GUIDE, INSTALLATION, INVISIMOUNT®

Document Number: 508988 RevJ

MARCH 2019

REV. DCN# DESCRIPTION DATE AUTHOR

A Initial Release 04/01/14 J. Lentz

DCR-
B Updates post beta installations. 08/06/14 J. Lentz
001081
DCR-
C Updates post limited launch. 12/29/14 J. Lentz
001464
DCR- Updates since limited launch, including end clamp
D 002158 grounding. 06/25/15 J. Lentz
DCR- Updates including graphics, rail length optimization;
E 002238 UOM adjustments, remove array width limitation. 08/01/15 J. Lentz
DCR- Updates post beta and LA County feedback.
F 002590 03/11/16 J. Lentz
DCR- Updates including R2R grounding clip, AC and DC rail
G 002725 clips, and Equinox parallels. 05/10/16 J. Lentz
DCR- Updates including R2R grounding clip, R2R spacer, rail-
H 003085 mounted J-box, roof transition flashing; new end clamp 02/05/17 J. Lentz
design; removal of all AC-related content.
DCR- Enphase E- and X- impact language; new attachments;
I 12/20/18 J. Lentz
003630 new rail bolts.
DCR- Enphase w A-Series impacts: span table, rail placement,
J 03/23/19 J. Lentz
003669 and L-foot language; shortened document title.

SUNPOWER CORPORATION
77 Rio Robles
San Jose, California 95134
1-855-977-7867
www.sunpowercorp.com
 ®
InvisiMount
INSTALLATION GUIDE

©SunPower Corporation

All Rights Reserved

March 2019

Document #508988 RevJ 2 SunPower Proprietary

 1.0 Overview and Scope ...................................................................................................................................................... 4

1.1 Safety and Warnings .................................................................................................................................................. 4

1.1.1 Site Safety ............................................................................................................................................................ 5

1.1.2 General Warnings ............................................................................................................................................... 5

1.2 Installer Responsibilities ........................................................................................................................................... 5

1.3 Tools, Components, and Torque Values ................................................................................................................. 7

1.1.1 Tools ..................................................................................................................................................................... 7

1.1.2 Components and Torque Values ...................................................................................................................... 8

2.0 Listings, Compatibility, and Classification ................................................................................................................ 12

2.1 Fire Classification ..................................................................................................................................................... 13

3.0 System Ground Path ................................................................................................................................................... 13

4.0 Installation Outline ...................................................................................................................................................... 16

5.0 Install System ............................................................................................................................................................... 16

5.1 Module Spacing ........................................................................................................................................................ 17

5.2 Attachment Span and Rail Cantilever .................................................................................................................... 17

5.3 Join Rails .................................................................................................................................................................... 18

5.4 Install Flashings, Roof Attachments, and Rails ..................................................................................................... 19

5.5 Attach Ground Wire ................................................................................................................................................. 22

5.6 Install Modules ......................................................................................................................................................... 25

5.6.1 Install R2R Grounding Clip .............................................................................................................................. 30

5.7 Standalone Modules ................................................................................................................................................ 32

Appendix A: Install Rail-Mounted Junction Box ................................................................................................................... 33

Appendix B: Install Rooftop Transition Flashing ................................................................................................................. 35

Appendix C: Rail Clips ............................................................................................................................................................. 41

Appendix D: Module Removal ............................................................................................................................................... 42

Document #508988 RevJ 3 SunPower Proprietary

1.0 Overview and Scope
This guide describes how to install the SunPower InvisiMount® Residential Mounting System (“the system”) on a
rooftop. Do not attempt any aspect of the installation until you have thoroughly read this entire guide. Failure to
follow these instructions can result in personal injury or equipment damage or failure, and may void the system
warranty.

The system includes the following standard components:

• rails
• splices and splice screws
• end clamps
• mid clamps
• ground lug assemblies (rail nut, fender washer, ground lug, and M6 bolt)
• row-to-row (R2R) spacers
• row-to-row (R2R) grounding clips
Depending on the roof type and attachment type, the following components are required and can be sourced from
SunPower as well:
• L-feet
• flashings
• roof attachment

1.1 Safety and Warnings

IMPORTANT SAFETY INSTRUCTIONS – SAVE THESE INSTRUCTIONS!

All personnel must adhere to the following safety procedures when working on the system, including inspection,
installation, operation, service work, repair, and testing. Failure to comply with these precautions or with specific
warnings elsewhere in this guide may violate safety standards of design, warranty, manufacture, and intended use
of the equipment. SunPower assumes no liability for failure to comply with these requirements.

Warning! The installation, adjustment, or repair of a solar system involves the risk of contact
with potentially lethal voltages and currents.

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Follow all applicable laws, including state and federal Occupational Safety and Health Administration (OSHA)
standards when working on any construction project. Always reference the National Fire Protection Agency (NFPA)
70E, Handbook for Electrical Safety in the Workplace when performing electrical work.

Perform the installation in accordance with all applicable codes. In addition, reference NEC Articles 250 and 690—as
well as applicable IEC standards—for proper compliance when wiring and grounding the system. All state and
federal guidelines and regulations must be followed as well.

