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Installation Manual 801.1 

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 fi ve 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 fi ve 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 fi rst two rails. 
Similarly, fi ve 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 fi nal 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 
fi nal 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 fi rst 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 fi nal 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

Summary of Contents for SUNFRAME - INSTALLATION 80I.I

Page 1: ...splicing requirements 9 Material planning for rails and cap strips 11 Frequently asked questions about standoffs and roof variations 12 October 2003 Pub 031016 1ii 2003 by UniRac Inc All rights reser...

Page 2: ...Page 2 Installation Manual 801 1 SunFrame Code Compliant Planning and Assembly...

Page 3: ...ct 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 includ...

Page 4: ...etal 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 roo ng ma...

Page 5: ...l 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...

Page 6: ...ing 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 7: ...31 497 662 828 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 7...

Page 8: ...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...

Page 9: ...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 wea...

Page 10: ...um visual appeal and material conservation see Material planning for rails and cap strips p 11 Slide the rst module into nal position at one end of the array Lay the remainging modules in the top row...

Page 11: ...ments with one segment spliced into each of the rst two rails Similarly ve 192 inch cap strips are numbered V through Z All cap strip segments are cut at the midpoint between prepunched screw holes Fo...

Page 12: ...ashings are described at www oatey com Your choice of sealant depends on roo ng material How do I attach SunFrame to a standing seam metal roof A good solution comes from Metal Roof Innovations Ltd M...

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