IronridgeXRS Rail System

8/3/2019 IronridgeXRS Rail System

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Installation ManualXRS Solar Rail System

June 2009 www.IronRidge.com 2009 IronRidge, Inc. All Rights Reserved

S o l a r M o u n t i n g S o l u t i o n s

Version 3.1

http://www.wholesalesolar.com/gridtie.html


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2 | XRS Solar Rail System Installation Guide

IntroductionThe XRS Solar Rail System is a exible and straightorward roo mounting solution or a wide variety o solar photo-voltaic (PV) needs. Due to its modular design, it can easily handle a wide variety o panel sizes and quantities.

1. Installer ResponsibilityThe installer is solely responsible or:

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

Ensuring that IronRidge and other products are appropriate or the particular installation and the installa-tion environment;

Ensuring that all structural support members, including the roo, its raters, and connections, can supportthe array under all code level loading conditions;

Using only IronRidge parts and installer-supplied parts as specied by IronRidge. Substitution parts may void the warranty;

Ensuring that anchoring devices including lag screws have adequate pullout strength and shear capacitiesas installed;

Maintaining the waterproo integrity o the structural support or roo, including selection o appropriateashing;

Ensuring sae installation o all electrical aspects o the PV array; and

Ensuring correct and appropriate design parameters are used in determining the design loading used orthe specic installation. Parameters, such as snow loading, wind speed, exposure and topographic actorshould be conrmed with the local building ocial or a licensed proessional engineer.

2. Customer SupportIronRidge makes every efort to ensure your mounting kit is easy to install. I you need assistance at any point withyour installation or have suggestions on how we can improve your experience, call IronRidge customer support:(707) 459-9523

3. Tools Required For AssemblyThe ollowing tools are required to assemble the XRS Solar Rail System:

Tool Use for

Wrenches

Open-end wrench, Box-end wrench, orsocket drive with sockets to support the ol-lowing size hex heads:

3/8

1/4

1/4 cap-end screws, 1/4 bolts

3/8 cap-end screws, 3/8 bolts



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4. Torque Values For Dry BoltsUse the ollowing torque values in this assembly.

Bolt Size Required Torque Value

1/4-20 84 in-lbs (unless otherwise noted).

5/16-18 144 in-lbs.

3/8-16 180 in-lbs.



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5. Component ListThe XRS Solar Rail System kit contains the ollowing parts:

Note: The component list indicated here is or reerence only. The actual component quantities will vary accord-

ing to the quantity and make o modules that the mount is congured or. Please check the packing list that shipswith every mount or a conrmation o the items that are intended to ship with the specic product on your order.

Foot (51-6000-002)

Attaches to the roo and is the anchor point or therest o the panel assembly

Internal Splice (51-7000-002)

Ties the extrusion rails together, extending theirlength.

Extruded Rail (51-7000-XXX)

Attaches to the oot via the oot clamp and providessupport or the PV modules

End Clamp (51-6000-004)

Clamps the outside ends o the PV modules to therails

Center Clamp (51-6000-005)

Clamps the inside edges o the PV modules to therails



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Component List continued...

Part Qty Part Number CommentsSplice Kit 1 29-7000-010 Used to join XRS rails together

1 kit is used to splice 2 pairs o rail.

Internal Splice 2 51-7000-002

10-16 x1/2 , sel-drilling, sel tappingscrew, SS

8 48-1016-500

L-Foot Assembly Kit 1 29-7000-014 Used to attach L-oot to XRS1 kit per 4 L-eet.

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 29-7000-108 Used between PV panels to secure to XRS rail1 kit will cover 2 PV panels within a row.Part number changes depending on panelrequired.

Center Clamp 4 51-6000-005

1/4-20 x 2.00 hex cap bolt, SS, or1/4-20 x 2.50 hex cap bolt, SS, or1/4-20 x 2.75 hex cap bolt, SS

4 23-2520-200,23-2520-250,23-2520-275

Length o bolt depends on the thickness othe PV panel.

1/4-20 ange nut, SS 4 25-2501-014

End Clamp Kit 1 29-7000-224 Used on the rst and last PV panel in a row1 kit will cover the rst and last PV panels in

a row. Part number changes depending onpanel used. Example part numbers shown.

End Clamp 4 51-6000-141

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

1/4-20 ange nut, SS 4 25-2501-014

XRS Spares Kit 1 29-7000-001



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6. Assembly

Step 1 - mounting the eet and the frst piece o rail

Parts required or this step Qty Part Number

Extruded Rail 4 51-7000-XXX

L-Foot Assembly Kit 1 29-7000-014

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 51-6000-005

1/4-20 x 2.00 hex cap bolt, SS, or

1/4-20 x 2.50 hex cap bolt, SS, or1/4-20 x 2.75 hex cap bolt, SS

4 23-2520-200,

23-2520-225,23-2520-250,23-2520-275

End Clamp Kit 1 29-7000-224


Mount all o the eet to the roo1.in the desired locations.

Note: Determine the maximumdistance between eet accordingto engineering specications.



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On the rst piece o rail, slide2.3/8-16 bolts into the side acingt-slot on the rail. Space the boltsout to match the oot spacing.

