IRONRIDGE Standard User manual

Roof
Mounting
System
Installation Manual
2013 Edition v1.13
A complete manual for the installation of IronRidge’s rail systems with integrated grounding.
Standard (XRS) and Light (XRL) Rails with Integrated Grounding
*Conforms to UL SUB 2703
4008083

Standard (XRS) and Light (XRL) Rails with Integrated Grounding
Introduction
1
Installer Responsibility
Electrical Considerations
3
This Installation Manual was created to assist the assembly of the IronRidge Standard (XRS) and Light (XRL) Rail
Mounting Systems with Integrated Grounding.
Customer Support
Tools Required For Assembly
Torque Values
Component List
Assembly: Steps 1-3
4
Assembly: Steps 3-4
5
Assembly: Steps 4-5
6
Assembly: Step 5-6
7
Warranty Information
9
TOC
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Module Clamp Table
2
Rails with Integrated Grounding
Installation Manual
8

Page 1
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Rails with Integrated Grounding
Installation Manual
Introduction
The IronRidge Standard (XRS) and Light (XRL) Rail Systems are exible and straightforward roof mounting solutions for
a wide variety of solar photovoltaic (PV) needs. Due to their modular design, they can easily handle a multitude of panel
sizes and quantities.
Installer Responsibility
The installer is solely responsible for:
I. Complying with all applicable local or national building codes, including any that may supersede this manual;
II. Ensuring that IronRidge and other products are appropriate for the particular installation and the installation
environment;
III. Ensuring that all structural support members, including the roof, its rafters, and connections, can support the array
under all code level loading conditions;
IV. Using only IronRidge parts and installer-supplied parts as specied by IronRidge. Substitution parts may void the
warranty;
V. Ensuring that anchoring devices including lag screws have adequate pullout strength and shear capacities as
installed;
VI. Maintaining the waterproof integrity of the structural support or roof, including selection of appropriate ashing;
VII. Ensuring safe installation of all electrical aspects of the PV array;
VIII. Ensuring that PV module is installed per module manufacturer’s installation requirements; the PV module
manufacturer accepts clamping and grounding methods described in this manual; that PV module is UL or CE listed
and verication of PV Module’s capacity to support the loads associated with the given array;
IX. 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.
Customer Support
IronRidge makes every eort to ensure your mounting kit is easy to install. If you need assistance at any point in your
installation or have suggestions on how we can improve your experience, call customer support at 1-800-227-9523 or
email us at [email protected].

Page 2
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Rails with Integrated Grounding
Installation Manual
Tools Required For Assembly
Hex Head Size Component
5/16” #10 Hardware and #12 Self-drilling/tapping screws
7/16” 1/4” Hardware (Clamps)
9/16” 3/8” Hardware (L-feet)
Torque Values
Bolt Size Required Torque Value
#10 32 in-lbs Dry (27 in-lbs Lubricated)
#12 84 in-lbs Dry (73 in-lbs Lubricated)
1/4-20 84 in-lbs Dry (73 in-lbs Lubricated)
1/4-20 (End Clamps) 65 in-lbs Dry (55 in-lbs Lubricated)
3/8-16 236 in-lbs (201 in-lbs Lubricated)
Use the following torque values in this assembly.
Module Clamp Table
Millimeters Inches End Clamp Grounding Mid Clamp
31.0 - 32.5 1.22 - 1.28 29-7000-125 RS-GD-MCL-200
33.3 - 34.8 1.31 - 1.37 29-7000-134 RS-GD-MCL-200
34.8 - 36.8 1.37 - 1.45 29-7000-224 RS-GD-MCL-225
39.0 - 41.0 1.53 - 1.61 29-7000-157 RS-GD-MCL-225
41.1 - 42.7 1.62 - 1.68 29-7000-165 RS-GD-MCL-250
42.7 - 44.2 1.68 - 1.74 29-7000-171 RS-GD-MCL-250
45.0 - 47.0 1.77 - 1.85 29-7000-214 RS-GD-MCL-250
46.7 - 48.3 1.84 - 1.90 29-7000-187 RS-GD-MCL-275
49.0 - 51.1 1.93 - 2.01 29-7000-204 RS-GD-MCL-275
57.4 - 58.9 2.26 - 2.32 29-7000-230 Unsupported
Module Thickness Part Numbers
Torque wrenches are required to assemble the rails. The sockets will need to support the following size hex heads:

