UNIRAC SUNFRAME - INSTALLATION 802 User manual

Contents
Letter of certification . . . . . . . . . . . . . . . . . . . . . . . 2
Scope, certification, and installer responsibility . . . . . . . . 3
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SunFrame components . . . . . . . . . . . . . . . . . . . . . . 4
Installer supplied materials . . . . . . . . . . . . . . . . . . . 4
Planning code-compliant SunFrame installations . . . . . . . 5
Installing the array . . . . . . . . . . . . . . . . . . . . . . . . 8
Footing and splicing requirements . . . . . . . . . . . . . . . 9
Material planning for rails and cap strips . . . . . . . . . . 11
Frequently asked questions
about standoffs and roof variations . . . . . . . . . . . . . . 12
October 2003
Pub 031016-2ii
©2003 by UniRac, Inc.
All rights reserved.
Code-Compliant Planning and Assembly
with California Building Code Certification*
Installation Manual 802
SunFrame™ products are U.S. patent pending.
*For Uniform Building Code certification for SunFrame, see Installation Manual 801.1.

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Installation Manual 802 SunFrame™ Code-Compliant Planning and Assembly

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Installation Manual 802 SunFrame™ Code-Compliant Planning and Assembly
Scope, certification, and installer responsibility
Please review this manual thoroughly
before installing your SunFrame.
This bulletin provides (1) support-
ing documentation for building per-
mit applications relating to UniRac’s
SunFrame™ PV module framing and
mounting system, and (2) planning
and assembly instructions for Sun-
Frame.
SunFrame products, when installed in
accordance with this bulletin, will be
structurally adequate and will meet the
Uniform Building Code, 1997, hereaf-
ter UBC 1997; and the 2001 California
Building Code. UniRac also provides a
limited warranty on SunFrame prod-
ucts (below).
The installer is solely responsible for:
• Complying with all applicable local or national
building codes, including any that may supercede
this manual;
• Ensuring that UniRac and other products are ap-
propriate for the particular installations and are
designed for the installation environment;
• Ensuring that the roof, its rafters, connections, and
other structural support members can support the
array under live load conditions;
• Ensuring that lag screws have adequate pullout
strength and shear capacities;
• Maintaining the waterproof integrity of the roof,
including selection of appropriate flashing; and
• Ensuring safe installation of all electrical aspects of
the PV array.
UniRac, Inc., warrants to the original purchaser of the Product (“Purchaser”)
at the original installation site (“Site”) that the SunFrame™ PV module framing
and mounting system (the “Product”) shall be free from defects in material and
workmanship for a period of ten (10) years, except for the anodized finish, which
warranty shall be free from visible peeling, cracking or chalking under normal
atmospheric conditions for a period of five (5) years, from the earlier of 1) the
date the installation of the Product at the Site is complete, or 2) 30 days after the
purchase of the Product by the original Purchaser of the Product.
The term “chalking” applies to the powdery residue formed by the breakdown
of the anodized finish. It does not apply to any foreign residue deposited on the
finish by the surrounding atmosphere, including, but not limited to, soot, dust,
plaster, cement, etc. All installations in corrosive atmospheric conditions are
excluded, including, but not limited to chemical fumes, salt spray or surface
temperatures which exceed 200 degrees F. This Warranty does not cover
damage to the finish caused by moisture, condensation, or other contamination
resulting from improper storage, packing or handling. The finish Warranty
is void if normal maintenance and cleaning practices are not followed by
Purchaser as specified by AAMA 609 & 610-02 – “Cleaning and Maintenance for
Architecturally Finished Aluminum” (www.aamanet.org).
This Warranty does not cover damage to the Product that occurs during
shipment, nor prior to or during installation.
This Warranty shall be void if installation of the Product is not performed in
accordance with UniRac’s written installation instructions for the Product,
or if the Product has been modified, repaired, or reworked in a manner not
previously authorized by UniRac in writing, or if the Product is installed in
an environment for which it was not designed. UniRac shall not be liable for
consequential, contingent, or incidental damages arising out of the use of the
Product by Purchaser.
