TM

POWER RAIL P6
ASSEMBLY INSTRUCTIONS
step-by-step
assembly and installation

YOUR DPW SOLAR DISTRIBUTOR Version 1, Rev H

SOLIGENT
PCN 013013-1
800-967-6917
www.soligent.net
 TM
Power Rail P6
A Few words about these Assembly Instructions
These instructions:
Ÿ Do not include any information on the selection or installation of
attaching hardware to be mounted to the roof substrate. For
information on compatible attaching hardware, see our publication
titled “Power Rail Design Guidelines”.
Ÿ Begin after all roof mounted attaching hardware has been installed and
secured to the roof substrate.
Ÿ Show the Power Rail Mounting System being installed on the “Power
Rail PV Flash” roof attachment system.
Ÿ Are intended to be used by individuals with sufficient technical skills
for the task. Knowledge and use of hand tools, measuring devices and
torque values is also required.

WARNING: Ÿ Include various precautions in the forms of Notes, Cautions, and

Follow the Warnings. These are to assist in the assembly process and/or to draw
procedures and attention to the fact that certain assembly steps may be dangerous and
precautions in could cause serious personal injury and/or damage to components.
these instructions Following the step-by-step procedures and these precautions should
carefully.
minimize the risk of any personal injury or damage to components
while making the installation an efficient process.

For questions on a specific installation please call us or e-mail us at:

Phone: 800-260-3792
Email: info@power-fab.com

Required Tools
1/2 inch wrench or socket for 5/16 inch module clamp hardware
Torque wrench
Ratchet wrench
Ratchet extension bar
Framing square
Tape Measure

Assembly Instructions, Power Rail P6 (Version 1, Rev H)

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5

Power Rail P6 Parts Identification

3

8
2

Assembly Instructions, Power Rail P6 (Version 1, Rev H)

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 Step 1: Securing Attaching Hardware
The selection of attaching hardware is dependent on the roof substrate and site
NOTE:
L-feet can be design conditions. Please consult the design manual for specifics. Instructions for
attached directly attaching anchoring hardware to the roof or structure are available on an individual
to the roof product basis.
substrate with the
proper hardware.
See Power Rail A. Place the “L” Foot onto the PV
Flash hanger bolt, aligning it to the 5/16”
Design Guidelines
Hex Nut
for more slot of the compression block. “L” Foot
information. Washer
B. Secure “L” Foot with 5/16” flat
washer and hex nut. Torque to
PV Flash
14-16 ft.-lbs. (See Figure 1-1) Hanger
Bolt

Compression
PV Block
Flash

Figure 1-1: Attaching “L” Foot to

the PV Flash

Step 2: Attach Power Rail to Roof Anchors

CAUTION: The Power Rail is secured to the “L” Feet using a 5/16” x 3/4” turn bolt. Hardware
Cantilever and may vary depending on design-specific requirements.
span dimensions
are a design The Power Rail overhangs beyond the outermost “L” Foot. This overhang is
specification. referred to as “cantilever”, or abbreviated as "C'ver". The distance between
Consult the
design manual to
adjacent “L” Feet is referred to as "span". The length of both the cantilever and the
match these span are dependent on several factors, unique to each installation and are
dimensions to site determined by the system design.
conditions. It's
important to use A. Measure and mark the cantilever dimension supplied by the design manual
the unique
onto the Power Rail. (See Figure 2-1)
cantilever and
span dimension
specific to the
install. Failure to Power Outermost Cantilever
do so could lead Rail “L” Foot
to excessive
deflection and/or
premature system
failure.
PV
Flash

Figure 2-1: Cantilever Measurement and Marking

Assembly Instructions, Power Rail P6 (Version 1, Rev H)

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NOTE: B. Line up the mark with the center of
Turn bolts must be the outermost “L” Foot. Power
locked into the C. Starting at the outermost “L” Foot Rail
channel by rotating mounting position, insert one 5/16”
clockwise 90- “L” Foot
degrees. Use the x 3/4” turn bolt into the channel of 5/16”
indicator slot on the Power Rail, rotate bolt to lock Flange
the threaded end into channel. Nut
to identify whether
or not the bolt has
D. Line-up and insert the 5/16” x 3/4”
5/16”
been locked. turn bolt into the “L” Foot and Turn Bolt
loosely secure with 5/16” flange
Turn bolt shown nut. Do not tighten until all bolts
in channel of have been positioned in the entire
Power Rail length of the Power Rail, the bolts
Locked
have been aligned and passed
through the “L” Feet, and the
flange nuts loosely started. Figure 2-2: Attaching Power Rail to
E. Check that the cantilever mark is “L” foot
lined up with the center of the
Indicator Slot outermost “L” Foot. If needed,
shown in Red
adjust its position to bring into
alignment. Hold
F. Double-check the cantilever Butt-Joint
alignment before tightening Power Closed
Rail to “L” Feet. Tighten all flange Splice
nuts and Torque to 14-16 ft.-lbs. Plate

