IRONRIDGE AIRE User manual

©2022 IRONRIDGE, INC. VERSION 1.5 AIRE INSTALLATION MANUAL - I
INSTALLATION MANUAL
AIRE
INSTALLATION MANUAL

CONTENTS
©2022 IRONRIDGE, INC. VERSION 1.5 AIRE INSTALLATION MANUAL - 1
DISCLAIMER 1
RATINGS 2
MARKINGS 2
ATTACHMENTS 3
COMPONENTS 4
1. PLACE ATTACHMENTS 5
2. PLACE RAILS 5
3. SECURE AIRE LUG 6
4. SECURE MODULES 6
SECURE MODULES (AIRE LOCK STEALTH) 7
EXPANSION JOINTS 8
ELECTRICAL DIAGRAM 9
COMPOSITION SHINGLE 10-12
TILE 12-13
ADDITIONAL ROOF TYPES 14
CABLE TRAY SYSTEM 15
AIRE CAP 15
AIRE CLIP 15
AIRE MLPE MOUNT 16
CONTOUR TRIM 17
MODULE COMPATIBILITY 18-24
DISCLAIMER
This manual describes proper installation procedures and provides necessary standards required for product reliability.
Warranty details are available on the website. All installers must thoroughly read this manual and have a clear
understanding of the installation procedures prior to installation. Failure to follow these guidelines may result in property
damage, bodily injury or even death.
IT IS THE INSTALLER’S RESPONSIBILITY TO:
• Ensure safe installation of all electrical aspects of the array. All electrical installation and procedures should be
conducted by a licensed and bonded electrician or solar contractor. All work must comply with national, state and local
installation procedures, product and safety standards.
• Comply with all applicable local or national building and re codes, including any that may supersede this manual.
• Ensure all products are appropriate for the installation, environment, and array under the site’s loading conditions.
• Use only IronRidge parts or parts recommended by IronRidge; substituting parts may void any applicable warranty.
• Review the Design Assistant and Certication Letters to conrm design specications.
• Ensure provided information is accurate. Issues resulting from inaccurate information are the installer’s responsibility.
• Ensure bare copper grounding wire does not contact aluminum and zinc-plated steel components, to prevent risk of
galvanic corrosion.
• If loose components or loose fasteners are found during periodic inspection, re-tighten immediately. Any components
showing signs of corrosion or damage that compromise safety shall be replaced immediately.
• Provide an appropriate method of direct-to-earth grounding according to the latest edition of the National Electrical
Code, including NEC 250: Grounding and Bonding, and NEC 690: Solar Photovoltaic Systems.
• Disconnect AC power before servicing or removing modules, AC modules, microinverters and power optimizers.
• Review module and any 3rd party manufacturer’s documentation for compatibility and compliance with warranty terms
and conditions.
• Aire rails shall not be used as sca󰀨olding, a roof jack, or any form of an anchoring point for roof personnel.

©2022 IRONRIDGE, INC. VERSION 1.5 AIRE INSTALLATION MANUAL - 2
RATINGS
Product markings are located on the Aire Dock Bolt.
MARKINGS
UL 2703 LISTED
Conforms to UL STD 2703 Standard for Safety First Edition: Mounting Systems, Mounting Devices, Clamping/
Retention Devices, and Ground Lugs for Use with Flat-Plate Photovoltaic Modules and Panels
•Scope of Evaluation includes bonding, grounding, mechanical loading, and re classication
• Max Overcurrent Protective Device (OCPD) Rating: 40A
• Max Module Size: 30.5 ft²
•Module Orientation: Portrait or Landscape
•System Design Load Rating: 10 PSF downward, 5 PSF upward, 5 PSF lateral
•Actual system structural capacity including spans and cantilevers are dened by PE stamped certication letters
CLASS A SYSTEM FIRE RATING PER UL 2703
•Any Roof Slope with Module Types 1, 2, 3, 13, 19, 25 & 29: Allowed with any roof slope. Any module-to-roof gap is
permitted, with no perimeter guarding required.
•Module Types 4 and 5: Allowed with Steep Slope Roofs (≥ 9.5°). Any module-to-roof gap is permitted, low edge
guarding (trim) required
• Class A rated PV systems can be installed on Class A, B, and C roofs without a󰀨ecting the roof re rating
CLASS B SYSTEM FIRE RATING PER UL 2703
•Module Types 4 and 5: Allowed with Steep Slope Roofs (≥ 9.5°). Any module-to-roof gap is permitted, with no
perimeter guarding required
CERTIFIED TO CSA STD TIL NO. A-40 PHOTOVOLTAIC MODULE RACKING SYSTEMS
•Load Rating: 2400 PA [50 PSF]
AIRE RAILS CERTIFIED TO CSA STD C22.2 #126.1 METAL CABLE TRAY SYSTEMS
•Conforms to NEMA VE1
• Rail Internal Cross Section: 2in²
•Material: Aluminum
• Nonventilated / non ventilé
WATER SEAL RATINGS:
•Conforms to UL Subject 2703A - Halo UltraGrip, Steep Slope, Asphalt Shingle Roof
•UL 441 and TAS100(A) (Flashfoot2, L-Mount, Flashvue, All Tile Hook, Knockout Tile, Halo
UltraGrip)
•Tested and evaluated without sealant
•Any roofing manufacturer approved sealant is allowed.
•Ratings applicable for steep roof slopes between 2:12 and above.
STRUCTURAL CERTIFICATION
•Designed and Certied for Compliance with the International Building Code & ASCE/SEI-7
FLORIDA PRODUCT APPROVAL #FL29843
•Approved for installation both inside and outside High Velocity Hurricane Zones (HVHZ)
• Additional details and full list of approved components can be found here
#5003807