If within the specified periods the Product shall be reasonably proven to be
defective, then UniRac shall repair or replace the defective Product, or any
part thereof, at UniRac’s sole option. Such repair or replacement shall fulfill all
UniRac’s liability with respect to this limited Warranty. Under no circumstances
shall UniRac be liable for special, indirect or consequential damages arising out
of or related to use by Purchaser of the Product .
Typically manufacturers of related items, such as PV modules, flashings and
specialized clamps, provide written warranties of their own. UniRac’s limited
Warranty covers only the Product, and not PV modules themselves or any other
related items.
10 year limited product warranty, 5 year limited finish warranty

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Installation Manual 802 SunFrame™ Code-Compliant Planning and Assembly
SunFrame components
1. Rail—Supports PV modules. Use 1 per row of modules
plus 1. Shipped in lengths of 16 feet. 6105-T5 aluminum extru-
sion, anodized (clear or dark bronze) to match PV module
frame.
2. Cap strip—Secures PV modules to rails and neatly frames
top of array. Use lengths equal to rail lengths. Cap strips are
sized for specific PV modules. Shipped in lengths of 16 feet
and predrilled every 16 inches. 6105-T5 aluminum extrusion,
anodized (clear or dark bronze) to match PV module frame.
3. Self-drilling screw (No. 12 x 1-1/2")—Use to secure each
cap strip (and PV modules) to rail, one per predrilled hole and
one within 8 inches of each end. 410 stainless steel, with or
without black oxide coating to match PV module frame.
4. Rail splice—Joins rail sections into single length of rail. It
can form either a rigid or thermal expansion joint. 8" long and
predrilled. 6105-T5 aluminum extrusion, anodized (clear or
dark bronze) to match PV module frame.
5. Self-drilling screw (No. 10 x 3/4")—Use 4 per rigid
splice or 2 per expansion splice. 410 stainless steel.
6. End caps—Use 1 to neatly close each rail end. Aluminum
plate (0.040"), clear anodized or black paint to match PV mod-
ule frame.
7. Pan-head sheet metal screw (No. 4 x 1/2")—Use 2 per
end cap to secure end cap to rail. 410 stainless steel; with or
without black oxide coating to match PV module frame.
8. L-foot—Use to secure rails either through roofing mate-
rial to rafters or to standoffs. Use no less than 1 L-foot per 4
feet of rail. 6105-T5 aluminum extrusion, anodized (clear or
dark bronze) to match PV module frame.
9. L-foot bolt (3/8" x 1-1/4")—Use 1 per L-foot to secure
rail to L-foot. 304 stainless steel.
10. Flange nut (3/8”)—Use 1 per L-foot bolt. 304 stainless steel.
Required torque: 30 to 35 foot-pounds.
11. Standoff (optional)—Use if L-foot cannot be secured directly
to rafter (with tile or shake roofs, for example). Sized to mini-
mize roof to rail spacing. Use 1 per L-foot. Service Condition 4
(very severe) zinc-plated welded steel. Includes 3/8" x 1-1/4"
bolt and lock washer for attaching L-foot.
Installer supplied materials
Lag screw—Attaches L-foot or standoff to rafter. Determine
length based on pull-out values in Table 3 (page 7). If bolt
head is exposed to elements, use stainless steel. Under flash-
ings, zinc plated hardware is adequate.
Waterproof roofing sealant appropriate to roofing material.
Flashing—Use with standoffs only, 1 per standoff. Standoffs
are designed for easiest installation with most Oatey® 1-1/4"
to 1-1/2" No-Calk® flashings. Other appropriate flashings may
also be used.
Clamps for standing seam metal roof—See “Frequently
Asked Questions . . .” (p. 12). Figure 1: SolarMount components
3
2
1
5
6
7
9
10
11
4
4
1
2
3
8
1
8

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Installation Manual 802 SunFrame™ Code-Compliant Planning and Assembly
Follow the six steps below to install SunFrame in compliance
with the UBC 1997. Before proceeding, note the following:
• This bulletin addresses only wind loads. Wind gener-
ally produces the maximum load factor affecting an
installation—however, verify that other local condi-
tions, such as snow loads and earthquake effects, do
not exceed the wind loads. If any loading type does
exceed wind loads, give precedence to that factor and
consult a local professional engineer or your local
building authority.