1.1.1 Site Safety

• These installation instructions are for use by qualified personnel only.
• System access is intended for authorized personnel only.
• Only authorized persons may shut down the system or open any system enclosure.
• To reduce the risk of fire, connect only to a circuit that has dedicated overcurrent protection not exceeding the
maximum value stated in the product’s Listing (20 A) in accordance with the NEC, ANSI/NFPA 70. Maximum
output (branch circuit) overcurrent protection: 20 A.
• The metal components of the module can reach temperatures of approximately 176°F (80°C). Use appropriate
safety procedures when handling modules.

1.1.2 General Warnings

• Do not attempt installation during conditions involving rain, snow, ice, or high winds.
• Do not attempt to install or service the system if you are not a qualified, trained electrician or technician familiar
with power electronic equipment.
• Always wear rubber insulating gloves rated for the appropriate voltage level, and suitable eye and head
protection when working near live electrical equipment.
• Always have a fully charged, operational cell phone available for calling emergency personnel.
• Never attempt to service any portion of the solar electric system.

Changes or modifications not expressly approved by the party responsible for compliance could void the user’s
authority to operate the equipment.
Note: Always perform all electrical installations in accordance with any local codes and the National Electrical Code
(NEC).

1.2 Installer Responsibilities

Warning! If installing InvisiMount on a metal roof, you must first ensure that the InvisiMount system is bonded to
the roof in compliance with grounding methods as required by the authority having jurisdiction (AHJ).

Installers are solely responsible for specific aspects of the system they are installing:

Document #508988 RevJ 5 SunPower Proprietary

• Selection and verification of design parameters, including wind and snow load and all related aspects.
• Validating of third-party roof attachment design and interoperability, including any stipulations for rail overhang
(cantilever) beyond the last roof attachment (standoff) at the end of a row.
• Validating the strength of the InvisiMount system relative to the design parameters.
Note: SunPower span tables are only valid when used with SunPower-provided attachments.
• Code compliance and permitting.
• Vetting InvisiMount system compatibility with the installation site and structures.
• Verifying the roof integrity prior to installation.
• Selecting the correct attachment and flashing type for the particular roof.
• Care of the roof during the installation.

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1.3 Tools, Components, and Torque Values

1.1.1 Tools
All applicable PPE (personal protective equipment) is always required. In addition, the following tools are required to
install the system:

Tool Task

1/2″ socket Attaching ground lugs.

10 mm and 15 mm Attaching L-foot nuts, mid clamps, end clamps, splices, and ground lugs, and splice screws.
deep sockets

Caulk gun Installing rooftop transition flashing.

CHANNELLOCK® Tightening fittings on rail-mounted j-box and rooftop transition flashing.

pliers (or
equivalent)

Claw hammer Installing rooftop transition flashing.

Cordless drill with Installing fasteners and drilling holes in rooftop transition flashing and rail-mounted j-box.
step bit and hole
saw

Metal saw Cutting rails.

Roofing bar Installing rooftop transition flashing.

Rubber mallet Removing end clamp.

Square-drive Removing and installing rail-mounted j-box cover.

screwdriver

Torque wrench Verifying fastener torque.

Utility knife Installing rooftop transition flashing.

Document #508988 RevJ 7 SunPower Proprietary

1.1.2 Components and Torque Values
Important! SunPower requires that you use a torque wrench—not an impact driver—to enforce consistent fastener
tightness, thereby ensuring safe, high-quality installations.

Term Definition Tool and Torque

Attaches to rails and helps N/A

to support wires above
the lower edge of the rails.

Rail clip

Equipment grounding As per NEC

conductor for row-to-row
and system grounding.
EGC

Module-to-rail fastener • 10 mm deep socket

that fits over the end of a • 85 +5/−0 in-lb
rail, clamps to secure each (9.6 N-m)
End clamp of the endmost modules
in a given row, and bonds
modules to the rail.

Thin sections of material N/A

that are installed between
the roof substrate and any
rooftop penetration in
Flashing order to prevent water
from penetrating the roof.

Note: Shown with L-foot—

a separate component.

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 Term Definition Tool and Torque

An assembly that fits For M6 bolt:

securely into the top rail
• 10 mm deep socket
channel and
accommodates the • 85 +5/−0 in-lb
equipment grounding (9.6 N-m)
conductor (EGC). Its
Ground lug For lug screw:
machined rail nut
assembly penetrates the rail • 1/2″ socket
anodizaton to provide a
• 35 +5/−0 in-lb
bond between
(4 N-m)
components.

Note: Refer to Section

5.5.

L-shaped bracket that Refer to the roof

provides interface attachment
between the roof manufacturer
attachment and the rail; guidance (included
typically made of stainless with the attachment
L-foot steel or aluminum. box). If using a roof
attachment other than
L-feet, refer to that
attachment
manufacturer
guidance.