On this same piece o rail, slide3.1/4-20 bolts into the top acingt-slot on the rail. Space the boltsout to match the panel spacing.

Attach this rst piece o rail to4.the eet mounted on the roo.Mount the rail to each oot witha ange nut and hex bolt. Handtighten the nuts and check thelevel o the rail.

Tighten 3/8-16 hardware to180in-lbs.

Step 2 - mounting the next pieces o rail


Extruded Rail 4 51-7000-XXX

L-Foot Assembly Kit 1 29-7000-014

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


1/4-20 x 2.00 hex cap bolt, SS, or1/4-20 x 2.50 hex cap bolt, SS, or1/4-20 x 2.75 hex cap bolt, SS

4 23-2520-200,23-2520-250,23-2520-275




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Splice Kit 1 29-7000-010

Internal Splice 2 51-7000-002110-16 x1/2 , sel-drilling, sel tapping screw, SS 8 48-1016-500

On the next piece o rail, slide 3/8-161.bolts into the side acing t-slot on therail. Space the bolts out to match the ootspacing.

On this same piece o rail, slide 1/4-202.bolts into the top acing t-slot on the rail.

Space the bolts out to match the panelspacing.

Lay the rail on its side, with the slotted3.side down as shown.

Slide the internal splice hal way into the4.internal cavity in the rail. It should extendapproximately 6 inches into the cavity.

Using two o the sel-drilling, sel-tapping5.screws, secure the internal splice into therail utilizing the screw pattern shown atright.



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Loosely mount this piece o rail onto its6.ootings.

By moving this second rail along its oot-7.ings, the internal splice should slip intothe cavity on the rst rail, with the railsbutting tightly and evenly together.

Maintain rail alignment while ollowing8.the next steps.

You should mark of approximately 69.inches rom the end o the rst rail (wherethe internal splice should end). Drive twosel tapping screws through the rst rail inutilizing the pattern shown at right withinthe area you marked of.

Repeat this procedure or the remaining10.rails.

Step 3 - clamping the panels to the rails

Parts required for this step Qty Part Number


1/4-20 ange nut, SS 4 25-2501-014


1/4 ange nut, SS 4 25-2501-014



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Lay the rst PV module in posi-1.tion on the rails.

Then slip the end clamp over2.the bolt, making sure it is rmly

hooked over the side o themodule.

Complete the clamp assembly3.with a ange nut as shown.

Tighten to 60-65 in-lbs.

Repeat with the other clamp.4.

Working rom the opposite side5.o the PV module. Assemblethe center clamps by putting aclamp on the bolt, ollowed bythe ange nut.



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Place the second PV Module6.into position on the rails, slidingit against the rst so the centerclamps are in contact with the

edges o both panels.

Tighten to 84 in-lbs.7.

Repeat the procedure using8.center clamps to secure eachsuccessive module.

Secure the last module at the9.end o the rails using the otherset o end clamps.



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12 | XRS Solar Rail System Installation Guide12 | XRS Solar Rail System Installation Guide

IronRidge 10-Year WarrantyTerms and Conditions

IronRidge warrants each Mounting Structure to be ree rom deects in materials and workmanship or ten (10)

years rom the date o rst purchase (Warranty Period), when installed properly and used or the purpose orwhich it is designed, except or the nish, which shall be ree rom visible peeling, or cracking or chalking undernormal atmospheric conditions or a period o three (3) years, rom the earlier o 1) the date the installation o theProduct is completed, or 2) 30 days ater the purchase o the Product by the original Purchaser (Finish Warranty).The Finish Warranty does not apply to any oreign residue deposited on the nish. All installations in corrosiveatmospheric conditions are excluded. The Finish Warranty is VOID i the practices specied by AAMA 609 & 610-02 Cleaning and Maintenance or Architecturally Finished Aluminum (www.aamanet.org) are not ollowed byPurchaser or IronRidges aluminum based products.

The warranty covers the replacement cost o parts to repair the product to proper working condition.Transportation and incidental costs associated with warranty items are not reimbursable. The warranty does notcover normal wear, or damage resulting rom misuse, abuse, improper installation, negligence, or accident. Thewarranty does not cover any deect that has not been reported in writing to IronRidge within ten (10) days ater

discovery o such deect. Furthermore, it does not cover units that have been altered, modied or repaired withoutwritten authorization rom the manuacturer or its authorized representative, or units used in a manner or or apurpose other than that specied by the manuacturer. IronRidges entire liability and Purchaser exclusive remedy,whether in contract, tort or otherwise, or any claim related to or arising out o breach o the warranty coveringthe Mounting Structures shall be correction o deects by repair, replacement, or credit, at IronRidges discretion.Reurbished Mounting Structures may be used to repair or replace the Mounting Structures.

IronRidge shall have no liability or any injuries or damages to persons or property resulting rom any cause,whatsoever, or any claims or demands brought against IronRidge by Purchaser, any employee o Purchaser, cliento Purchaser, end-user o the Product or other party, even i IronRidge has been advised o the possibility o suchclaims or demands (collectively, Third Party Claims). This limitation applies to all materials provided by IronRidgeduring and ater the Warranty Period.


IronridgeXRS Rail System

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