• The roof on which the SolarMount will be installed
must be capable of withstanding the design dead load
and design live load per footing, listed in Table 2 on
page 7.
1. Determine basic wind speed at your installation site.
For the United States, see the UBC chart, “Minimum Basic
Wind Speeds in Miles per Hour,” reproduced below.
If you need clarifications or further assistance or if your instal-
lation is outside the United States, consult a local professional
engineer or your local building authority.
Figure 2. Minimum Basic Wind Speeds. Reproduced from UBC 1997, Vol. 2, Structural Engineering Design Provisions,
Chap. 16, Div. III, Wind Design, Fig. 16.1, “Minimum Basic Wind Speeds in Miles per Hour,” p. 36. The 2001 California
Building code refers to the same map.
2. Determine exposure category of your installation site.
The UBC* defines wind exposure categories as follows:
exposure b has terrain with buildings, forests or
surface irregularities, covering at least 20 percent of the
ground level area extending 1 mile (1.61 km) or more
from the site.
exposure c has terrain that is flat and generally open
extending ½ mile (0.81 km) or more from the site in any
quadrant.
exposure d represents the most severe exposure in
areas with basic wind speeds of 80 miles per hour (mph)
(129 km/h) or greater and has terrain that is flat and
unobstructed facing large bodies of water over 1 mile
(1.61 km) in width relative to any quadrant of the build-
ing site. Exposure D extends inland from the shoreline ¼
mile (0.40 km) or 10 times the building height, which-
ever is greater.
Planning code-compliant SunFrame installations
* UBC 1997, Vol. 2, Structural Engineering Design Provisions, Chapter
16, Div. III, Wind Design, p. 7. The 2001 California Building Code uses
the same definitions.

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Installation Manual 802 SunFrame™ Code-Compliant Planning and Assembly
3. Determine the design wind pressure required for your
installation.
Design wind pressure is the amount of wind pressure that a
structure is designed to withstand, expressed here in pounds
per square foot (psf). To determine the design wind pressure
required for your installation, apply the following factors using
Table 1:
• your basic wind speed (determined in step 1),
• your exposure category (determined in step 2), and
• the height of your roof above the ground.
If your values fall outside the range of the table, or if your
design wind pressure exceeds 50 psf, consult UniRac, a profes-
sional engineer, or your local building authority.
Module manufacturers provide wind pressure rating for
their modules. Confirm that they meet or exceed the wind
speed rating for your installation. If in doubt, contact the
module manufacturer.
Table 1. Design Wind Pressure (psf)
by Wind Speed and Exposure Category
Basic wind speed (mph)
70 80 90 100 110 120 130
Category B
15' roof height 10 13 17 21 25 30 35
20' roof height 11 14 18 22 27 32 38
25' roof height 12 15 19 24 29 35 41
30' roof height 12 16 21 25 31 36 43
Category C
15' roof height 17 23 29 35 43 51 60
20' roof height 19 24 31 38 46 54 64
25' roof height 19 25 32 40 48 57 67
30' roof height 20 26 33 41 50 59 69
Category D
15' roof height 23 30 38 46 56 67 78
20' roof height 24 31 39 48 58 70 82
25' roof height 25 32 41 50 60 72 84
30' roof height 25 33 42 51 62 74 87
Source: These design wind pressure (P) values are based on the formula
P = Ce
* Cq * qs * Iw ( UBC 1997,Vol. 2, Structural Engineering Design
Provisions, Chapter 16, Div. III,Wind Design, p. 7). Assumptions: Iw = 1 and
Cq
= 1.3.
Figure 3. Foot spacing and overhang defined.
4. Determine minimum design dead and live loads for
standard rafter spacing.
Foot spacing refers to the space between L-feet (or standoffs,
if used) along the same SunFrame rail (Fig. 3). Foot spac-
ing may not exceed 48 inches. For the rafter spacing at your
installation, consult Table 2 (facing page) to determine your
minimum design live loads and design dead loads per footing.