Module-to-rail fastener • 10 mm deep socket

that attaches in the top • 85 +5/−0 in-lb
rail channel; secures (9.6 N-m)
Mid clamp
module frames; and
bonds modules to the rail
throughout a row.

Extruded aluminum For the nuts that fit

component that attaches onto the bolts which
to the L-feet and supports slide into the side
clamped modules. Each channel:
Rail
rail section is 10.76′
• 15 mm deep socket
(129.13″ or 3.28 m) long.
• 375 +20/−0 in-lb
(42 +2/−0 N-m)

Document #508988 RevJ 9 SunPower Proprietary

 Term Definition Tool and Torque

Junctions array curcuits on For cover screws:

the roof; attaches to the
• #2 square-drive
rail with no tools.
Rail-mounted screwdriver
J-box • 16 in-lb
(1.8 N-m)

Installs on the rooftop and • Utility knife

enables the array wiring • Roofing bar
to transition to the
building wiring. • Caulk gun

Rooftop • Claw hammer

transition • Drill with step bit
flashing and hole saw bit
(optional)
• Two
CHANNELLOCK®
tongue & groove
pliers (or
equivalent)

Attaches between module • 10 mm deep socket

Row-to-row rows and enables the • 85 +5/−0 in-lb
(R2R) ground path to continue (9.6 N-m)
grounding clip from one row to the
adjacent row.

Plastic spacer that snaps N/A

into the exterior module
frame and uniformly
Row-to-row
enforces the distance
(R2R) spacer
between rows of adjacent
modules.

Document #508988 RevJ 10 SunPower Proprietary

 Term Definition Tool and Torque

Extruded aluminum Refer to splice screw

connector that, along with
splice screws, joins two
Splice
rails.

Black oxide coated • 10 mm deep socket

stainless steel fastener • 40 +5/−0 in-lb
that, in conjunction with a (4.5 N-m)
splice, attaches two
Splice screw
sections of rail together.

Note: Refer to Section

5.3.

Document #508988 RevJ 11 SunPower Proprietary

2.0 Listings, Compatibility, and Classification
The SunPower InvisiMount Residential Mounting System is UL 2703 Listed. The InvisiMount Listing includes the
following SunPower InvisiMount-compatible modules, which are the only modules that are compatible with the
InvisMount system:

DC Modules AC Modules

• SPR-X22-370-E-AC
• SPR-X22-360-E-AC
• SPR-X22-370 • SPR-A425-G-AC
• SPR-X21-350-BLK-E-AC
• SPR-X22-360 • SPR-A415-G-AC
• SPR-X21-335-BLK-E-AC
• SPR-X21-350-BLK • SPR-A400-G-AC
• SPR-X20-327-BLK-E-AC
• SPR-X21-335-BLK • SPR-A390-G-AC
• SPR-X21-345-E-AC
• SPR-X21-345
• SPR-X21-335-E-AC
• SPR-E20-327
• SPR-X20-327-E-AC
• SPR-E19-320
• SPR-E20-327-E-AC
• SPR-E19-320-E-AC

Grounding from the module to the rail is accomplished through both the mid clamp and end clamp. The Listing also
includes the following components, which have been evaluated for both mounting and bonding in accordance with
UL 2703:

• end clamp
• mid clamp
• rail
• splice and splice screw
• ground lug assembly
• L-foot
• row-to-row (R2R) grounding clip
• row-to-row (R2R) spacer

Document #508988 RevJ 12 SunPower Proprietary

2.1 Fire Classification
• The maximum distance between the roof deck and the bottom of the module frame is 3” (7.6 cm).
• In order to maintain the system classification, this assembly must be mounted over a fire resistant roof covering
for the application.
• The system achieves a Class A fire rating when installed with modules having a Type 2 fire classification; or for
modules specifically fire tested with the InvisiMount system.
• The system achieves a Class A fire rating when installed in the manner specified in these instructions.
• The system was evaluated for use on roofs having a pitch ≥ 2″/foot (greater than or equal to 2:12).

3.0 System Ground Path

The InvisiMount system features:

• Integrated module-to-rail as well as adjacent-module bonding (achieved through the mid clamp and end clamp).
• Integrated rail-to-rail bonding (achieved through the self-drilling splice screws and the splice).
• System bonding achieved through the equipment ground conductor (EGC).
For arrays where the installer chooses to use row-to-row (R2R) grounding clips (refer to Section 5.6.1) instead of
additional ground lugs and copper wire, system bonding is achieved through the R2R clips.

The following two diagrams illustrate the key grounding and bonding aspects of the InvisiMount system with and
without the R2R grounding clip:

• the system ground path

• each component
• each bonding point
• the applicable NEC and UL references

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Document #508988 RevJ 14 SunPower Proprietary
Document #508988 RevJ 15 SunPower Proprietary
4.0 Installation Outline
1. Mark the array layout on the roof surface.
2. Install flashings (if part of your chosen attachment solution) and roof attachments.
3. Join and install rails.
4. Attach ground wire.
5. Install modules.

