PV PROFILE CROSS CONNECTOR

The ULAMEX PV Profile Cross Connector is a stainless steel junction element designed to create 90° perpendicular connections between PV mounting rails, enabling T-shaped junctions, cross-shaped intersections, and grid configurations that are essential for large-scale photovoltaic array layouts. Where standard profile connectors join rails end-to-end in a straight line, the cross connector joins rails at right angles — expanding the mounting system from linear runs to two-dimensional structural frameworks.

Installation Guidelines

Position the cross connector at the intended junction point where two rails meet at 90°. The connector bridges the upper surfaces of both rails, clamping them together at the intersection. Insert an M10 hammer bolt into the T-slot channel of the first rail (the continuous rail) and pass it through the corresponding slot in the cross connector plate. Insert a second M10 hammer bolt into the T-slot of the perpendicular rail and through the other slot in the connector.

Before final tightening, verify the 90° angle between the rails using a square or angle gauge. The slotted bolt holes in the connector allow fine adjustment of the rail position before lock-down. Tighten both DIN 6923 M10 flange serrated nuts to 18–22 Nm. The serrated flanges grip the connector plate and prevent rotational loosening under vibration and thermal cycling loads.

For T-junctions (where a perpendicular rail terminates against a continuous rail), position the cross connector so that the continuous rail slot runs along the full plate length and the perpendicular rail slot is centred at the T-intersection. For cross (+) junctions (two rails crossing), centre the connector at the intersection point. Verify that the connector does not obstruct module clamp positions on either rail.

Applications

• Large rooftop array grid structures — connecting east-west and north-south rail axes to form rigid two-dimensional frameworks for commercial PV systems
• Ground-mount cross-bracing — perpendicular rail connections in ground-mount post structures for lateral stiffening
• T-junction support points — connecting short stub rails to main rail runs for module edge support or array termination
• Carport PV canopy grids — overhead rail intersections in multi-direction carport canopy designs
• Flat-roof ballast system frames — perpendicular rail connections in ballasted support frameworks
• Custom array geometries — non-standard module layouts requiring angled or branching rail arrangements

Material Properties

Stainless steel construction provides the corrosion resistance and mechanical strength required for a structural junction element that is permanently exposed to outdoor weathering. Unlike aluminium connectors, the stainless steel cross connector does not deform under the high clamping forces needed to lock two rails at a fixed 90° angle. The material hardness prevents embedment of the bolt head and nut into the connector plate surface, maintaining consistent clamping force over the installation lifetime.

The stainless steel also provides beneficial galvanic compatibility when used with the aluminium rails: because the connector is a small cathodic area relative to the large anodic aluminium surface, galvanic corrosion effects are negligible. For installations in aggressive environments (coastal, industrial), an EPDM isolation strip between the connector and rail surfaces is recommended as additional protection.

Compatibility

The ULAMEX cross connector is designed to work with:

• ULAMEX PV profiles 40×40 mm — standard single-module rail, the primary compatible profile
• ULAMEX PV profiles 80×40 mm — double-width rail for heavy-duty configurations
• M10 hammer bolts — inserted into the rail T-slot channel for through-connector fastening
• DIN 933 M10 hex bolts + DIN 6923 flange nuts — alternative bolting through the connector slots
• ULAMEX mid-clamps and end-clamps — module clamps mount on either rail axis, including adjacent to the junction

Frequently Asked Questions

Q: What is the difference between a profile connector and a cross connector?

A profile connector (product 450) joins two rails end-to-end in a straight line — it is an internal splice. A cross connector joins two rails at a 90° angle — it is an external junction plate. They serve completely different structural functions: one extends rail length, the other creates two-dimensional frameworks.

Q: Can I create angles other than 90° with the cross connector?

The cross connector is designed for 90° perpendicular junctions only. For angled connections other than 90°, custom brackets or adjustable angle connectors would be required. The vast majority of PV array layouts use strictly orthogonal (90°) rail grids.

Q: How many cross connectors do I need per junction?

One cross connector per junction is standard for most applications. For junctions carrying high structural loads (long unsupported spans, high wind zones), two connectors can be stacked — one above and one below the junction point — to double the connection strength.

Q: Do I need isolation between the stainless connector and aluminium rails?

For standard inland installations, isolation is not required — the galvanic potential difference is minimal and the area ratio (small cathode / large anode) is favourable. For coastal or industrial environments, adding an EPDM tape strip between the connector and rail surfaces provides additional galvanic isolation as a precaution.

Need cross connectors for your PV rail grid? Request a Quote | +48 504 424 761 | [email protected]