Locate the manufacturer and model of the PV module that you
plan to install and the rafter spacing at your installation site.
Read or interpolate live loads for the design wind pressure you
determined in Step 3. For assistance on this point, consult a
local professional engineer.
SunFrame
foot spacing
Overhang
6. Ensure that live loads do not exceed pull-out limits.
Based on the characteristics of your roof truss lumber and the
lag screws, consult Table 3 to determine the lag pull-out value
per 1-inch thread depth. Compare that value to the minimum
design live load per footing determined in step 4. Based on
these values, determine the length of the lag-screw thread
depth you require to resist the design live load. To ensure code
compliance, the lag pull-out value per footing must be greater
than the footing design live load.
If your SunFrame rails require splices, see also “Splicing re-
quirements,” page 9, before beginning your installation.
If your SunFrame requires standoffs, always use at least two
lag screws to secure the standoff to the rafter. Bolt the L-foot
to the standoff through the slot nearest the bend in the L-foot
(see Fig. 1, p. 4).
Verify that roof framing has adequate capacity to support
these design loads. If they do not, try a smaller footer spac-
ing. If the result is still not acceptable, relocate the array to a
stronger area of the roof or strengthen the inadequate framing
elements.
5. Verify acceptable rail end overhang.
Rail overhang (Fig. 3) must equal 50 percent or less of foot
spacing. For example, if foot spacing is 48 inches, the rail over-
hang can be up to 24 inches. In this case, two feet can support
a rail of as long as 96 inches (48 inches between the feet and
24 inches of overhang at each end).

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Installation Manual 802 SunFrame™ Code-Compliant Planning and Assembly
Kyocera KC120 / KC125G
24" rafter (foot) spacing 34 187 281 374 468
32" rafter (foot) spacing 45 249 374 499 623
48" rafter (foot) spacing 68 374 561 748 NA*
Kyocera KC158G / KC167G
24" rafter (foot) spacing 28 169 254 339 423
32" rafter (foot) spacing 37 226 339 452 564
48" rafter (foot) spacing 56 339 508 677 847
Photowatt PW1250
24" rafter (foot) spacing 30 163 245 327 408
32" rafter (foot) spacing 39 218 327 436 544
48" rafter (foot) spacing 59 327 490 653 817
Photowatt PW1650
24" rafter (foot) spacing 31 162 244 325 406
32" rafter (foot) spacing 41 216 325 433 541
48" rafter (foot) spacing 62 325 487 649 812
Sharp 70, 140
24" rafter (foot) spacing 26 153 229 306 382
32" rafter (foot) spacing 34 204 306 408 510
48" rafter (foot) spacing 52 306 459 612 765
Sharp 165, 175, 185
24" rafter (foot) spacing 35 207 310 413 517
32" rafter (foot) spacing 47 276 413 551 689
48" rafter (foot) spacing 70 413 620 827 NA*
Sharp 167
24" rafter (foot) spacing 28 174 261 349 436
32" rafter (foot) spacing 37 232 249 465 581
48" rafter (foot) spacing 55 349 523 697 871
Shell SQ140, SQ150, SQ160
24" rafter (foot) spacing 32 213 319 425 531
32" rafter (foot) spacing 43 283 425 567 708
48" rafter (foot) spacing 64 425 638 850 NA*
To meet code, your design point loads (capacity per footing) must be at
or above those indicated. The installer is solely responsible for verifying
that the roof can withstand these design point loads. For specifications
based on design wind pressure values greater than 50 pounts per square
Minimum design live load
Minimum as a function of
design design wind pressure
dead
load 20 psf 30 psf 40 psf 50 psf
ASE 300
24" rafter (foot) spacing 58 248 373 497 621
32" rafter (foot) spacing 77 331 497 662 828
48" rafter (foot) spacing 116 497 745 NA* NA*
AstroPower APi100, APi110
24" rafter (foot) spacing 33 194 291 387 484
32" rafter (foot) spacing 44 258 387 516 646
48" rafter (foot) spacing 66 387 581 775 NA*
AstroPower APi165, APi173
24" rafter (foot) spacing 34 194 291 388 485
32" rafter (foot) spacing 46 258 388 517 646
48" rafter (foot) spacing 69 388 582 775 NA*
BP Solar 3160, 4160, 5170, SX150
24" rafter (foot) spacing 33 208 313 417 521
32" rafter (foot) spacing 44 278 417 556 694
48" rafter (foot) spacing 67 417 625 833 NA*
Evergreen EC94, EC102, EC110
24" rafter (foot) spacing 35 208 312 416 520
32" rafter (foot) spacing 46 277 416 555 693
48" rafter (foot) spacing 69 416 624 832 NA*
Minimum design live load
Minimum as a function of
design design wind pressure
dead
load 20 psf 30 psf 40 psf 50 psf
Table 2. SunFrame™ Loads (pounds per footing) at Standard Rafter Spacings
foot, contact UniRac. In general, the minimum design live load equals the
footing spacing times the rail spacing times the design wind presure from
Table 1.
