Ironridge Standard rail roof mounting User manual

Standard Rail Roof Mounting

Installation Manual

2| Standard Rail Installation Manual

Introduction

The IronRidge Standard Rail System is a exible and straightforward roof mounting solution for a wide variety of solar

photo- voltaic (PV) needs. Due to its modular design, it can easily handle a wide variety of panel sizes and quantities.

1. Installer Responsibility

The installer is solely responsible for:

♦Complying with all applicable local or national building codes, including any that may supersede this manual;

♦Ensuring that IronRidge and other products are appropriate for the particular installation and the installation

environment;

♦Ensuring that all structural support members, including the roof, its rafters, and connections, can support the

array under all code level loading conditions;

♦Using only IronRidge parts and installer-supplied parts as specied by IronRidge. Substitution parts may void

the warranty;

♦Ensuring that anchoring devices including lag screws have adequate pullout strength and shear capacities as

installed;

♦Maintaining the waterproof integrity of the structural support or roof, including selection of appropriate ash-

ing;

♦Ensuring safe installation of all electrical aspects of the PV array; and

♦Ensuring correct and appropriate design parameters are used in determining the design loading used for the

specic installation. Parameters, such as snow loading, wind speed, exposure and topographic factor should be

conrmed with the local building ocial or a licensed professional engineer.

2. Customer Support

IronRidge makes every eort to ensure your mounting kit is easy to install. If you need assistance at any point with

your installation or have suggestions on how we can improve your experience, call IronRidge customer support: (707)

459-9523

3. Tools Required For Assembly

The following tools are required to assemble the IronRidge Standard Rail System:

Tool Use for

Wrenches

Open-end wrench, Box-end wrench, or

socket drive with sockets to support the fol-

lowing size hex heads:

♦7/16”

♦9/16”

♦1/4 cap-end screws and bolts

♦3/8 cap-end screws and bolts

3| Standard Rail Installation Manual

4. Torque Values For Dry Bolts

Use the following torque values in this assembly.

Bolt Size Required Torque Value

♦1/4-20 120 in-lbs.

♦3/8-16 180 in-lbs.

5. Grounding Setup

All electrical installation and procedures should be conducted by skilled, licensed and bonded electricians.

All work must comply with all national, state and local installation procedures, product and safety standards.

These standards include but are not limited to applicable National Electrical Code (NEC®), National Electrical

Installation Standards (NEIS™), UL Standards, and OSHA Regulations.

For installations that utilize WEEBs, WEEB Lugs and WEEB Bonding Jumpers, please refer to Wiley/Burndy

installation manual for“IronRidge Light and Standard Series Rail” for proper installation procedures.

4| Standard Rail Installation Manual

6. Component List

The IronRidge Standard Rail System contains the following parts:

Note: The component list indicated here is for reference only. The actual component quantities will vary according to

the quantity and make of modules that the mount is congured for. Please check the packing list that ships with every

mount for a conrmation of the items that are intended to ship with the specic product on your order.

L-Foot (51-6000-002)

Attaches to the roof and is the anchor point for the

rest of the panel assembly

Internal Splice (51-7000-002)

Ties the extrusion rails together, extending their

length.

Standard Rail (51-7000-XXX)

Attaches to the foot via the foot clamp and provides

support for the PV modules

End Clamp (51-6000-XXX)

Clamps the outside ends of the PV modules to the

rails

Center Clamp (51-6000-005)

Clamps the inside edges of the PV modules to the

rails

5| Standard Rail Installation Manual

Component List continued...

Part Qty Part Number Comments

Internal Splice 1 29-7000-010 Used to join Standard Rails together

1 splice is used to splice 2 pairs of rail.

10-16 x1/2” , self-drilling, self tapping

screw, SS

8 48-1016-500

L-Foot Kit 1 29-7000-017 Used to attach L-foot to Standard Rail

1 kit per 4 L-feet.

L-Foot 4 51-7000-001

3/8-16-1” hex cap bolt, SS 4 23-3716-100

3/8-16, ange nut, SS 4 25-2501-016

Center Clamp Kit 1 29-7000-xxx Used between PV panels to secure to Stan-

dard Rail

1 kit will cover 2 PV panels within a row.

Part number changes depending on panel

required.

Center Clamp 4 51-6000-005

1/4-20 x 2.00” hex cap bolt, SS, or

1/4-20 x 2.50” hex cap bolt, SS, or

1/4-20 x 2.75” hex cap bolt, SS

4 23-2520-200,

23-2520-250,

23-2520-275

Length of bolt depends on the thickness of

the PV panel.

1/4-20 ange nut, SS 4 25-2501-014

End Clamp Kit 1 29-7000-xxx Used on the rst and last PV panel in a row

1 kit will cover the rst and last PV panels in

a row. Part number changes depending on

panel used. Example part numbers shown.