5.0 Install System

These instructions describe attaching the rails parallel to the peak (“E–W”). The rail length accommodates SunPower
modules as follows:

Size Orientation Number of Modules per Rail Section

Portrait 3
96 cell
Landscape 2
Portrait 4
72 cell
Landscape 2
Portrait 3
66 cell
Landscape 1.8

Your array should be fully designed and all required permitting obtained before you begin. The SunPower Design
Tool—or the SunPower Span Tables—determine the actual span between attachments for a given system.
Designers can access the Tool by logging into the Partner Portal and then clicking the Design Tool link. The Tool
yields all the racking–specific structural calculations that can then be provided to the AHJ and that are typically part
of the permitting process. Ensure that you bring the PDF file from the Design Tool output to the site!

It is acceptable to attach either to the rafters or to the roof deck. SunPower recommends the following attachments:
• For comp shingle roofs: InvisiMount Comp Shingle Attachment with Pegasus (531766)
• For tile roofs:
o InvisiMount Flat Tile Attachment with Pegasus Tile Replacement (532911)
o InvisiMount S-Tile Attachment with Pegasus Tile Replacement (532910)
o InvisiMount W-Tile Attachment with Pegasus Tile Replacement (532912)
Instructions for installing the attachments are included with their packaging.

Document #508988 RevJ 16 SunPower Proprietary

5.1 Module Spacing
The spacing between the modules shall be as follows:

• Intra-row spacing (side to side in a typical row): spacing is governed and enforced when the mid clamps are
installed, and is 0.8” (20 mm).
• Row-to-row spacing (between an upper and a lower row in a typical array); spacing is governed and enforced
when the row-row (R2R) spacers are installed, and is 0.8” (20 mm).

5.2 Attachment Span and Rail Cantilever

The maximum distance (span) between roof attachments (L-feet or other attachment type) is 8ʼ (2.4 m).

The maximum rail overhang distance (cantilever) is 24″ (61 cm). Refer to the InvisiMount Span Tables for allowable
span and cantilever relative to your design requirements.

Note: A spliced rail does not require any special allowance for span nor cantilever.

Document #508988 RevJ 17 SunPower Proprietary

5.3 Join Rails
Depending on the roof slope, you may instead
decide to join rails on the ground before
transporting them to the rooftop. The rails and the
splices have pre-drilled holes for the splice screws.
You install one screw in each end of the splice (one
screw per rail, furthest from its end) (Fig. 1).

Important! The splice is an integral part of the

ground path. There must be no interference
between the splice screws and the L-feet.
Fig. 1
Therefore, ensure that the splice screws will not
interfere with your eventual attachment of the rail
to the L-feet (refer to Fig. 5 and Fig. 6).

1. Fit a splice halfway into a rail end, align the

splice hole with the rail hole, secure the
components so that they will not move, and
then drive a splice screw through the aligned
hole stopping 1/3 turn after the screw face has
contacted the rail face (Fig. 2). This method
provides 40 +5/−0 in-lb (4.5 N-m) of torque. Use
a torque wrench to verify and (if necessary)
apply final torque to each screw. Fig. 2
Splice screws are single use. If a screw becomes
dull or prevents smooth, consistent penetration
of the splice, use a new screw in the original
hole. If a screw breaks, use the other hole that is
provided—do not reuse the original hole. Ensure
that you deburr the new hole.
2. Fit the second rail all the way onto the splice
protruding from the first rail, align the
respective holes, and install the second screw.
The rail holes and splice holes must be aligned;
the rail ends are not required to be in contact
with each other. The maximum distance
between a spliced rail pair is 1/4″ (6.4 mm).

Document #508988 RevJ 18 SunPower Proprietary

5.4 Install Flashings, Roof
Attachments, and Rails
1. Define the installation zone and array layout on
the rooftop and mark it for penetrations as
necessary.
2. Referring both to the flashing (if appropriate for
the roof type) and to the attachment
manufacturer guidance:

a. Install the flashings and the roof

attachments.

b. Attach an L-foot to each of the roof

attachments according to the method
described by the attachment manufacturer
guidance. Leave the hardware finger-tight for
the moment.

3. Position the rails on the roof, adjacent to the L-

feet.
For aesthetic purposes, SunPower recommends
that you install the rails with their side channel
facing the roof peak (Fig. 3 and Fig. 4), but you Fig. 3
may install rails with their side channel facing
the eave instead.
Important! To ensure precise alignment with the
finished array’s footprint (perimeter), cut rails
only after you have adjusted them to an even
height and fully secured them to the
attachments.

Important! For your roof attachment strategy,

remember that a spliced rail is the same as a
solid rail in that a spliced rail does not require
any special allowance in terms of overhang
or attachments.

4. Position the rail adjacent to and “below” Fig. 4

(relative to the peak) the L-feet for the given
row (Fig. 4).

Document #508988 RevJ 19 SunPower Proprietary

 Note: L-feet are shown “facing” the peak (Fig. 4
and Fig. 5), but may be installed facing the eave
instead.