*NA = not applicable. Never allow total load (live load plus dead load) to
exceed 1,000 pounds per footing.
Table 3. Lag Screw Design Pull-Out Values
(pounds per embedded 1" thread depth)
in Typical Roof Truss Lumber
Specific
Lag screw
gravity 5/16" 3/8"
Douglas Fir — Larch 0.50 266 304
Douglas Fir — South 0.46 235 269
Engelmann Spruce, Lodgepole
Pine (MSR 1650 f & higher) 0.46 235 269
Hem — Fir 0.43 212 243
Hem — Fir (North) 0.46 235 269
Southern Pine 0.55 307 352
Spruce, Pine, Fir 0.42 205 235
Spruce, Pine, Fir
(E of 2 million psi and higher
grades of MSR and MEL) 0.50 266 304
Sources: UBC 1997, American Wood Council.
Notes: (1) Thread must be embedded in a rafter or other structural roof
member. (2) Pull-out values incorporate a 1.6 safety factor recommended
by the American Wood Council. (3) See UBC for required edge distances.
Thread
depth
*NA = not applicable. Never allow total load (live load plus dead load) to
exceed 1,000 pounds per footing.

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Installation Manual 802 SunFrame™ Code-Compliant Planning and Assembly
Installing the array
Safe, efficient SunFrame installation involves three principal
tasks:
A. Laying out the installation area and planning for mate-
rial conservation.
B. Installing footings and rails, beginning with the lowest
rail and moving up the roof.
C. Placing modules and cap strips, beginning with the
highest row and moving down the roof.
The following illustrated steps describe the procedure in detail.
Before beginning, please note these important considerations.
Footings must be lagged into rafters. Never attach them to the
decking alone, which leaves both the array and roof susceptible
to severe damage.
For array widths or lengths greater than 32 feet, contact Uni-
Rac concerning thermal expansion issues.
For roof slopes greater than 45 degress, consult UniRac.
Sample layout, illustrated in Figure 4
Assumptions: 12 modules (60˝ x 36˝), arranged in 3 rows of 4 modules
Array width = 144˝ (36˝ module width x 4 modules per row) = 144˝
Array length = 180˝ (60˝ module length x 3 rows)
+ 3˝ (1-1/2˝ end rail width x 2 rails)
+ 1-1/2˝ (3/4˝ between-module rail width x 2 rails)
= 184-1/2˝
Figure 4. Installation area layout. Note: Module length is not
necessarily measured from the edges of the frame. Some frames
have lips. Others are assembled with pan-head screws. All such
features must be included in module length.
Array width
(module width times modules per row)
Rails
1-1/2˝at each end of array
Module
width
3/4˝space between module rows
Module
length (see
caption)
3/4˝
1-1/2˝
Array
length
Roof
peak
1. Laying out the installation area
Always install SunFrame rails perpendicular to rafters.
(These instructions assume typical rafters that run from the
gutter to the peak of the roof. If this is not the case, contact
UniRac.) Rails are typically mounted horizontally (parallel
to the edge of the roof), and must be mounted within 10
degrees of horizontal.