CONTENTS
©2022 IRONRIDGE, INC. VERSION 1.5 AIRE INSTALLATION MANUAL - 3
BONDING HARDWARE TORQUE VALUES
Please refer to each attachment's individual section for full details
on all torque values and instructions.
☐3/8" Aire Dock Bolt (1/2" Socket): 250 in-lbs
☐All Tile Hook Carriage Bolts (1/2" Socket): 132 in-lbs
☐Lynx Set Screw (3/16" Hex Drive): 150 in-lbs
☐Lynx Flange Nut (1/2" Socket): 150 in-lbs
ATTACHMENTS
QM L-MountFlashVue
QM QBase Universal
Tile
Knockout Tile Aire All Tile Hook and
Flashing (optional)
FlashFoot2
COMPOSITION SHINGLE
TILE
QM Tile Replacement
QM QBase Comp
QM QBase Shake -
Slate - Metal Shingle
ADDITIONAL ROOF TYPES
PRE-INSTALLATION
☐Verify module compatibility. See Page 19 for info.
TOOLS REQUIRED
☐Cordless Drill (non-impact)
☐Impact Driver (for lag bolts)
☐Torque Wrench (0-250 in-lbs)
☐1/2" Socket
☐7/16" Socket
☐7/32" Drill Bit
☐1/8" Drill Bit
☐5/8" Socket
☐1/4" Drill Bit
☐T30 Torx Bit
☐Channel Lock Pliers
☐#3 Phillips Bit
☐ 3/16" Hex Bit
QM Lynx Metal Roof
Attachment
ATTACHMENTS
HUG
(Halo UltraGrip)

©2022 IRONRIDGE, INC. VERSION 1.5 AIRE INSTALLATION MANUAL - 4
COMPONENTS
PRE-INSTALLATION
☐Verify module compatibility. See Page 19 for info.
TOOLS REQUIRED
☐Cordless Drill (non-impact)
☐Torque Wrench (0-250 in-lbs)
☐1/2" Socket
☐T30 Torx Bit
COMPONENTS
Aire A1 and A2 TiesAire A1 and A2 Rails
Aire Lock Mid
30-40mm Aire Lock Stealth
Aire Lug
Aire A1 and A2 Caps
Aire MLPE Mount
Aire Dock
TORQUE SPECIFICATIONS
Please refer to each attachment's individual section for full details
on all torque values and instructions.
☐Aire Tie Bolt (1/2" Socket): 144 in-lbs
☐Aire Lock Mid (1/2" Socket): 144 in-lbs
☐Aire Lock End (1/2" Socket): 144 in-lbs
☐Aire Lock Stealth (1/2" Socket): 144 in-lbs
☐Aire Dock (1/2" Socket): 250 in-lbs
☐Aire Lug (1/2" Socket): 144 in-lbs
☐Aire MLPE Mount (1/2" Socket): 144 in-lbs
☐Contour Clamp (T-30 Torx Bit): 80 in-lbs
☐Module Grounding Lug
☐Grounding Nut (7/16" Socket): 60 in-lbs
☐Grounding Lug Terminal Screws (7/16" Socket): 20 in-lbs
Aire Lock End
Aire Clip Ironridge L-Foot and
QM L-Foot
8" Bonding Jumper
Single Use Only
Contour Trim Module Grounding
Lug
Contour Clamp
JAYBOX