L-feet (or any other attachment type) must be

positioned such that the L-foot-to-rail bolt is a
minimum of 2″ (5 cm) from the end of a rail (Fig. Fig. 5
5); and a minimum of 2″ (5 cm) from any rail
joint (Fig. 6).

Fig. 6

Document #508988 RevJ 20 SunPower Proprietary

5. Attach the rail to each L-foot by inserting the T-
head of the rail bolt into the side channel and
then turning it to the right 90° (until you feel it
seat) (Fig. 7), then fitting the bolt ends through
the slots on the L-feet.
6. Temporarily finger-tighten an M10 nut on each of
the bolts. (You apply torque to these nuts in
Step 9.)

Best Practice: Position each bolt

at the midpoint of the vertical slot
in its L-foot (Fig. 8). This will
provide the greatest vertical
Fig. 7
adjustment flexibility.

7. To ensure that the installed modules will appear

as an even plane, SunPower recommends that
you use a string line and level (or other method)
to ensure that the top surface of the rails is even
(Fig. 9).
8. After you are satisfied that the rails are level,
tighten each L-foot nut to 375 +20/−0 in-lb (42
+2/−0 N-m).
9. Tighten all of the L-foot-to-roof-attachment
hardware according to the attachment
manufacturer guidance. (If you are not using L-
Fig. 8
feet, tighten the attachment hardware according
to the attachment manufacturer guidance.)

Fig. 9

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5.5 Attach Ground Wire
For arrays with two or more rows, in order to
achieve row-to-row grounding, you must install
either:
• one ground wire, one ground lug assembly, and
an R2R grounding clip (Fig. 10 and Section 5.6.1)
Note: An R2R grounding clip is required
between each row pair—e.g. a three-row array
would require two R2R clips.
or
• two ground wires and two ground lug
assemblies (Fig. 11)
If your array has a standalone module (refer to
Section 5.7), you must install a ground lug assembly
on one of its rails as well.
Fig. 10
Important! Ensure that you install the system such
that the copper ground wire will never contact any
aluminum! (Refer to Fig. 16.)

Fig. 11

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1. Slide the lug’s rail nut (Fig. 12) into the end of the
top channel of a rail and position it where you
want to attach the ground wire (you can
disassemble the ground lug first if necessary).

Fig. 12

2. Position the washer directly over the rail nut

(Fig. 13), and then use the M6 bolt to attach the
lug to the rail nut by first orienting the lug
parallel to the array (Fig. 14), finger-tightening
the M6 bolt, and then using a 10 mm deep
socket to apply an additional 5/6 of a turn only
(Fig. 15). Doing so provides 85 +5/−0 in-lb (9.6 N-
m) of torque. After tightening in this manner,
verify the value with a torque wrench.

Fig. 13

Fig. 14

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3. Attach the copper ground wire to the lug as per
NEC. Tighten the lug bolt (refer to Fig. 13) to 35
in-lbs (4 N-m).
As you add modules, reposition the ground wire
as necessary such that it will remain below the
module frames but above the rails and will never
contact the module frames or the rails!

Fig. 15
4. Following standard construction practices and
the NEC, connect the array ground wire to the
building’s ground.
Warning! The ground wire must never be any
closer to any other metal than 1/4″ (0.6 cm) (Fig.
16).

Fig. 16

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5.6 Install Modules
Important! If you are installing the rail-mounted J-
box (Appendix A), do so now before installing
modules. If your wire management strategy
includes the rail clips (Appendix C), it is easiest to
install them before you install modules.

Always check the SunPower Span Tables before

committing to rail placement. Rails may be
positioned in the green (non-crosshatch) regions
only, as follows:

Size Tolerances

96 cell • Short side: Minimum of 2″

(5 cm) but not more than 15″
(Fig. 17 (38 cm) from any module
and corner.
Fig. 18) • Long side: Minimum of 2″
(5 cm) but not more than 16″
Fig. 17
(40 cm) from any module
corner.

72 cell • Short side: Minimum of 2″

(5 cm) but not more than 10″
(Fig. 19 (25 cm) from any module
and corner.
Fig. 20)
• Long side: Minimum of 2″
(5 cm) but not more than 16″
(40 cm) from any module
corner.

66 cell • Short side: Minimum of 2″

(5 cm) but not more than 13″
(Fig. 21 (33 cm) from any module
and corner. Fig. 18
Fig. 22)
• Long side: Minimum of 11″
(28 cm) but not more than
28″ (71 cm) from any
module corner.