End Clamp 4 51-6000-xxx

1/4-20 x 1” SS hex-cap bolt, SS 4 23-2520-100

1/4-20 ange nut, SS 4 25-2501-014

Standard Rail Spares Kit 1 29-7000-001

6| Standard Rail Installation Manual

7. Assembly

Step 1 - mounting the feet and the rst piece of rail

Parts required for this step Qty Part Number

Standard Rail 4 51-7000-XXX

L-Foot Assembly Kit 1 29-7000-017

Foot 4 51-7000-001

3/8-16 x 1”, hex cap bolt, SS 4 23-3716-100

3/8-16, ange nut, SS 4 25-2501-016

Center Clamp Kit 1 29-7000-xxx

1/4-20 x 2.00” hex cap bolt, SS, or

1/4-20 x 2.50” hex cap bolt, SS, or

1/4-20 x 2.75” hex cap bolt, SS

4 23-2520-200,

23-2520-225,

23-2520-250,

23-2520-275

End Clamp Kit 1 29-7000-xxx

1/4-20 x 1” SS hex-cap bolt, SS 4 23-2520-100

1. Mount all of the feet to the roof

in the desired locations.

Note: Determine the maximum

distance between feet according

to engineering specications.

7| Standard Rail Installation Manual

2. On the rst piece of rail, slide

3/8-16” bolts into the side facing

t-slot on the rail. Space the bolts

out to match the foot spacing.

3. On this same piece of rail, slide

1/4-20” bolts into the top facing

t-slot on the rail. Space the bolts

out to match the panel spacing.

4. Attach this rst piece of rail to

the feet mounted on the roof.

Mount the rail to each foot with

a ange nut and hex bolt. Hand

tighten the nuts and check the

level of the rail.

Tighten 3/8-16 hardware to 180

in-lbs.

Step 2 - mounting the next pieces of rail

Parts required for this step Qty Part Number

Standard Rail 4 51-7000-XXX

L-Foot Assembly Kit 1 29-7000-017

Foot 4 51-7000-001

3/8-16 x 1”, hex cap bolt, SS 4 23-3716-100

3/8-16, ange nut, SS 4 25-2501-016

Center Clamp Kit 1 29-7000-xxx

1/4-20 x 2.00” hex cap bolt, SS, or

1/4-20 x 2.50” hex cap bolt, SS, or

1/4-20 x 2.75” hex cap bolt, SS

4 23-2520-200,

23-2520-250,

23-2520-275

End Clamp Kit 1 29-7000-xxx

1/4-20 x 1” SS hex-cap bolt, SS 4 23-2520-100

8| Standard Rail Installation Manual

Parts required for this step Qty Part Number

Internal Splice 1 29-7000-010

110-16 x1/2” , self-drilling, self tapping screw, SS 8 48-1016-500

WEEB Bond Jumper (if used) see below 29-4000-003

1. On the next piece of rail, slide 3/8-16”

bolts into the side facing t-slot on the

rail. Space the bolts out to match the foot

spacing.

2. On this same piece of rail, slide 1/4-20”

bolts into the top facing t-slot on the rail.

Space the bolts out to match the panel

spacing.

3. Lay the rail on its side, with the slotted

side down as shown.

4. Slide the internal splice half way into the

internal cavity in the rail. It should extend

approximately six (6) inches into the cav-

ity.

5. Using two of the self-drilling, self-tapping

screws, secure the internal splice into the

rail utilizing the screw pattern shown at

right. (Note- For installations that utilize

WEEB Bonding Jumpers, please refer to

Wiley/Burndy installation manual for

“IronRidge Light and Standard Series

Rails” for proper installation proce-

dures.)

6. Loosely mount this piece of rail onto its

footings.

7. By moving this second rail along its foot-

ings, the internal splice should slip into

the cavity on the rst rail, with the rails

butting tightly and evenly together.

9| Standard Rail Installation Manual

8. Maintain rail alignment while following

the next steps.

9. You should mark o approximately six (6)

inches from the end of the rst rail (where

the internal splice should end). Drive two

self tapping screws through the rst rail in

utilizing the pattern shown at right within

the area you marked o.

10. Repeat this procedure for the remaining

rails.

Step 3 - clamping the panels to the rails

Parts required for this step Qty Part Number

Center Clamp Kit 1 29-7000-xxx

1/4-20 ange nut, SS 4 25-2501-014

End Clamp Kit 1 29-7000-xxx

1/4 ange nut, SS 4 25-2501-014

WEEB-DMC (if used) see below 29-4000-001

1. Lay the rst PV module in posi-

tion on the rails. (Note- For

installations that utilize WEEBs,

please refer to Wiley/Burndy in-

stallation manual for“IronRidge

Light and Standard Series Rails”

for proper installation proce-

dures.)

