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1 Contents Introduction Our Company Mission Statement Safety and Installer's Responsibility Handling and installation of Rail Calculation and Design Technical Specifications Features Before Installing Receipt of Goods Tools required for Installation Components List Fixing Locations and Array Placement Installation Procedure for 1 row situation Installation Procedure for 2 row situation Installation Procedure for 3 row situation or more Installation Detail System Component Evaluation Design for Wind load ASCE7-05 Structure Calculation for Rail and Components Warranty Conditions

2 Thank you for choosing the solar panel mounting system. Made from custom-built aluminum extrusions and components, streamlined design and improved frame strength greatly simplify solar panel installation. Offering a high level of adjustability for module width and quantity, the 's versatile design makes it suitable for a wide variety of building types and zones including residential, commercial and remote environments. 's is backed by a 15-year warranty and is compliant with the IBC 2006, IBC 2003, ASCE 7-02, ASCE 7-05 and California Building Code 2007 Our Company specializes in the development, manufacturing, and marketing of photovoltaic racking solutions. Since its foundation Orion has released a wide range of high-quality and innovative mounting systems. We provide roof and ground mounting solutions for residential, agriculture, industrial, government, commercial, and utility grade projects. Each day we endeavor to make innovative solar racking solutions more affordable and accessible. Our focus is to provide renewable energy solutions that continue to make solar installation simple. Orion has many unique custom tailored solutions which can be assembled into a variety of structures to accommodate most job sites. Orion provides a technical support system complete with installation and code compliance documentation, an online estimator, and design assistance to help you solve the toughest challenges. We now play a leading role in the solar industry and have rapidly gained popularity among systems integrators, installers and distributors across the World. The most versatile PV mounting systems in the market. Proud to be designed, engineered, and manufactured in the USA. Solutions For ARRA Projects.

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4 It is critically important to observe standard safety practices when installing. Stop work during stormy weather. Solar modules can be caught in the wind. Never step or sit on the glass surface of a solar module. The glass may break, resulting in shock or bodily injury. Do not throw or roughly handle any components. Do not bring the into contact with sharp or heavy objects. Do not modify components in any way. The exchange of bolts, drilling of holes, bending and any other physical changes not intended in standard installation procedure will void the warranty. Product should be installed and maintained by qualified personnel. Keep unauthorized personnel away from solar modules It is the installer s responsibility to verify the integrity of the structure to which is fixed. Roofs or structures with rotten/rusted bearers, undersized bearers, excessively spaced bearers, or any other unsuitable substructure cannot be used with Orion Solar Racking, and installation on such structures will void the warranty, and could result in death or serious injury. Rail calculations are based on code approved conventional mechanical section properties, material properties, stress equations, and allowable margins of safety. Beam calculations have been conservatively performed in non-snow areas with simply supported assumptions. Components have had full envelope forces from the tables applied to each component. This is prescriptive in nature and not a site specific engineering document for building permit application. Please contact Orion Racking Systems for more detailed information and for site specific engineering data on specific projects. ASCE 7-05 guidance for Wind is used in the tables.

5 Commercial and residential buildings Marine applications and remote areas Aluminum 6106-T6 extrusion Suitable for buildings up to 30' in height Suitable for roof slope range from 0º to 65º Static load capacity from 20 N to 1800 N Significantly higher strength-to-weight ratio than other framing products,providing improved efficiency due to greater frame spans, inherent corrosion. resistance resulting in low ongoing maintenance and an extended product life. Complies with ASCE 7-05 guidance for wind load design. Check that the equipment is undamaged and that the order is complete.

6 6mm metric Allen Key or 6mm hexagonal driver bit. Drill or impact driver for driving roof material fixings. Measuring tape Chalk Line Reel Glove Helmet

7 Orion Rail Rail Splice Kit Mid Clamp End Clamp Tile Hook for Spanish Tile Tile Hook for Flat Tile Tile Hook for Shingle Roof Ground Clip Ground Lug To determine bill of material for your project, Please log on Orion Racking Universal Calculator OrionRacking.com To find out how to install this system. Please click the link below Installation Procedure

8 The solar panels must be located in the Roof Internal Zone. Placement of the array outside this zone will inflict undue stress on the framing fixings and clamps, and the warranty will be voided.

