TTI FLAT JACK Installation Manual
Installation Manual
FLAT JACK® Low-Profile Roof Mount
System
NOTICE
This document is proprietary, and must not be replicated. It is for TTi internal
use only and is subject to
changes for upgrades and
improvements.
Part Number 99906 Rev. D
Release 11.17.2008
Thompson Technology Industries, Inc.
16 Digital Drive
Novato, CA 94949
www.thompsontec.com
Proprietary Information
Copyright© 2008, Thompson Technology Industries, Inc. All rights
reserved. Other names, brands and trademarks are the property
of others. Thompson Technology Industries, Inc. (TTi) assumes no
responsibility or liability for information contained in this document. TTi reserves the right to make corrections, modifications,
enhancements, improvements, and other changes to its products
and services at any time and to discontinue any product or services without notice. The information contained herein is
believed to be accurate and reliable at the time of printing.
Thompson Technology Industries, Inc.
16 Digital Drive
Novato, CA 94949
www.thompsontec.com
FLAT JACK Installation Manual
Contents
1 About This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Use of Ladders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.3 Electrical Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.4 Installation & Servicing. . . . . . . . . . . . . . . . . . . . . 2-3
2.5 Fire or Explosion . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.6 Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.7 Inhalation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.8 Entanglement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.9 Cuts or Burns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Contents
2.10 Heart Pacemakers . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.11 Eye or Head Injury . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.12 Noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.13 Chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
3 FLAT JACK® Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1 About This Chapter . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
4 Site Layout Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 About This Chapter . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Installer's Responsibilities . . . . . . . . . . . . . . . . . . 4-1
4.3 FLAT JACK® Mounting Configurations vs.
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Selecting Mounting Configurations . . . . . . 4-2
Configuration A Description . . . . . . . . . . . . . 4-2
Configuration B Description . . . . . . . . . . . . . 4-3
Configuration C Description . . . . . . . . . . . . . 4-3
Lateral Load Considerations . . . . . . . . . . . . . 4-4
4.4 Selecting Appropriate Screws/Bolts . . . . . . . . 4-4
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Contents
4.5 Example Wind Load Calculation
using ASCE 7-05 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Example System Characteristics. . . . . . . . . . 4-5
Wind Load Calculation. . . . . . . . . . . . . . . . . . . 4-5
5 Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 About This Chapter . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Additional Materials needed . . . . . . . . . . . . . . . 5-2
5.3 Recommended Tools . . . . . . . . . . . . . . . . . . . . . . 5-2
5.4 Other Preparation Required . . . . . . . . . . . . . . . . 5-2
Step 1. Position FLAT JACK® Base Plates. . . . . 5-3
Step 2. Install Base Plates. . . . . . . . . . . . . . . . . . . 5-4
Step 3. Install Flashing Plates . . . . . . . . . . . . . . . 5-5
Step 4. Install Weather-Guard® Block
and PV Module Mounting Hardware. . . . . . . . 5-6
6 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 About This Chapter . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Rust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
7 Obtaining Assistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1 About This Chapter . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 Contact Information . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.3 Requesting Information. . . . . . . . . . . . . . . . . . . . 7-1
7.4 Requesting Onsite Support . . . . . . . . . . . . . . . . 7-1
7.5 Requesting Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.6 Requesting Engineering Support. . . . . . . . . . . 7-2
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FLAT JACK® Installation Manual
1
About This Manual
This manual is designed to assist you in preparing for and
installing your FLAT JACK® roof mount system.
The following other chapters are included:
•
Chapter 2, Safety Information
•
Chapter 3, FLAT JACK® Overview
•
Chapter 4, Site Layout Preparation
•
Chapter 5, Installation Instructions
•
Chapter 6, Preventive Maintenance
•
Chapter 7, Obtaining Assistance
1. About This Manual
Thompson Technology Industries, Inc.
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2
2. Safety Information
Safety Information
This chapter contains important safety instructions. You
must read, understand, and comply with all of these
safety instructions in order to protect your life and safety,
and to prevent equipment problems or damage. Failure
to follow the instructions in this chapter may void
equipment warranties.