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 Fig. 21
Fig. 19

Fig. 20

Fig. 22

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Warning! Do not step on, stand on, or walk on the
modules or the module frames, and do not place
anything on them—even for a moment.
1. Position the first module of the row atop and at
the end of the rails.
2. With the SunPower logo upward, insert an end
clamp into each of the rail ends by holding the
clamp with your thumb and middle finger, and
pressing on the bolt head with your index finger
as you slide the clamp as far into the rail as
possible (Fig. 23). If the clamp does not slide in
easily, push on the bolt head.
3. Fit the top lip of the end clamp cover up and Fig. 23
over the bottom edge of the module frame (Fig.
24). Do this for both end clamps.
Verify correct module position and full end
clamp engagement, and then tighten each end
clamp bolt to 85 +5/−0 in-lb (9.6 N-m) with a 10
mm socket.
Note: If you need to remove an end clamp, first
loosen its bolt two turns and then tap on its bolt
head to free its engagement mechanism.
4. Fit one mid clamp down into the top channel of
each of the row’s two rails, rotate it 90° (Fig. 25),
and slide it toward the first module. Leave the
Fig. 24
two mid clamps loose for now.
5. Position the second module next to the first
module.
6. For each of the two mid clamps: fit one side (two
teeth) of each clamp over the respective
adjacent frame edge of each of the two modules
(the first and second modules) (Fig. 26; second
module not shown).

Fig. 25

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7. Tighten each of the two mid clamps to 85 +5/−0
in-lb (9.6 N-m).
Important! Each mid clamp’s four teeth must
solidly engage the module frames to ensure
continuity of the module–rail ground path (Fig.
26).
8. Repeat Steps 4–7 until you have installed all
except for the last module in the row.
9. For the last module in the row, position it on the
rails in the desired location, and then mark a cut
line on each of the rails at the module edge (Fig.
27). Fig. 26

10. Remove the module to ensure it is not damaged

in the cutting process, and then cut the rails
along the lines you marked.
Important! The maximum distance the module
is permitted to overhang the rail is 1/4″ (0.6 cm)
(Fig. 28).
11. Place the module in position again and then add
its two mid clamps (which also secure the
second-to-last module in the row), tightening
them as you did in Step 7.
12. Add and tighten the last module’s two end
clamps as you did in Steps 2–3.
If you’re installing a second row, you must Fig. 27
add two row-to-row (R2R) spacers to the upper
edge of each of the completed first row’s
modules.

Note: These instructions assume that any

second row you add will be “above” the first row
(between the peak and the first row).

Fig. 28

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13. For each of the modules in the first row, fit two
R2R spacers in its upper frame edge, one each
approximately 8″ (20 cm) from each upper
frame corner (Fig. 29 and Fig. 30).
Note: When installing the R2R grounding clip to
achieve row-to-row grounding (Section 5.6.1), it
is acceptable to shift the position of the spacer
nearest the grounding clip just enough to
correctly install the R2R clip—but you must still
install two spacers on the module that engages
the R2R clip.
14. Repeat Steps 1–12 to fully install the second
row, allowing the second row’s modules to
gently rest evenly on the spacers.
Note: The spacers provide no structural Fig. 29
support for the modules. Leave the spacers in
place after module installation.

Fig. 30

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5.6.1 Install R2R Grounding Clip
Note: Refer to Section 5.5.

The R2R grounding clip can be installed even

after you have built the array. The R2R spacers
enforce the correct spacing to enable easy
installation of the R2R grounding clip even after the
array is complete. Fig. 31

The row-to-row (R2R) grounding clip provides a

grounding path between adjacent rows of modules
that are not mounted on the same rail pair.

The R2R grounding clip is not applicable for arrays

that consist of a single row.

You must still connect one ground lug to one of the

rails in the first row, and run the copper ground
wire to it so that its electrical bond will transfer to
the other rows through the R2R clip (refer to Fig.
10).

1. The R2R clip has two threaded bosses with bolts

(Fig. 31). Fit the R2R clip (with bolt heads up) Fig. 32
between one row-end module in the first row
and the adjacent module in the second row; 8”
(20 cm) from the end of the row (Fig. 32 and Fig.
33).

Fig. 33

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2. Ensure that the both jaws of the clip fit over the
respective module frames fully (Fig. 34).
3. Tighten the first-row bolt (the outer one, nearest
the module corner) to 85 +5/−0 in-lb (9.6 N-m),
so that the clip firmly clamps onto the module
frame.
4. Tighten the second-row bolt (the inner bolt) on
the R2R clip to as described in Step 3.
Fig. 34

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5.6.2 Standalone Modules
Any module in an array that will not include mid
clamps as part of its mounting hardware is
considered a “standalone module.” Typically a
standalone module arises when an array has a
module “missing” in order to accommodate a
rooftop feature or obstruction, or when an array
forms a “pyramid” shape and the topmost (or
bottommost) row contains only a single module.

You must ground a standalone module as if it were

its own row, and you must do so in one of the
following two ways:

• Attach a ground lug assembly to one of its rails Fig. 35

(Fig. 35), and route the copper ground wire to it.

OR

• Install another R2R grounding clip (Fig. 36; refer

to Section 5.6.1).

Fig. 36

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Appendix A: Install Rail-Mounted Junction Box
If you decide to use the rail-mounted J-box (RMJ), install it before you install modules.

Important! Only glands and fittings that have gaskets and that are suitable for wet locations may be used.