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16 2 rows situation

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20 To see detail installation animation please click the link below or Visit our website for actual installation photos

21 3 or more rows situation

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24 To see detail installation animation please click the link below or Visit our website for actual installation photos

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27 Rail calculations are based on code approved conventional mechanical section properties, material properties, stress equations, and allowable margins of safety. Beam calculations have been conservatively performed in non-snow areas with simply supported assumptions. Components have had full envelope forces from the tables applied to each component. This is prescriptive in nature and not a site specific engineering document for building permit application. Please contact Orion Racking Systems for more detailed information and for site specific engineering data on specific projects. ASCE 7-05 guidance for Wind is used in the tables. Rail Span Chart The following pages show engineering evaluations of the Orion Racking Flush-Mount System. Evaluations Include: Adjustable End Clamp Mid Clamp A270 Bolt Rail Foot Standard Rail Heavy Duty Rail L Foot Roof Bolt

28 Component: Adjustable End Clamp Allowable Load: 600lb Maximum Stress: 30ksi, OK Filenames Min Max Number Next Active Color Coordinate System Point Curve Surface Solid/ Valume Connector Region Connection Property Text Node Element Material Property Load Set Constraint Set View Group 1 Output Set Output Format 1 Workplane Origin X Y Z Workplane Normal X Y Z Workplane X Axis X Y Z Snap X Y Angle Model Extents X Y Z

29 Component: Mid Clamp Allowable Load: 600lb on a side Maximum Stress: 2.1ksi, OK Applied Tensile Force: N Mid Clamp Cantilever beam AB result N/mm2 moment (mm*n) I= bh-3/12 c Bending Stress Stress= M c/l psi psi result Shear Stress 3V/2A 1.26 N/mm psi

30 Component: A270 Bolt Allowable Load: 1200lb Tension 1200lb Shear Maximum Stress: 1.5ksi, OK Applied Tensile force : N Bolt bending Stress Stress= M c/l 0 N/mm2 result Moment (mm*n) I= bh-3/12 C 0 psi Result Shear Stress 3v/2A N/mm Component: Rail Foot Allowable Load: 1200lb Maximum Stress: 1ksi, OK psi Result P A=p i*r N/mm psi *A2-70 is a 304 stainless steel screw with a 700 N/mm2 tensile strength Foot Clamp cantilever beam BC Applied Tensile force : N result Moment (mm*n) I= bh- 3/12 C bending Stress Stress= M c/l 6.88 N/mm psi Result Shear Stress 3v/2A 4.82 N/mm psi *model as solid prismatic beam of length 1.5mm and height 4.2 mm

31 Component: Standard Rail See Span Charts for ratings Section Property Calculations Section Property Calculations Std base height area centroid height m base I (in^4) d ad^2 A b b c c d d e f f es bot g h ang i j k k l m h ave m v ave ^ centroid S in^3

32 Component: Heavy Duty Rail (See Span Charts for ratings) (0.5 added to interior void and thickened side wall) Add 0.5 to cut ine Section Property Calculations Section Property Calculations Added 0.5 In base height area centroid height m base I (in^4) d ad^2 A b b c c d d e f f es bot g h ang i j k k l m h ave m v ave ^ centroid S in^3

33 Rail Span Calculations Beam Calculations Parameters non-italics = calculated by internal software italics = location specific (engineering input) Beams L Trib Area LL w M Fb S req defl E I req R ft ft sf psf plf lb-ft psi in3 in psi in4 lb Simple Span hvy +.5 Standard Rail reg St h=20 w=85 t= E h=20 w=85 t= E h=20 w=85 t= E h=20 w=85 t= E h=20 w=85 t= E h=20 w=85 t= E h=30 w=85 t= E h=30 w=85 t= E h=30 w=85 t= E h=30 w=85 t= E h=30 w=85 t= E h=30 w=85 t= E h=40 w=85 t= E h=40 w=85 t= E h=40 w=85 t= E h=40 w=85 t= E h=40 w=85 t= E h=40 w=85 t= E h=30 w=90 t= E h=30 w=90 t= E h=30 w=90 t= E h=30 w=90 t= E h=30 w=90 t= E h=30 w=95 t= E h=30 w=95 t= E h=30 w=95 t= E h=30 w=95 t= E h=30 w=95 t= E h=30 w=100 t= E h=30 w=100 t= E h=30 w=100 t= E h=30 w=100 t= E h=30 w=100 t= E h=30 w=105 t= E h=30 w=105 t= E h=30 w=105 t= E h=30 w=105 t= E h=30 w=105 t= E h=30 w=110 t= E h=30 w=110 t= E h=30 w=110 t= E h=30 w=110 t= E h=30 w=110 t= E h=30 w=115 t= E h=30 w=115 t= E h=30 w=115 t= E h=30 w=115 t= E h=30 w=115 t= E h=30 w=120 t= E h=30 w=120 t= E h=30 w=120 t= E h=30 w=120 t= E h=30 w=120 t= E ,034 h=30 w=125 t= E h=30 w=125 t= E h=30 w=125 t= E h=30 w=125 t= E h=30 w=125 t= E