©2022 IRONRIDGE, INC. VERSION 1.5 AIRE INSTALLATION MANUAL - 5
1. PLACE ATTACHMENTS
Tested or evaluated third-party roof attachments:
• S-5! Standing Seam Metal Roof Clamps -Certication of metal
roof clamps includes bonding to both painted and galvalume metal
roofs. Tighten S-5! and S-5! Mini set screws to 130-150 in-lbs (≥ 24 gauge) or 160-180 in-lbs (22 gauge) roofs. Tighten S-5! M10 bolt to 240 in-lbs
or S-5! Mini M8 bolt to 160 in-lbs. Use the following fastening guidelines for other S-5! roof clamps: ProteaBracket™ - rmly seat roof screws and
tighten hinge bolt to 225 in-lbs; RibBracket™ - rmly seat roof screws and tighten M8 bolt (M8-1.25 x 22mm sold separately) to 160 in-lbs; and
SolarFoot™ - rmly seat roof screws and tighten M8 ange nut to 160 in-lbs.
• EcoFasten Green Fasten GF-1 Anchors
The general installation method for attachments is to
locate a rafter, drill a pilot hole and install the attachment.
When using approved third party attachments, refer to that
manufacturer's install instructions.
A. Connect Aire Tie
Insert Aire Tie 4” into rst Rail and secure with pre-
assembled Splice Bolt. Torque to 144 in-lbs. Slide
second Rail over Aire Tie and secure to second Rail with
second Splice Bolt.
➢Aire Tie may be installed in any location between two
attachments.
➢Rows of continious Rail exceeding 60 feet must use Expansion
Joints.
B. Place Aire Dock on Roof Attachments
Place Aire Dock on Roof Attachments, preparing Aire Dock
to attach to Rail. Do not torque until after Rail has been
installed.
➢Aire dock can be installed on the upslope or downslope side of
a roof attachment.
➢For steeper roof pitches greater than 8/12 (33 degs) It is
recommended that Aire dock be installed on the upslope side.
➢Aire Lock Mid and Aire Dock must be installed 1” away from
where two Rails join together.
C. Attach Rails
Drop Rail into Aire Dock, level Rail to desired height and
torque to 250 in-lbs. Ensure Rail is properly engaged in
Dock after torquing.
➢Rail can face either upslope or downslope on roof.
➢When using attachments with longer slots, do not install Rail
lower than the top of the L-Foot to avoid damage to modules.
2. PLACE RAILS
4.00
Torque to
144 in-lbs
Torque to
144 in-lbs
Aire Tie Center Mark
A.
Torque to
144 in-lbs
B.
C.

©2022 IRONRIDGE, INC. VERSION 1.5 AIRE INSTALLATION MANUAL - 6
3. SECURE AIRE LUG
4. SECURE MODULES
A. SECURE FIRST AIRE LOCK END CLAMP
Place rst module in position on Rails, a minimum of 1”
from Rail ends. Rotate clamp quarter-turn into place in
Rail. Fasten module to Rail ensuring clamp is fully enaged
with module frame. Torque to 144 in-lbs.
➢Ensure Rails are square before placing modules
➢Hold Aire Lock End while torquing to prevent rotation.
➢If using Aire Lock Stealth, see Aire Lock Stealth section.
B. SECURE NEXT MODULES
Rotate Aire Lock Mid clamp quarter-turn into each Rail,
slide them into place ush against the rst module. Slide
second module against Aire Lock Mids, torque to 144 in-
lbs. Repeat for each following module.
C. SECURE LAST AIRE END CLAMP
Place last module in position on Rails, a minimum of 1”
from Rail ends. Rotate clamp quarter-turn into place in
Rail. Fasten module to Rail ensuring clamp is fully en-
gaged with module frame. Torque to 144 in-lbs.
Repeat all steps for each following row of modules, leaving
a minimum of 1/2” gap between rows.
Aire Lug
Insert Aire Lug into Rail and twist quarter-turn clockwise to engage with Rail. Install a 10-6 AWG solid copper or stranded
grounding wire. Torque pre-assembled Terminal Bolt to 144 in-lbs securing wire to Lug and Lug to Rail.
➢Aire Lugs are intended for use with one solid or stranded copper wire, conductor size 10-6 AWG.
➢Aire Lugs can be installed anywhere along the Rail.
➢Ensure bare copper grounding wire does not contact aluminum and zinc-plated steel components, to prevent risk of galvanic corrosion.
Torque to
144 in-lbs
A.
B.
C.
Torque to
144 in-lbs