Step 3: Splicing Power Rail with

Splice Plates
Splice Plates are used to butt-joint Power
Rail sections and extend their length as 5/16”
needed. They are attached to the Power Turn 5/16”
Bolts Flange Nuts
Rail using 5/16” x 3/4” turn bolts and
flange nuts. There are two types, a 2-hole
Figure 3-1: 2-Hole Splice Plate
and or 4-hole. (See Figures 3-1 and 3-2)
A. Insert 5/16” x 3/4” turn bolts into Hold
the channel of each Power Rail Butt-Joint
section to be spliced. Closed
B. Hold the two ends of the Power Splice
Plate
Rail together.
C. Position the Splice Plate onto the
Power Rail and the turn bolts.
D. Align the Splice Plate so that it's
equally divided along the Power
5/16”
Rail butt-joint. Turn 5/16”
E. Secure the Splice Plate to Power Bolts Flange Nuts
Rails with 5/16” flange nuts.
Torque to 14-16 ft.-lbs. Figure 3-2: 4-Hole Splice Plate

Assembly Instructions, Power Rail P6 (Version 1, Rev H)

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 Step 4: Installing PV Modules to Power Rails with Module Clamps
WARNING: PV Modules are secured to the Power Rail using Mid Clamps (Standard or RAD)
This is a two and End Clamps (Standard, RAD or Universal), along with the appropriate
person activity. attaching hardware.
In addition to the
difficulties Attaching hardware includes Carriage Bolts or RAD Bolts for Mid Clamps and End
associated with Clamps, while the Universal End Clamp includes a preassembled Hex Bolt.
working on a
sloped rooftop, The importance of correctly installing End and Mid Clamps:
PV Modules are
heavy. One
There is only one correct method of installing End Clamps and Mid Clamps. Failure
person should to follow the correct method could lead to personal injury, structural failure, and/or
hold and align the damaged components. See Figure 4-1 for proper method of installation for an End
modules while a Clamp and Figure 4-2 for the Mid Clamp. Refer to these figures during the
second person installation of the Modules to prevent any undue problems associated with an
secures modules
with clamping improper installation.
hardware. Failure
to do so could
lead to serious CORRECT WRONG
personal injury
and/or damaged
components.

NOTE: End
End
Hardware is Clamp
Clamp
dependent on Installed
Correctly
particular features Incorrectly
Installed
and system design.
Therefore, it may
appear different
from these Figure 4-1: Correct and Wrong methods of installing Standard End-Clamp
instructions. (using Carriage or RAD Bolts)

CORRECT Tabs WRONG

Mid Clamp
is not square
to Modules

Installed with Visible Gaps

Modules butted between Mid
against Mid Clamp Tabs and
Clamp Tabs Module Frames Modules

Figure 4-2: Correct and Wrong methods of installing a Mid Clamp

(using Carriage or RAD Bolts)

Assembly Instructions, Power Rail P6 (Version 1, Rev H)

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 Installing Modules using Standard End and Mid Clamps:
Start with exterior Module and End Clamps.
NOTE:
If using standard A. Place Module on two Power Rails,
5/16” carriage centering it lengthwise. Use a
bolts for Mid End Clamp 5/16”
Clamps, the bolts square to square-up the Module to Flange
must be inserted the Power Rails. Nut
into Power Rail
before installing B. Insert one 5/16” x 2, 2-1/4, 2-1/2 or
interior PV 2-3/4” carriage bolt into the top
Modules. slot of the Power Rail. Push the
If using RAD bolt against the side of the module
hardware, the frame. Install End Clamp onto bolt
hardware can be and secure with 5/16" flange nut.
inserted anytime Torque to 14-16 ft.-lbs. (See
at any position
along the Figures 4-1 and 4-3)
Power Rail. Now install the next in-line Module using
Mid Clamps.
5/16” x **
Carriage Bolt
P6 Power Rail

C. Before placing the interior Module

onto the Power Rails, first insert ** 5/16 x 2, 2-1/4, 2-1/2, or 2-3/4 inch bolt.
Length is dependent on depth of Module
frame.
5/16” x 2, 2-1/4, 2-1/2, or 2-3/4”
carriage bolts (bolt length is Figure 4-3: Installing Modules using
dependent on depth of Module Standard End-Clamp
frame) into the Module Rail,
sliding the bolts inward next to the previously installed exterior Module.
(See Figure 4-4)

Insert 5/16 x
**
Carriage Bolts into
Slide Carriage Bolts Module Rail
inward, adjacent
to Exterior PV
Exterior Module
PV Module