Leave adequate room to move safely around the array dur-
ing installation. During module installation, you will need
to slide one module in each row about a foot beyond the end
of the rails on one side. Using the number of rows and the
number of modules per row in your installation, determine
the size or your array area following Figure 4.
2. Installing the lowest row of L-feet and rail
Install L-feet directly onto low profile roofing material such
as asphalt shingles or sheet metal. (For high profile roofs,
such as tile or shake, use optional standoffs with flashing to
raise L-feet. L-feet must be flush with or above the highest
point of the roof surface.)
L-feet can be placed with the double-slotted side against the
roof surface (illustrations in this manual show this arrange-
ment) or with the single-slotted side against the roof (which
increases air circulation beneath modules). Module-to-roof
dimensions are listed on page 12 for both arrangements.
Install the first row of L-feet at the lower edge of the instal-
lation area (Fig. 5). Ensure feet are aligned by using a chalk
line. (A SunFrame rail can also be used as a straight edge.)
Figure 5. Placement of first L-foot row.
Rafters
Lag
screw
L feet
2-3/4˝
Lower edge of installation area
Always lag into slot
nearest the bend in
the L foot

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Installation Manual 802 SunFrame™ Code-Compliant Planning and Assembly
Footing and splicing requirements
The following criteria must be met to ensure code compli-
ance of SunFrame installations.
Some of these criteria involve short sections of rail. In practice,
these can usually be avoided (while maintaining code compli-
ance) by effective planning. See “Material planning for rails
and cap strips” (p. 11) for one example.
1. The installer is solely responsible for ensuring
that the roof and its rafters can support the array and
expected loads associated with the array.
2. Foot spacing along the rail (A in illustration be-
low) is to be no more than 48 inches. (See also “Plan-
ning code-compliant SunFrame intstallations,” pp. 5–7,
especially step 4, concerning maximum foot spacing.)
3. Overhang (B) must be no more than half the
length of the maximum footer spacing (A). For ex-
ample, if Span A is 32 inches, Overhang B should not
exceed 16 inches.
4. In a spliced length of rail, all end sections must be
supported by no less than two L-feet.
5. In a spliced length of rail, all interior rail sections
must be supported by no less than 1 L-foot.
6. Interior rail sections supported by only 1 L-foot
must be adjacent, on at least one side, to a rail section
supported by no less than two L-feet.
7. Rail sections longer than half the footer spacing
require no fewer than two L-feet.
8. Long rails require slip joints (for thermal expan-
sion) every 32 feet. Before installing rails longer than
32 feet, contact UniRac.
9. Total design loads per footer (live load plus dead
load) shall not exceed 1,000 pounds.
B
A
End rail sections
Interior rail sections
Splice
L-foot
KEY
Position the L-feet with respect
to the lower edge of the roof as
illustrated in Figures 5 and 6.
Drill a 3/16-inch pilot hole
through roof into the center of
rafter at each L-foot lag screw
hole location. Squirt weather-
proof sealant into the hole and
onto shafts of the lag screws.
Seal the underside of the L-feet
with a suitable weatherproof
sealant. Figure 6. L-Foot orientation.
Roof peak
Figure 7. L-foot separation. See the note on module length in the
caption of Figure 4 (p. 8).
Fasten the L-feet to the roof with the lag screws. If the double
slotted sides of the L-feet are against the roof, lag through
the slot nearest the bend in the L-foot (Figs. 5 and 6).
Cut the rails to your array width, being sure to keep rail slots
free of roofing grit or other debris. If your installation requires
splices, assemble them prior to attaching L-feet (see “Splicing
requirements,” below, and “Material planning for rails and cap
strips,” p. 11). If more than one splice is used on a rail, slide L-
foot bolt(s) into the footing slot(s) of the interior rail segment(s)
before splicing.
Slide the 3/8-inch mounting bolts into the footing slots.
Loosely attach the rails to the L-feet with the flange nuts.