©2022 IRONRIDGE, INC. VERSION 1.5 AIRE INSTALLATION MANUAL - 7
AIRE LOCK STEALTH CLAMP
A. Slide Aire Lock Stealth into Rail
Slide Aire Lock Stealth into Rail channel far enough to
clear module frame.
B. Place module
Place module on rail over clamp, pull clamp onto module
frame (towards Rail end) by pulling on the clamp tether.
Pull until clamp can no longer move any further and is fully
engaged with module frame bottom ange.
C. Secure Aire Lock Stealth
Secure the clamp to module frame and Rail by torquing the
Aire Lock Stealth bolt. Pull the clamp tether as you torque
the clamp bolt into place, ensuring the clamp remains in
position and is fully engaged with module frame bottom
ange. Torque to 144 in-lbs.
Tuck the clamp tether into the rail and out of the way by
bending it to t inside the rail channel.
FRAME COMPATIBILITY
Aire Lock Stealth has been tested or evaluated with
all modules listed in the Module Compatibility section
having frames within the referenced dimensions. Be sure
the specic module being used meets the dimension
requirements.
➢Flange Thickness (X): 1-5 mm
➢Useable Bottom Flange Length (Y): 8-35 mm
Frame Compatibility:
X = 1-5mm
Y = 8-35mm
Torque to
144 in-lbs
B.
A.
C.
(Teather hidden
for clarity)

©2022 IRONRIDGE, INC. VERSION 1.5 AIRE INSTALLATION MANUAL - 8
EXPANSION JOINTS
ExpansionJoint
Alignment Mark
A.
No Bonding
Strap Required
No Modules
Over Gap
1”
Expansion Joints are required every 60' of continuous
Rail to allow for thermal expansion and contraction of the
system.
A. Insert Aire Tie to alignment marks
Insert Aire Tie into rst Rail up to Expansion Joint
alignment mark. Slide second Rail over Aire Tie to the
second Expansion Joint Alignment Mark, leaving a 1" gap
between the Rails. Torque only one side of the Aire Tie,
securing to Rail. Torque to 144 in-lbs.
B. Ensure 1" gap
There must be a minimum 1" of space between both the
edge of the Rail and the edge of the module, and between
the two pieces of Rail, as shown below. The 1" of space
between the edge of the Rail and the edge of the module
is to allow proper installation of the Aire Lock End.
C. Install 8" Bonding Jumper
Install the 8" Bonding Jumper between the two modules.
➢Alternatively two Aire Lugs or Module Grounding Lugs can be
used with a 10 AWG or larger copper wire.
➢Do not install modules over Expansion Joints.
1"
B.
A.
C.
1"
1"
8" Bonding Jumper

END CAPS (OPTIONAL)
©2022 IRONRIDGE, INC. VERSION 1.5 AIRE INSTALLATION MANUAL - 9
ELECTRICAL DIAGRAM
Grounding Lug Minimum 10 AWG
Copper Wire
Aire Lock Mid
Aire Lock End
Aire Lock Stealth
Fault Current
Ground Path
Aire Tie (Rail Connection)
Aire Tie Expansion Joint (Rail Connection)
Module Grounding Lug
8" Bonding Jumper **
*One Module Grounding Lug or Rail Grounding lug is required per row of a system.
Expansion joint bonding options**:
(1) 8" bonding jumper attached to module frames.
(2) PV grounding lugs attached to module frames with 10 AWG or larger ground wire.
(3) Two grounding lugs installed to one row of rails with 10AWG or larger copper wire.
Ground Lug with copper wire**
During servicing or maintenance, if the Dynobond is used at a splice location or used between rows to bond rows together
or if using a module lug instead of rail lug to bond rows together, module removal may disrupt the bonding path and could
introduce the risk of electric shock. If module removal is required for servicing, then a Bonding Jumper shall be installed to
the adjacent modules to maintain the ground path. Modules should only be removed by qualied persons in compliance
with the instructions in this manual.
*