTION #1: Aluminum
Characteristics & Properties
What are the differences in aluminum characteristics
& what are they used for?
SECTION #2: Design
Why do we use Stainless Steel hardware?
How did we come up with the design?
How do we receive such high strength numbers using such a soft alloy on
for
rails?
Why aren't your clamps universal?
SECTION #1 - ALUMINUM
CHARACTERISTICS AND PROPERTIES:
WHAT
IS THE DIFFERENCE IN ALUMINUM CHARACTERISTICS & WHAT ARE THEY USED FOR?
Aluminum is widely available in different alloys
which are meant for different purposes. Listed below are the three alloys
Professional Solar Products uses in their product line. The use of each alloy is
based on their serving properties - the cost for each alloy is relatively the
same..
6061-T6 - (FASTJACKS, FASTJACK 2X
BRACKETS, ETC.) Harder
alloys such as 6061
are typically used for high speed machining or structural profiles which do not
require close tolerances. This alloy is a poor choice
for support rails because it does not hold tolerances, has a relatively short
extrusion die life and does not commercially anodize well.
6063 T-6 - (RESIDENTIAL SUPPORT
RAILS, END CLAMPS, ETC.) An excellent choice where structural values can be
achieved through design. This alloy is normally used for module frames and other
components that require precision tolerances. This alloy anodizes exceptionally
well in both black and clear.
6005 T-5 - (INTERMODULE CLAMPS,
SLIDE NUTS, ETC.) This alloy combines two of the major benefits of the above
listed alloys: Higher strength yield and machining speeds like 6061 (drilling,
tapping and cutting) yet it anodizes well like 6063. Many products fabricated by
Professional Solar Products use this alloy. Although this alloy has many
benefits, 6063 will still provide the most consistent tolerances over the life
of the extrusion die.
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SECTION #2 - DESIGN:
HOW DID WE COME UP
WITH THE DESIGN?
When designing the Roof Trac mounting system
ProSolar needed a design that would be cost effective, aesthetically pleasing
and easy to install.
SAFE:
All parts related to the mounting systems manufactured by Professional Solar
Products are designed and engineered for safety and reliability over time. A
large factor in why all mounting systems utilize an open C-channel is to allow
water to flow through without becoming trapped. This is extremely important in
colder climates such as in the North East where trapped water can promote freeze
damage. The C-channel rail and all splice accessories are designed to prevent
this. The Roof Trac mounting system is load tested
for snow load along with a high wind aperture (125mph) and has been successfully
installed in the northeast and southwest, including Hawaii, since 1999. Load
testing not only proves in a real world setup that the system will remain on the
roof during these conditions, but that the modules will remain in the frame
under extreme load.
COST EFFECTIVE: Rail extrusion uses an
efficient "C" channel design which structural properties were analyzed
on a computer model. Since the
market for aluminum is global and prices will always fluctuate up or down,
efficient use of aluminum provides stable pricing. Additionally - lighter weight
dramatically reduces shipping and handling costs.
AESTHETICALLY PLEASING: All hardware and
connections are concealed within the C-channel support rail. The innovative
support channel when incorporated with the Slide-n-Clamp system (as explained
below) provides structural support at a lower profile to the roof. All exposed
vertical surfaces are flat and smooth - there are no pockets or grooves to trap
dirt, debris or moisture which causes corrosion.
EASY TO INSTALL: Holes are easily drilled
in the support channel by using a #10 UniBit drill bit (it takes less than 3 seconds
per hole). The bottom of the support rail contains a specially extruded
"V-groove" to facilitate perfect centering of the hole. Top-down clamps are easy to install using the sliding channel nut
Example of how the channel nut integrates with
the rail (top view)
Tolerances are
built into the design to allow the channel nut to slide freely and remain captive for easy installation and servicing.
The Channel nut provides a full 3" of gripping
area.
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HOW DOES
THE PROSOLAR RACKS ACHIEVE SUCH HIGH ENGINEERING STANDARDS BY USING SUCH A SMALL
AMOUNT OF MATERIAL?
The essence of the patented clamp and rail design
is the most innovative in the industry. Anyone can come up with a
design to bolt a module down to a rail/structural member, but it's a good design
that can do it inexpensively, with efficient use of materials and achieve high
engineering standards while still looking great on the roof. The Roof Trac/Ground
Trac/Commercial Roof Trac mounting systems were designed with the Slide-n-Clamp
method. This clamping system doesn't just mount modules to a rail - it
integrates the modules strength properties to create a monolithic array. The
mounting system becomes part of the modules. What this means is we can use a
lighter rail profile and can still achieve industry standards of strength.
The design of the Roof Trac system locks the
module case vertically.
As shown in the illustration above, the end clamp
is designed with a small heel at the bottom. The size of this heel is determined
by the module frame height. This heel controls the amount of tension the end
clamp locks the module frame case with. It also insures that the clamp and
module frame will not be distorted or pushed under load.
This end clamp design also provides superior
strength by locking the base of the clamp and the module together. When fully
installed this design creates a monolithic frame which incorporates the strength properties of
not just the rails but the module as well. Another strength-giving attribute of
the system is when the clamps (both end and Intermodule) are installed, the
channel nut pulls upward on the C-channel opening (see illustration below). The
Slide-n-Clamp system design changes the structural properties of the C-channel
to a square tube which greatly enhances the strength. <<Back to top
A) The hex bolt is tightened.
B) The pressure from the bolt pulls upward on the channel nut. This pulls the
"teeth" on the C-channel opening inward.
C) The small heel on the end clamp pushes the end clamp inward toward the module
frame
D) The rail is now a theoretical square - an extremely strong geometrical
shape
WHY AREN'T END
CLAMPS UNIVERSAL?
As stated above, the rail that was once easy to
bend is now capable of holding up 50 lbs. per square foot*. It is now obvious
that in order to achieve this performance rating it is essential to have
components that fit the module perfectly. Since the End clamp is essentially the
part that creates this impressive feat, it is the most tolerance-crucial and
thus ProSolar holds proprietary end clamp dies at their extruder for each module
frame case specification. By extruding the specific sizes instead of modifying a
universal die, tolerances are easily upheld and production is fast and accurate.
In turn this creates a more cost effective and better quality system.
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EXAMPLE OF A LOAD TEST: Notice that when
the setup is loaded, the module frames show the most deflection. In this
particular setup Roof Trac tested at 50 lbs. per square foot, tilt up in the
upload and download conditions (download shown here - see
ENGINEERING for photos of the uplift condition.
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