1. Determine the location for the RMJ. You can mount the RMJ “above” or “below” the rail (Fig. A1).

Fig. A1
2. According to your wire management strategy, determine, mark, and drill out the necessary entry locations on the
sides of RMJ (do not drill the cover).
3. Drill a weep hole (min. 1/8″; max. 1/4″) in the RMJ at its lowest point.
Note: SunPower provides one Heyco 3/4” cable gland; the maximum conduit size is 1″.
4. Install glands or conduit fittings in the RMJ. If you’re using a provided cable gland, torque its locknut to 40 +5/−0
in-lb (4.5 N-m).
Important! Do not mount conduit or glands to the box cover.
5. Fit the RMJ lip into the top channel of the rail (Fig. A2), and then tilt the RMJ downward until both of its tabs click
around and fully engage the rail (Fig. A3).

Fig. A2 Fig. A3

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6. Manually squeeze each tab upward to verify full engagement (Fig. A4)

Fig. A4
7. Remove the RMJ cover and insert the cable ends. For the provided glands, torque sealing nuts to 70 in-lb (7.9 N-
m).
8. Complete the installation of any conduit and wiring.
9. Fit the cover on the RMJ and use the #2 square-drive screwdriver to torque each of the four cover screws to 16
in-lbs (1.8 N-m).

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Appendix B: Install Rooftop Transition Flashing
Decide on the position of the installed flashing with respect to your array. Install the flashing only at a location that
is both between the rafters and within the array perimeter, such that it will be underneath and fully concealed by the
array when the array is complete.
1. After you have selected the location for the flashing, position the flashing on the roof as follows:
• With its ROOF RIDGE arrow toward the peak.
• Such that its lower alignment marks are positioned at or a maximum 1″ (2.5 cm) above the bottom edge of
the second of the two affected shingle courses at your chosen location (Fig. B1).
• Such that the left and right edges of the flashing are perpendicular to the shingle courses.

Fig. B1
2. Keeping the flashing in position, trace its perimeter onto the shingles, and mark the flashing’s alignment marks
on the shingles as well.
3. Remove the flashing and use a straight edge to trace the lines between the alignment marks onto the shingles
(Fig. B2).

Fig. B2

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4. Using a roofing bar, gently separate the two courses of affected shingles from underlying layers in the marked
region, while leaving the shingles in place.

5. Cut and remove one layer of shingle material in the crosshatched area (Fig. B3 and Fig. B4).

Important! DO NOT REMOVE ANY SHINGLE MATERIAL FROM ANY COURSES THAT EXTEND BELOW THE
BOTTOM OF THE FLASHING, EVEN IF THAT MATERIAL IS INSIDE THE BOX. DO NOT CUT THROUGH THE ROOF
MOISTURE BARRIER EXCEPT FOR THE TRANSITION HOLE INTO THE ATTIC OR BUILDING SPACE.

Fig. B3

Fig. B4

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6. To test fit, slide the flashing up under the shingle course that will align with the lower edge of the flashing (the
“middle” course of the three affected courses). If roof nails are in the way, remove them with a roofing bar and
seal the remaining holes with appropriate sealant for the particular roof type.
7. Remove the flashing.
8. Through the roof surface from which you removed material, drill a single pass-through hole no larger than 5 cm
(2″), centered E–W, and no less than 4″ (10 cm) from the lower edge of the flashing (Fig. B5).
Important! The bottom point of the hole must be a minimum of 4″ (10 cm) from the bottom edge of the flashing.

Fig. B5
9. The flashing comes with three hole locations each marked with a white dot. Allowing for the size of your chosen
gland, drill the flashing with a step drill tip (or knockout tool) centered on one of the dots (Fig. B6).

Important! Use only liquid-tight glands with gaskets appropriate for your chosen wire type.

Note: Use only the three provided drill locations, and do not drill more holes than necessary.

Fig. B6

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10. Install and torque the gland and back nut as per the manufacturer guidance (Fig. B7 and Fig. B8).

Fig. B7 Fig. B8

Important! UF-B wire is used in this example because it is Listed for exterior and interior use. SunPower
recommends that you refer to the applicable NEC edition for your region (some regions adopt editions later than
others)—as well as consult with your AHJ—before choosing a wiring strategy.

11. Route and prepare a length of UF-B wire from the service panel entrance to the rooftop. Allow several extra feet
for final installation.
12. Insert the cut end of the wire through the roof cutout, leaving sufficient length beyond the roof transition.
13. From the underside of the flashing, thread the UF-B wire through the gland, and then carefully slide the flashing
into position (Fig. B9).

Fig. B9 Fig. B10

14. Ensuring that you leave enough extra wire length, tighten the gland around the wire per the gland manufacturer
specification (Fig. B10).
Important! Do not loosen the seal at the base of the gland!
15. Remove the flashing and turn it over, taking care to not disturb the gland.

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16. Apply a single 1/2″ continuous bead of sealant to the underside of the flashing, approximately 1″ (2.5 cm) from its
perimeter (Fig. B11). Use only 100% silicone roof sealant, such as Henry 884 Tropi-Cool® or equivalent. Ensure
that the sealant has not exceeded its shelf life and has not exceeded the recommended maximum time-to-use
period after opening, as defined in the manufacturer guidance.