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Component List
The IronRidge Standard and Light Rail System with Integrated Grounding contains the following parts:
L-Foot
Attaches to the roof and
supports rails.
Standard (XRS) and Light (XRL) Rail
Attaches to L-foot and
provides support
for the PV modules.
Grounding Mid Clamp
Secures PV modules to rails
and provides grounding to
the rail and between the two
adjacent modules.
Internal Splice
Provides a structural connection
when connecting rails.
End Clamp
Secures PV modules to rails
utilizing the rail top slot.
End Cap
Caps o the end of the rail
and prevents the collection
of debris inside rail.
Grounding Solutions
Rail to Rail Grounding Strap and
Grounding Lugs.
Wire Clips
Wire management for rails.

Page 4
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A. Determine the appropriate ashing required for your roof type and
project. Install ashing per manufacturer’s requirements.
B. Mount all the L-feet to the roof in the desired locations using a minimum
5/16” x 3” long Lag Bolt. The 5/16” Lag Bolt attached to a structural roof
member such as a rafter. For metal or tile roofs, install a mount suitable
for the application, per mount manufacturer’s requirements.
Note: The roof attachment spacings are dened by many variables such as site
conditions, rail type and roof structure. Refer to the IronRidge Certication letters
or online Design Assistant to determine appropriate attachment spacing.
Assembly Steps
Step 1. Install Applicable Roof Flashing and L-feet
Step 3. Rail to Rail Connections
Step 2. Attaching Rails To L-Feet
A. Slide the 3/8” bolts into rail side slot. Space bolts to match the L-feet
spacing.
B. Loosely attach rail to L-feet using 3/8”hardware. Position rail at desired
height and level. Once level torque 3/8”hardware to 236 in-lbs (dry).
Move to Step 3 for Rail to Rail Connections then repeat Step 2 for each
L-foot connection.
Note: Attaching rails to L-Feet may be performed before or after making rail-to-
rail connections, depending on the installer’s preference.
Note: This connection requires proper grounding on rails with grounding lugs by using one of the two following Rail to Rail Connection
methods. For rails without lugs, use the Internal Splice and self-drilling screws without the grounding strap and star washers (See Page 8). For
rows exceeding 50 feet of rail, IronRidge recommends the Rail to Rail Expansion Joint. Expansion joints prevent the potential buckling of rails
due to thermal expansion. At the installer’s discretion, a Rail to Rail Expansion Joint may also be used at lengths of less than 50 feet of rail.
Rail to Rail (Basic) Connection
A. Insert internal splice into rst rail then secure splice with hardware and Grounding Strap (9AWG). Attach and assemble as shown.
B. Next, slide second rail over splice and secure with hardware on opposite end of Grounding Strap.
C. Repeat this procedure for remaining Rail to Rail Connections. (Use Grounding Strap only on rails with lugs.)
Standard Rail Light Rail
Centered 1”From Edge
Torque to 84 in-lbs
6” inside Rail
Self-drilling screw
Grounding
Strap
Star Washer
Centered 1”From Edge
Torque to 84 in-lbs
Centered 1”From Edge
Torque to 84 in-lbs
3” inside Rail
Self-drilling screw
Grounding
Strap
Star Washer
Centered 1”From Edge
Torque to 84 in-lbs