Ensure that rails are oriented with respect to the L-feet as
shown in Figure 6. Align the ends of the rail to the edge of the
installation area. Ensure that the rail is straight and parallel to
the edge of the roof. Securely tighten the lag screws.
3. Laying out and installing the next row of L-feet
Position the second row of L-feet in accordance with Figure 7.
Ensure that you measure between the lower bolt hole centers
of each row of L feet. Install the second row of L-feet in the
same manner and orientation as the first row, but leave the lag
screws a half turn loose. Be aware of the set-up time of your
sealant; the L-feet will not be fully tightened until Step. 4.
Module length + 3/4˝
(hole to hole)

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Installation Manual 802 SunFrame™ Code-Compliant Planning and Assembly
4. Installing the second rails
Install and align the second rail in the same manner
and orientation as the first rail. After rail alignment,
securely tighten the rail mounting bolts to between
30 and 35 foot-pounds.
Lay one module in place at one end of the rails, and
snug the rail (Fig. 8), leaving no gap between the
ends fo the module and either rail. (If pan-head
screw heads represent the true end of the modules,
be sure the screw heads touch the rails on both
ends.) Securely tighten the lag screw on that end.
Slide the module down the rails, snugging the rails
and securing the remaining lag screws snug tight as
you go.
5. Installing remaining L-feet and rails
Install the L-feet and the rails for the remaining
rows, following Steps 3 and 4. You may use the
same module to snug all the rows. When complete,
confirm that:
• All rails are fitted and aligned.
Figure 9. Begin cap strip installation.
• All footing bolts and lag screws
are secure.
• The module used for fitting is
resting (but not secured) in the
highest row.
6. Securing the first module
Gather sufficient lengths of cap strip
to cover the length of the first rail. For
maximum visual appeal and material
conservation see “Material planning for
rails and cap strips” (p. 11).
Slide the first module into final position at
one end of the array. Lay the remainging
modules in the top row module, leaving
a gap about a foot wide between the first
and second modules (Fig. 9).
The temporary gap allows the installer
to place one of his feet between modules.
He can access the section of the cap strip
he needs to secure while leaning toward
Flanges
Lag screws
(tight)
Lag screw
(half turn loose)
Module
Figure 8. Position and secure top rail.
Snug
No. 12 1-1/2” self-drilling screws
Stepping gap
Permissable overhang:
1/3 module width
1. Slide
2. Install screws
Figure 10. Position and secure modules one by one.
Stepping gap
Do not install second
cap strip until lower
modules are placed
If it is ever necessary to make a new hole in a cap strip, drill
a 1/4-inch hole before installing the self-drilling screw.
7. Installing the remaining modules in the top row
Slide the next module into final position and install the screws
to secure it (Fig. 10). For a neat installation, use cable clamps
with self-tapping screws to attach excess cable to the rail
beneath the flanges.
the peak of the roof. For the time being, the last module may
overhang the rail by up to one third its width.
Attach the end of the cap strip with the No. 12 self-drilling
screws (Fig. 9, inset), so that the upper end of the first module
is secure.

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Installation Manual 802 SunFrame™ Code-Compliant Planning and Assembly
Material planning for rails and cap strips
Typically, 192-inch standard rail and cap strip lengths will
not match the size of your array. Preplanning material use
for your particular array can prevent structural or asthetic
problems, particularly those caused by very short lengths of rail
or cap strip.
Stuctural requirements for rails are detailed in “Footing and
splicing requirement” (p. 9). Structurally, cap strips require:
• A screw in every prepunched hole (which occur ev-
ery 16 inches, beginning 8 inches from the ends of
the rails). If it is ever necessary to make a new hole
in a cap strip, drill a 1/4-inch hole before installing
the self-drilling screw.
• One screw no more than 8 inches from the end of
each segment.
For maximum asthetic appeal:
• Cap strip screws on every rail should align (see, for
example, the center line holes in the illustration
below).
• End screws should be equidistant from both sides of
the array.
The example below assumes an array of three rows, each
holding five modules 41 inches wide. Thus, four 205-inch
rail–cap strip assemblies need to be cut and spliced from
192-inch sections of rail and cap strip. The example illus-
trates one means of doing so, which meets all structural and
aesthetic requirements while conserving material.