Fig. B11

17. Conforming to the exact outline you made previously, fit the flashing back into position while sliding the excess
wire down into the attic space (Fig. B12).

Fig. B12 Fig. B13

18. Lift the middle course of shingles and secure the flashing with one sheet metal screw (#9-15 1-1/2”); or nail (#12
ring shank 1-1/4”); on each side of the flashing; 1” (2.5 cm) from the flashing edge.
19. Apply a liberal cap of sealant on the head of each screw (or nail) (Fig. B13).
20. Lift the two courses of shingles and apply a horseshoe-shaped bead of sealant on the top surface of the flashing
(as you did on the bottom of the flashing in Step 16) (Fig. B14).

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 Fig. B14

21. Press down firmly on the shingles over the flashing outline to properly bond the assembly to the roof surface.
22. Similar to Step 9, drill the flashing for conduit entry.
23. Install and torque all conduit fittings as per manufacturer guidance.
24. Mount conduit as per your array design. Conduit must be rated for the appropriate exposure. Exterior conduit
and fittings must be rated liquid tight, and installed in an appropriate liquid-tight manner, including gaskets on
all sealing faces where needed. A coupling can be used to connect interior and exterior raceways through the
flashing.

For the flashing side of the conduit run, secure the conduit within 12″ (30 cm) of either side (attic side or roof side)
of the flashing.

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Appendix C: Rail Clips
Rail clips provide optional additional means of wire management. Use them as necessary to help keep all wiring off
of the roof surface. The maximum number of wires that each rail clip is permitted to carry is one. Space rail clips no
more than 24″ (61 cm) apart.

In addition, always prevent wires from drooping below the lower edge of the rails.

1. Place the wire into the wire channel of the clip (Fig. C1), position the clip beneath the rail, and then fit the lower
lip into the side channel of the rail (Fig. C2).

Fig. C1 Fig. C2

2. Holding the wire in position within the clip, rotate the clip under and around toward the top of the rail (Fig. C3),
gently pushing the upper lip over the top of the rail until it snaps into the top channel of the rail (Fig. C4). You
should hear the upper lip click into the channel.
To remove clips, simply press down on the lower lip to release it from the rail.

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Appendix D: Module Removal

Important! If you have to remove a module from an array, note that leaving any module in the array when it is
physically secured only by two end clamps is expressly prohibited.

To remove a module from an existing array:

1. Turn off the DC disconnect at the inverter.

2. Using a clamp-on multimeter, verify that current flow has stopped on all DC source circuit conductors. If fuses
are installed at the combiner, remove the fuses to isolate the circuit with the target module from parallel-
connected sources.
3. Using a clamp-on current meter, test each individual circuit conductor AND each equipment ground conductor
on the rooftop before opening any module connectors (before disconnecting any module leads).
4. If the current is zero amps, it is safe to proceed to Step 8. If there is any current present (greater than 0 amps),
double-check that the circuit is in fact disconnected from the inverter and proceed to Step 5.
5. If the circuit has been disconnected from the inverter and current is still present, DO NOT INTERRUPT THE
CIRCUIT! (Do not unplug any module leads or open any breakers, for example.) It is likely that a short circuit or a
ground fault is present—or both.
6. Troubleshoot and correct the short circuit, the ground fault, or both.
7. After verifying that the circuit is disconnected from the inverter and that there are no short circuits or ground
faults present, use the clamp-on meter to retest each individual circuit conductor AND each equipment ground
conductor. Verify that the current for each is zero before proceeding.
8. Disconnect (unplug) the target module’s two electrical leads from the modules that are adjacent to the target
module.
9. Remove the adjacent modules and mid clamps, ideally from the side of the row that contains fewer modules
between the target module and the end of the row (Fig. D1 and Fig. D2). If there is any other grounding or wire
management hardware present, remove it as well.
10. Remove the target module.
• If the target module will be out of the array solely for the purposes of replacing it with another module
immediately, ensure that you remain aware of the adjacent module’s temporary partial securement, and
execute the swap efficiently, reusing all of the mid clamps and end clamps.
• If the target module will be out of the array for an extended period, carefully attach two mid clamps to the
now-exposed edge of each adjacent module (Fig. D1, Fig. D2, and Fig. D3) according to Section 5.6 of this
guide (note that two of the teeth on these mid clamps will instead directly engage the top of the rail—this is
acceptable for module removal and replacement). The mid clamps will keep the modules bonded to the rail,
which is bonded to the equipment grounding conductor (EGC) and in turn the grounding electrode conductor
(GEC).
11. After replacing or servicing the target module, reassemble the row according to the instructions in this guide.

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 Important! When reinstalling a removed module, shift its original location slightly (min. 1/16″) relative to its
original installed position and in the direction perpendicular to the rail before retightening the mid clamps and
end clamps.

Fig. D1

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 Fig. D2

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 Fig. D3

SUNPOWER™, the SUNPOWER logo, and InvisiMount are registered trademarks of SunPower Corporation.

© 2019 SunPower Corporation. All rights reserved. Specifications included in this document are subject to change without notice.

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