IRONRIDGE XRL Light Rail User manual

Installation Manual
A complete Manual for the installation of IronRidge’s Light Rail system.
Solar Mounting Made Simple R
Roof
Mounting
System
2013 Edition v1.3
Light Rail (XRL)

Solar Mounting Made Simple R
Light Rail
Introduction
1
Installer Responsibility
Module Clamp Table
2
This Installation Manual was created to help with
the assembly of the IronRidge Light Rail Mounting
System.
TOC
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Table of Contents
Installation Manual
Customer Support
Tools Required For Assembly
Torque Values For Dry Bolts
Component List
Assembly: Step 1
5
Assembly: Step 2
6
Assembly: Step 3
7
Assembly: Step 3
8
Warranty Information
9
Assembly: Step 2
Grounding Setup
4

Solar Mounting Made Simple RLight Rail
Installation Manual
Page 1
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Introduction
The IronRidge Light Rail System is a exible and straightforward roof mounting solution for a wide variety of solar photovoltaic (PV)
needs. Due to its modular design, it can easily handle a wide variety 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; and
viii. Ensuring 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; and
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 with your installation or
have suggestions on how we can improve your experience, call IronRidge customer support: [phone]
Tools Required For Assembly
Hex Head Size Component
5/16” #12 Self Drilling/tapping screws
7/16” 1/4 cap-end screws and bolts
9/16” 3/8 cap-end screws and bolts
Wrenches are required to assemble the IronRidge Light Rail System. An open-end wrench, box-end wrench, or socket drive with
sockets will suce. The sockets will need to support the following size hex heads:
Torque Values For Dry Bolts
Bolt Size Required Torque Value
1/4-20 120 in-lbs. (dry), 100 in-lbs. (wet), 65 in-lbs. on End Clamps (wet or dry)
3/8-16 236 in-lbs.
Use the following torque values in this assembly.

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Installation Manual
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Module Clamp Table
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.
Note: 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.
Mm Inches Clamp Type Bolt Height End Clamp Mid Clamp (hex) Mid Clamp (tbolt)
31.0 - 32.5 1.22 - 1.28 I 2.00” 29-7000-125 29-7000-105 29-70TB-105
33.3 - 34.8 1.31 - 1.37 A 2.00” 29-7000-134 29-7000-105 29-70TB-105
34.8 - 36.8 1.37 - 1.45 B 2.00” 29-7000-224 29-7000-105 29-70TB-105
39.0 - 41.0 1.53 - 1.61 C 2.25” 29-7000-157 29-7000-101 29-70TB-101
41.1 - 42.7 1.62 - 1.68 J 2.25” 29-7000-165 29-7000-101 29-70TB-101
42.7 - 44.2 1.68 - 1.74 E 2.25” 29-7000-171 29-7000-101 29-70TB-101
45.0 - 47.0 1.77 - 1.85 F 2.50” 29-7000-214 29-7000-108 29-70TB-108
46.7 - 48.3 1.84 - 1.90 K 2.50” 29-7000-187 29-7000-108 29-70TB-108
49.0 - 51.1 1.93 - 2.01 G 2.50” 29-7000-204 29-7000-108 29-70TB-108
57.4 - 58.9 2.26 - 2.32 H 2.75” 29-7000-230 29-7000-104 29-70TB-104
Module Thickness Part Numers
Clamp Info

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Installation Manual
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Component List
The IronRidge Light Rail System contains the following parts:
L-Foot
Attaches to the roof and is the
anchor point for the rest of the
panel assembly.
Light Rail
Attaches to the foot
via foot clamp and
provides support
for the PV modules.
Mid Clamp
Clamps the inside edges of the PV
modules to the rails.
Internal Splice
Ties the extrusion rails
together, extending their
length.
End Clamp
Clamps the outside ends of the
PV modules to the rails.
End Cap
Caps o the end of the rail
and prevents the collection
of debri inside rail.

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Installation Manual
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A. Mount all of the feet to the roof
in the desired locations.
Note: Determine the maximum
distance between feet according
to engineering specications.
Assembly
Step 1. Mounting the feet and the rst piece of rail.
Step 2. Mounting the next pieces of rail.
B. 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.
B. 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.
D. 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 236 in-lbs.
C. 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.
C. 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.

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Installation Manual
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C. Lay the rail on its side, with the
slotted side down as shown.
D. Slide the internal splice half way
into the internal cavity in the rail.
It should extend approximately
three (3) inches into the cavity.
F. Loosely mount this piece of rail
onto its footings.
G. By moving this second rail along
its footings, the internal splice
should slip into the cavity on the
rst rail, with the rails butting
tightly and evenly together.
H. Maintain rail alignment while
following the next steps.
I. You should mark o approximately
three (3) inches from the end of the
rst rail (where the internal splice
should end). Drive one (1) self-
tapping screws through the second
rail, one (1”) inch from the edge
utilizing the same horizontal
location as the rst rail.
E. Using one (1) self-drilling,
self-tapping screw, one (1”) inch
from the edge of the rail, secure the
internal splice into the rail as shown
on the 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 procedures.
J. Repeat this procedure for the
remaining rails.

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Installation Manual
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Step 3. Clamping the panels to the rails.
A. Lay the rst PV module in position
on the rails.
Note: For installations that utilize
WEEBs, please refer to Wiley/Burndy
installation manual for “IronRidge
Light and Standard Series Rails”
for proper installation procedures.
C. Complete the clamp assembly
with a ange nut as shown.
Tighten end clamp to 65 in-lbs.
D. Repeat with the other clamp.
E. Working from the opposite side of
the PV module. Assemble the mid
clamps by putting a clamp on the
bolt, followed by the ange nut.
B. Then slip the end clamp over the
bolt, making sure it is rmly
hooked over the side of the
module.

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Installation Manual
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F. Place the second PV Module into
position on the rails, sliding it against
the rst so the mid clamps are in
contact with the edges of both panels.
Note: For installations that utilize
WEEBs, please refer to Wiley/Burndy
installation manual for “IronRidge
Light and Standard Series Rails” for
proper installation procedures.
G. Tighten to 120 in-lbs. (dry), 100 in-lbs. (wet).
H. Repeat the procedure using
mid clamps to secure each
successive module.
I. Secure the last module at the end
of the rails using the other set of
end clamps. Tighten to 65 in-lbs.

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Installation Manual
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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.