2.1 Safety Notices
The following notices may appear throughout this
chapter:
WARNING! WARNINGS ALERT YOU TO THE POSSIBILITY
OF DEATH OR PERSONAL INJURY IF THESE INSTRUCTIONS
ARE NOT FOLLOWED.
CAUTION: CAUTIONS ALERT YOU TO THE POSSIBILITY OF
EQUIPMENT DAMAGE AND/OR ERRONEOUS DATA IF
THESE INSTRUCTIONS ARE NOT FOLLOWED.
2.2 Use of Ladders
•
DON'T stand above the highest safe standing level.
•
DON'T stand above the second step from the top of a
stepladder or the fourth rung from the top of an
extension ladder.
•
DON'T climb a closed stepladder.
•
DON'T climb on the back of a stepladder.
•
DON'T stand or sit on a stepladder top or pail shelf.
•
DON'T climb a ladder if you are not physically and
mentally up to the task.
•
DON'T exceed the Duty Rating (maximum load
capacity) of a ladder.
•
DON’T permit more than one person on a singlesided stepladder or an extension ladder.
•
DON'T place the base of an extension ladder too
close to or too far away from the building.
•
DON'T over-reach, lean to one side, or try to move a
ladder while on it. Climb down and then reposition
the ladder closer to your work.
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2. Safety Information
•
Properly set up and use the ladder in accordance with
safety instructions and warnings.
•
Wear shoes with non-slip soles.
•
Center your body on the ladder and keep belt buckle
between the rails while maintaining a firm grip.
•
Move materials with extreme caution so as not to
lose balance or tip the ladder.
•
Have another person help with a heavy ladder.
•
Have another person hold the ladder while you are
working on it.
•
Climb facing the ladder, move one step at a time, and
set each foot firmly before moving the other.
•
Haul materials with a line rather than carry them up
an extension ladder.
•
Use extra caution when carrying anything on a ladder.
2.3 Electrical Safety
•
There is an increased risk of electric shock if your
body is grounded.
•
Do not touch any energized component parts.
Always shut down and verify that electrical components are de-energized prior to performing any work
on them.
•
Never perform any work on any electrical component
or use any electrical tool while in contact with any
water or wet surface.
•
Read, understand, and comply with all electrical
safety instructions for all electrical tools you use.
•
Never work around or in any energized electrical
components. Always shut down electrical components and verify that they are de-energized before
performing any work on or inside them.
•
Insulate all connections and disconnected wires in
accordance with all applicable electrical codes, standards, and regulations. Improper electrical connections can result in death, serious personal injury, and/
or property damage.
•
Know your work area. Use extreme caution when
drilling, nailing, or cutting into any wall or other surface that might contain hidden electrical wiring or
components. Fasteners that come into contact with
2-2
FLAT JACK® Installation Manual
hidden electrical wiring or components could cause
electrocution or death.
2.4 Installation & Servicing
•
Installation or service performed by unqualified personnel increases the risk of injury and/or property
damage.
•
Always lift with your legs, holding your back straight
and vertical. Never overreach, twist, or use your back
when lifting any heavy object.
•
Using unauthorized parts will void your TTi warranty.
2.5 Fire or Explosion
•
Never store any flammable material near any electrical components. This includes solids, liquids capable
of producing flammable or explosive vapors, or flammable/explosive gases.
•
Never operate any tool near flammable substances
such as sawdust, petroleum products, solvents, etc.
2. Safety Information
•
Work in a clean, well-ventilated area free of combustible materials.
•
Never overload any electrical component or tool.
•
Never use flammable liquids or gases in any confined
area.
•
Do not smoke near live electrical equipment.
•
Keep your work area and surrounding environment
clean at all times.
•
Should a fire occur, shut off all live electrical equipment if you can do so without risking your personal
safety.
2.6 Personal Safety
•
Clutter, insufficient light, and improper ventilation
contribute to many accidents. Always keep your work
area clean, well lit, and well ventilated.
•
Electrical components and tools can cause sparks
that can ignite dust or fumes. Never operate any electrical component or tool where there is a risk of fire
from flammable liquids, gases, or dust.
•
Unauthorized persons can create additional hazards.
Keep bystanders, children, and visitors away from
your work area at all times.
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