Page 5
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Rail to Rail Expansion Joint
A. Insert splice into rst rail then secure splice with self-drilling screw.
B. Attach hardware and Grounding Strap (9AWG) one (1) inch from end of rail as shown below.
C. Next, slide the second rail over the splice and attach other end of Grounding Strap with hardware. (Use Grounding Strap only on
rails with lugs.)
Standard Rail Light Rail
1/2” Gap
6” inside Rail
Self-drilling screw
Grounding
Strap
1” From Edge (2x)
Torque to 84 in-lbs
Centered 1”From Edge
Torque to 84 in-lbs
1/4” Hex Nut
Grounding Strap
1/4” T-Bolt
1/2” Gap
3” inside Rail
Self-drilling screw
Grounding
Strap
1” From Edge (2x)
Torque to 84 in-lbs
Centered 1”From Edge
Torque to 84 in-lbs
1/4” Hex Nut
Grounding Strap
1/4” T-Bolt
Step 4. Equipment Grounding
Note: In order to properly ground the PV modules and IronRidge components to the equipment ground, a grounding lug or Lay-in Lug must
be attached to one (1) rail near the end of each row. This connection requires the use of one of the two following lugs.
IronRidge Grounding Lug
1. Using a 13/64”or #7 drill bit, drill a hole through one side of the Standard Rail (both sides for Light Rail), a minimum of ½” from
the end of the rail; roughly centered on internal cavity of rail as shown below. (Debur as needed)
2. Next assemble the Grounding Lug with the provided #10-32 Machine Screw, #10 Star Washer and #10 Kep Nut.
3. Install a minimum 10AWG solid copper grounding conducting wire. Torque to 20 in-lbs for 10AWG, 25 in-lbs for 8AWG, or 35 in-
lbs for 4 and 6AWG.
Standard Rail Light Rail
#10 Kep Nut
Star Washer
#10 Hex Bolt
Torque to 32 in-lbs
#10 Set Screw Torque
to 20 in-lbs for 10AWG
Star Washer
#10 Hex Bolt
Torque to 32 in-lbs
#10 Set Screw Torque
to 20 in-lbs for 10AWG
#10 Kep Nut

Page 6
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Rails with Integrated Grounding
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Wiley Grounding Lug (WEEB-6.7)
1. Install grounding lug per manufacturer’s recommendations as shown below (same for both Light and Standard Rails).
2. Install minimum 6-10AWG solid copper grounding conducting wire.
1/4” Hex Nut Torque to 10 ft-lbs
1/4” Lock Washer
1/4” Flat Washer
1/4” Hex Bolt Torque to 7 ft-lbs
Weeb
1/4” Hex Bolt
Step 5. Installing Modules
End Clamp
A. Place the rst PV module in position on the rails. Module should be a minimum of 1.5”from end of rail.
B. Next, secure End Clamp on rail as shown. Ensure End Clamp is securely hooked over top of module.
C. Repeat with end clamp on the other rail.
Torque to 65 in-lbs
1/4” Hex Nut
End Clamp
1/4” Hex Bolt

Page 7
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Grounding Mid Clamp
D. Once the rst PV module is in place, loosely assemble hardware and Grounding Mid Clamp as shown below.
E. Next, slide second PV module into position underneath the Grounding Mid Clamp and secure with hardware. Ensure the
Grounding Mid Clamp teeth are in contact with both of the PV module frames and the T-Bolt is properly aligned in track. T-Bolt
indent should be perpendicular to rail.
F. Repeat steps for other clamp and modules.
End Clamp
G. Secure the last PV Module with an End Clamp repeating steps above.
1/4” Hex Nut
Grounding
Mid Clamp
1/4” T-Bolt
Torque to 84 in-lbs
Step 6. Installing End Caps
A. Firmly press End Caps on with hand or rubber mallet.
T-bolt Indent

Page 8
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Electrical Considerations
Note: IronRidge Standard (XRS) and Light (XRL) Rail Mounting Systems with Integrated Grounding must be used with UL1703 listed
PV modules and must be installed per PV module manufacturer’s installation instructions. All electrical installation and procedures should
be conducted by skilled, licensed and bonded electricians or solar contractor. 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®) sections, National Electrical Installation Standards (NEIS™), UL Standards, and OSHA Regulations.
Basic Grounding Diagram
A. IronRidge Grounding Lugs and Wiley Electronics, LLC #WEEB-6.7 are approved for use with this system.
B. The Rail to Rail (Splice) Connection requires proper grounding on rails with grounding lugs by using one of the two Rail to Rail
Connection methods described in Step 3 of this manual.
C. A minimum 10 AWG solid copper grounding conductor must be used to properly ground the system, as shown below.

Page 9
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Installation Manual
Warranty Information
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 HotDip 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 nonfunctionally-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.