** 5/16 x 2, 2-1/4,
2-1/2 or 2-3/4
inch bolt. Length
is dependent on
depth of PV
Module frame.

Figure 4-4: Inserting Mid Clamp Hardware into Power Rail

Assembly Instructions, Power Rail P6 (Version 1, Rev H)

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 D. Install a Mid Clamp onto each
carriage bolt making certain that
the Mid Clamp tabs rest between 5/16”
the two modules. Standard Flange
Mid Clamp Nut
E. Push Modules against Mid Clamp
tabs and secure Mid Clamp with Push Modules
5/16” flange nut. Torque to 14-16 against Tabs
ft.-lbs. (See Figures 4-2 and 4-5) Tabs of Mid Clamp

Pre-loaded
Carriage Bolt

Figure 4-5: Installing Modules using

Standard Mid Clamp

Installing Modules using RAD End and Mid Clamps:

Start with exterior Module and End Clamps.
NOTE:
RAD bolts must be A. Place Module on two Power Rails,
locked into the centering it lengthwise. Use a
channel by rotating square to square-up the Module to End Clamp 5/16”
clockwise 90- Flange
degrees. Use the the Power Rails.
Nut
indicator slot on B. Insert one 5/16” x 2, 2-1/4, 2-1/2 or
the threaded end
to identify whether 2-3/4” RAD bolt into the top slot
or not the bolt has of the Power Rail. Push the bolt
been locked. against the side of the module
5/16” x
RAD Bolt
**
frame and twist to lock in place.
RAD bolt shown Install End Clamp onto bolt and
in channel of secure with 5/16" flange nut. Rotate
Power Rail
Torque to 14-16 ft.-lbs. (See to Lock
Locked Figures 4-1 and 4-6)
Install next in-line Module using Mid Clamps.
P6 Power Rail
C. Insert one 5/16” x 2, 2-1/4, 2-1/2,
Indicator Slot
or 2-3/4” RAD bolt (bolt length is ** 5/16 x 2, 2-1/4, 2-1/2, or 2-3/4 inch bolt.
Length is dependent on depth of Module

shown in Red
dependent on depth of Module frame.
frame) into each Rail, next to the
previously installed exterior Figure 4-6: Installing Modules using
Module. Twist RAD bolt to lock in RAD End Clamp
place. (See Figure 4-7)

Assembly Instructions, Power Rail P6 (Version 1, Rev H)

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 D. Place next Module onto Rails. 5/16”
RAD
E. Install a Mid Clamp onto each Mid Clamp Flange
Nut
RAD bolt making certain that the
Mid Clamp tabs rest between the
two modules.
F. Push Modules against Mid Clamp Tabs 5/16” x
RAD Bolt
**
tabs and secure Mid Clamp with
5/16” flange nut. Torque to 14-16
ft.-lbs. (See Figures 4-2 and 4-7) Push Modules
Rotate against Tabs
to Lock of Mid Clamp
Installing Modules using Universal End
Clamps:
A. Place Module on two Power Rails,
centering it lengthwise. Use a
square to square-up the Module to
the Power Rails. ** 5/16 x 2, 2-1/4, 2-1/2, or 2-3/4 inch bolt.
Length is dependent on depth of Module
frame.
B. Position Universal Clamp
underneath the module with Figure 4-7: Installing Modules using
notches facing the outside edge of RAD Mid Clamp
the module, and rail centered
between 'forks' of the clamp. Slide clamp notches towards the module flange
until the flange bottoms out in the notches. Tighten 5/16" bolt on bottom of
universal end clamp. Torque to 14-16 ft.-lbs. Repeat for both end clamps.
(See Figure 4-8)

PV Module
Notches

WARNING:
Be certain that all Slide
Flange Nuts on
the End and Mid
Clamps are Power
tightened and Universal
Rail
torqued to the End Clamp
stated values.
Failure to do so
could lead to Installed
serious personal (Views looking from underside)
Position
injury and/or
damaged
components and
property.

5/16” Bolt

Figure 4-8: Installing PV Modules using Universal End Clamp

Assembly Instructions, Power Rail P6 (Version 1, Rev H)

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Direct Power & Water Corporation Preformed Line Products
4000-B Vassar Drive NE (Canada) Limited
Albuquerque, New Mexico 87107 1711 Bishop St. E
USA Cambridge, ON N1T 1N5

Telephone: 800.260.3792 Telephone: 519.740.6666

Fax: 505.889.3548 Fax: 519.740.7917
Web Site: www.DPWSolar.com Web Site: www.preformed.on.ca
E-mail: info@power-fab.com E-mail: sales@preformed.on.ca

© 2013 Preformed Line Products

PCN 013013-1
Version 1, Rev H