Rails segments come from five 192-inch lengths, lettered A
thru E. Rail A, for example, is cut into two 96-inch segments,
with one segment spliced into each of the first two rails.
Similarly, five 192-inch cap strips are numbered V through Z.
All cap strip segments are cut at the midpoint between
prepunched screw holes. For each rail, start with the cap
strip segment that crosses the array center line, and align the
appropriate hole with the center line.
Position each cap strip onto its rail and mark its trim point.
Remove and trim before final mounting.
Code compliance note: If your planning sketch shows
that end holes will be more than 8 inches from the ends
of the rails, re-start by aligning a midpoint between holes
with the array center line.
A 96″B 109″
A 96″
B 83″
C 83″
C 109″
D 122″
E 122″
Array center line
V 112″
W 112″
W 80″
V 80″
X 96″
Y 128″
X 96″
Z 128″
Usable remainder: D, 70″; E, 70″; Y, 64″; Z, 64″.
4th cap strip
1st rail
3rd cap strip
2nd rail
2nd cap strip
3rd rail
1st cap strip
4th rail
Trim line (array edge)
Trim line (array edge)
Continue the process until all modules in the top row are in
final place and secured from the top. When complete, every
prepunched hole in the cap strip will be secured by a screw,
and the top end of the first row of modules will be secure.
8. Installing the remaining modules row by row
Repeat Steps 6 and 7 for the remaing rows (Fig. 11). Each
subsequent cap strip will secure the tops to the modules being
installed and the bottoms of the modules in the row above.
Place the final cap strip in the lowest rail, securing the bottom
of the lowest module row.
Figure 11. As modules slide into place, the stepping gap shifts,
always allowing access to the section of cap strip being secured.
Secured
1st module
Slide and
secure one
by one
Stepping gap

UniRac, Inc.
www.unirac.com
3201 University Boulevard SE, Suite 110
Albuquerque NM 87106-5635 USA
505.242.6411
505.242.6412 Fax
Page
12
Installation Manual 802 SunFrame™ Code-Compliant Planning and Assembly
9. Installing the end caps
Attach the end caps to the ends of the rails by securing with
the round head sheet metal screws provided (Fig. 12).
Figure 12. End cap installation.
Frequently asked questions about standoffs and roof variations
How high above the roof does SunFrame raise the PV
modules?
The answer depends on whether standoffs are used with
the L-feet, and if so, what size. The illustrations at right
provide dimensions for all cases.
How can I seal the roof penetration required when
standoffs are lagged below the roofing material?
Many types and brands of flashing can be used with Sun-
Frame. However, UniRac designed them for Oatey® 1-1/4˝
to 1-1/2˝ “No-Calk” flashing. A wide variety of flashings
are described at www.oatey.com. Your choice of sealant
depends on roofing material.
How do I attach SunFrame to a standing-seam metal
roof?
A good solution comes from Metal Roof Innovations, Ltd.
(MRI). It manufactures the S-5!™ clamp, designed to attach
a wide variety of products to most standing-seam metal
roofs. It is an elegant solution that eliminates flashings
altogether.
SunFrame L-feet will mount to the top of the S-5! clamps
with the 3/8-inch stainless steel bolt provided with the S-5!
Module
thickness
varies
1-3/4˝± 1/8˝
3-1/8˝± 1/8˝
Module
thickness
varies
Standoff height
(3˝, 4˝, 6˝, or 7˝
all ± 1/8″)
2-1/4˝± 1/8˝
7/8˝± 1/8˝
See www.s-5solutions.com for different clamp models and
details regarding installation.
When using S-5! clamps, make sure that there are enough
clamp/L-feet attachments to the metal roof to meet the
Metal Roof Manufacturers’ and MRI specifications regarding
wind loads, etc.
Module
thickness
varies
2-1/4˝± 1/8˝
7/8˝± 1/8˝
We welcome your input
UniRac appreciates receiving corrections, clarifications, or
any other comments concerning this manual . Please write to
[email protected].