How to Install Ballast System Solar Brackets on Flat Roof and Metal Roof?
Yuens TP-2 Ballasted Triangle Solar System, a roof-protection solution that eliminates the need for drilling holes. Designed for flat and metal roofs, it offers cost savings through its low ballast requirements per square meter. With components pre-assembled for quick installation and flat-packed for easy storage and transport, the system maximizes efficiency. Ideal for various solar projects, it ensures reliable performance while safeguarding your roof.
Now let’s read the installation guide carefully before starting the setup.
Tools & Equipment
Components
Installation Steps
1. Preassemble the Ballasted Triangle Frames
Before beginning installation, ensure that all necessary tools and products are prepared. Mark the positions of the ballasted triangle frames according to the L1 measurement in the construction drawing. Use connectors, M8x55mm bolts, and flange nuts to join each row of triangle frames. Confirm that all frames are aligned both horizontally and vertically for proper setup.
2. Install the rails
- Rail Assembly: If the rails are not long enough, use rail splices to extend them. Insert one half of the rail splice into rail A and secure it with a M8x12 hex bolt. Then insert the other half into rail B, aligning both rails, and fasten with another M8x12 hex bolt.
- Rail Attachment: Secure the rails onto the ballasted triangle frames using the fixing clamp kit.
- Repeat Rail Installation: Continue fixing the remaining rails as per the construction drawing. Ensure all bolts are securely tightened. The spacing between rails should match the half-length of the solar panels (L2).
3. Install ballasted pans and concrete foundations
Place the ballasted pans onto the triangle frames, fastening them with either 8 or 6 self-tapping screws (6.3x25mm). After securing the pans, place concrete foundations on both sides of the pans to stabilize the system.
4. Install the solar panels
Start solar panel installation from the bottom left side. For each mid clamp, include a grounding washer. Each array should have two end clamps, each equipped with two grounding lugs for proper grounding.
PS: To adjust the tilt angle of the triangle frames, modify the length of the rear leg according to your local latitude and longitude. Secure the desired tilt angle with a hex bolt. The adjustable range will be determined by the design in the construction drawing.
Installation notes
1. Dimensions
All dimensions should strictly follow the construction drawings provided. This guide serves as a general reference for installation and should not be considered a replacement for detailed construction specifications.
2. Stainless steel fasteners
Stainless steel, due to its high ductility, behaves differently from carbon steel, and improper handling can lead to a condition known as “lock up” or “dead lock,” where bolts and nuts become difficult to unscrew. To prevent this, follow these steps:
(1) Reduce Friction:
- Ensure that the surface of the threads is clean and free from dust or clutters.
- Apply water wax or a suitable lubricant (such as butter or 40# machine oil) to the threads before installation to reduce friction.
(2) Use Proper Installation Techniques:
- When screwing the bolt, it must remain perpendicular to the axis of the thread—do not tilt the bolt.
- Apply force evenly while tightening, and do not exceed the recommended secure torque value.
- Whenever possible, use a torque wrench or socket spanner. Avoid using a monkey wrench or electric wrench. If using an electric wrench, keep the rotational speed as low as possible.
- Prevent overheating by controlling the speed of rotation, especially with electric tools, to avoid temperature spikes that can cause lock up.
What can Yuens Offer?
Yuens is committed to providing innovative and reliable solutions for solar mounting systems. Our adjustable solar panel mount systems, like the TP-4 Triangle Solar Panel Mount, are also designed for easy installation, durability, and versatility across different roof types. Whether you’re working with flat or metal roofs, our ballast system solar solutions ensure secure, long-lasting installations without the need for roof penetration.
In addition to offering high-quality products, we provide comprehensive support, including installation guides and expert consultation. Contact us to learn more about how our solar mounting systems can meet your project needs.