1. Then slip the end clamp over

the bolt, making sure it is rmly

hooked over the side of the

module.

10 | Standard Rail Installation Manual

2. Complete the clamp assembly

with a ange nut as shown.

Tighten to 60-65 in-lbs.

3. Repeat with the other clamp.

4. Working from the opposite side

of the PV module. Assemble

the center clamps by putting a

clamp on the bolt, followed by

the ange nut.

5. Place the second PV Module

into position on the rails, sliding

it against the rst so the center

clamps are in contact with the

edges of both panels. (Note- For

installations that utilize WEEBs,

please refer to Wiley/Burndy in-

stallation manual for“IronRidge

Light and Standard Series Rails”

for proper installation proce-

dures.)

11 | Standard Rail Installation Manual

6. Tighten to 10 ft-lbs (120 in-lbs).

7. Repeat the procedure using

center clamps to secure each

successive module.

8. Secure the last module at the

end of the rails using the other

set of end clamps.

12 | Standard Rail Installation Manual

IronRidge Limited Warranties

Eective for IronRidge, Inc. (“IronRidge”) mounting structure components (“Products”) manufactured after

April 1st, 2012, IronRidge provides the following warranties, for Products installed properly and used for the

purpose for which the Products are designed:

• nishes shall be free of visible defects, peeling, or cracking, under normal atmospheric conditions, for

a period of three (3) years from the earlier of (i) the date of complete installation of the Product or (ii)

thirty days after the original purchaser’s date of purchase of the Product (“Finish Warranty”);

• components shall be free of structurally-related defects in materials for a period of ten (10) years

from the earlier of (i) the date of complete installation of the Product or (ii) thirty days after the original

purchaser’s date of purchase of the Product;

• components shall be free of functionally-related manufacturing defects for a period of twenty (20)

years from date of manufacture.

The Finish Warranty does not apply to: (a) surface oxidation of the galvanized steel components or any

foreign residue deposited on Product nish; and (b) Products installed in corrosive atmospheric conditions,

as dened solely by IronRidge; corrosive atmospheric conditions include, but are not limited to, conditions

where Product is exposed to corrosive chemicals, fumes, cement dust, salt water marine environments or

to continual spraying of either salt or fresh water. The Finish Warranty is VOID if (c) the practices specied by

AAMA 609 & 610-02 –“Cleaning and Maintenance for Architecturally Finished Aluminum”(www.aamanet.

org) are not followed by Purchaser for IronRidge’s aluminum based components; and (d) if the practices

specied by ASTM A780 / A780M - 09“Standard Practice for Repair of Damaged and Uncoated Areas of Hot-

Dip Galvanized Coatings”are not followed by Purchaser for IronRidge’s galvanized steel-based components.

The warranties above do not cover any parts or materials not manufactured by IronRidge, and exclude non-

functionally-related defects, as dened solely by IronRidge. The warranties do not cover any defect that has

not been reported to IronRidge in writing within twenty (20) days after discovery of such defect.

In the event of breach of or non-compliance with the warranties set forth above, IronRidge’s sole obligation

and liability, and the sole and exclusive remedy for such breach or non-compliance, shall be correction of

defects by repair, replacement, or credit, at IronRidge’s sole discretion. Such repair, replacement or credit

shall completely satisfy and discharge all of IronRidge’s liability with respect to these warranties.

Refurbished Product may be used to repair or replace the defective components. Transportation, installation,

labor, or any other costs associated with Product replacement are not covered by these warranties and are

not reimbursable. These warranties additionally do not cover (a) normal wear, or damage resulting from

misuse, overloading, abuse, improper installation (including failure to follow professional instruction and

certication), negligence, or accident, or from force majeure acts including any natural disasters, war or

criminal acts; and (b) Products that have been altered, modied or repaired without written authorization

from IronRidge or its authorized representative; and (c) Products used in a manner or for a purpose other

than that specied by IronRidge. A formal document proving the purchase and the purchase date of the

Product is required with any warranty claim.

Except as set forth above, IronRidge sells the Products on an “AS IS” basis, which may not be free of errors or

defects, and ALL EXPRESS OR IMPLIED REPRESENTATIONS AND WARRANTIES, INCLUDING ANY WARRANTIES

OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, QUALITY, WORKMANLIKE EFFORT,

CORRESPONDENCE TO DESCRIPTION, DESIGN, TITLE OR NON-INFRINGEMENT, OR ARISING FROM COURSE OF

DEALING, COURSE OF PERFORMANCE OR TRADE PRACTICE, ARE HEREBY DISCLAIMED.

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