34 Rail Span Chart Rail Span Summary Height Wind Tilt Span ft mph degrees ft h=20 w=85 t= Standard Duty h=20 w=85 t= Standard Duty h=20 w=85 t= Standard Duty h=20 w=85 t= Standard Duty h=20 w=85 t= Heavy Duty h=20 w=85 t= Heavy Duty h=30 w=85 t= h=30 w=85 t= h=30 w=85 t= h=30 w=85 t= h=30 w=85 t= Heavy Duty h=30 w=85 t= Heavy Duty h=40 w=85 t= h=40 w=85 t= h=40 w=85 t= h=40 w=85 t= h=40 w=85 t= Heavy Duty h=40 w=85 t= Heavy Duty h=30 w=90 t= h=30 w=90 t= h=30 w=90 t= h=30 w=90 t= Heavy Duty h=30 w=90 t= Heavy Duty h=30 w=95 t= h=30 w=95 t= h=30 w=95 t= h=30 w=95 t= Heavy Duty h=30 w=95 t= Heavy Duty h=30 w=100 t= h=30 w=100 t= h=30 w=100 t= h=30 w=100 t= Heavy Duty h=30 w=100 t= Heavy Duty h=30 w=105 t= h=30 w=105 t= h=30 w=105 t= Heavy Duty h=30 w=105 t= Heavy Duty h=30 w=105 t= Heavy Duty h=30 w=110 t= h=30 w=110 t= h=30 w=110 t= Heavy Duty h=30 w=110 t= Heavy Duty h=30 w=110 t= Heavy Duty h=30 w=115 t= h=30 w=115 t= h=30 w=115 t= Heavy Duty h=30 w=115 t= Heavy Duty h=30 w=115 t= Heavy Duty h=30 w=120 t= h=30 w=120 t= h=30 w=120 t= Heavy Duty h=30 w=120 t= Heavy Duty h=30 w=120 t= Heavy Duty h=30 w=125 t= h=30 w=125 t= h=30 w=125 t= Heavy Duty h=30 w=125 t= Heavy Duty h=30 w=125 t= Heavy Duty

35 Component: L Foot Allowable Load: Maximum Stress: 2200lb Reaction 7.8ksi, OK L Foot Cantilever beam EF Applied Tensile force : N 500 Moment (mm*n) I= bh-3/12 C result bending Stress Stress= M c/l N/mm Component: Roof Bolt Allowable Load: Maximum Stress: L Foot Cantilever beam EF 2200lb Reaction 7.8ksi, OK Applied Tensile force : N 500 Result Moment (mm*n) I= bh-3/12 C Shear Stress 3v/2A 19.5 N/mm psi Result Axial Stress P/A 13 N/mm /8 lag, 4" into roof Graming member psi

36 warrants that its Solar Panel Mounting System (Frame) is free from defects in materials and workmanship for a period of 17 years from the date on which the Frame is purchased from Orion Solar Racking (Warranty Period), on the terms set out in this warranty. In the event that the Frame does not conform to this warranty during the Warranty Period, will, at its option, either repair or replace the Frame or pay the cost of having the Frame repaired or replaced. To the extent permitted by law, s total liability under this warranty will in no circumstances exceed the repair or replacement of the Frame or payment of the cost of having the Frame repaired or replaced. In the event of replacement of the Frame, any remaining part of the Warranty Period will be transferred to the replacement Frame. This warranty will not apply to any defect or damage to the Frame arising directly or indirectly from: A. shipment or storage of the Frame; B. improper installation, maintenance, repair or use of the Frame; C. normal wear and tear; D. misuse, neglect, abuse, accidental damage or modification to the Frame; E. failure to observe the instructions set out in the System Manual; or F. power failure, power surges, lightning, fire, explosion, flood, extreme weather conditions, environmental disasters or other causes outside s control, as determined by in its sole discretion. This warranty does not cover, and under no circumstances will be liable for, any costs associated with the removal, shipping, handling or re-installation of the Frame or the costs of sending personnel to any site to repair or replace the Frame. This warranty is only provided to the original purchaser of the Frame from (Purchaser) or, where the Purchaser is an installer or builder who on-supplies the Frame to another party, to that other party (End-User). This warranty is not transferable. Where an End-User wants make a claim under this warranty, the End-User must in the first instance contact the installer or builder from whom the Frame was purchased. All warranty claims must be: made in writing and addressed to the Customer Service Office: : 2917 Vail Ave., Commerce, CA 90040; and accompanied by proof of purchase of the Frame in a form acceptable to. This warranty will not apply to any claims received by after the expiration of the Warranty Period. makes no warranties, express or implied, other than the warranties made herein, and specifically disclaims all other warranties, representations and conditions to the extent permitted by law. To the extent permitted by law, in no circumstances will be liable for direct, indirect, special or consequential damages arising from a defective Frame or for any damage or injury to persons or property. s aggregate liability, if any, in damages or otherwise, will not exceed the invoice value of the Frame at the time of purchase from. Any provision contained in this warranty which is prohibited or unenforceable in any jurisdiction will be deemed to be ineffective to the extent of such prohibition or unenforceability and will not invalidate the remaining provisions nor affect the validity or enforceability of that provision in any other jurisdiction. This warranty will be governed and construed in accordance with the laws of the State of California and the parties irrevocably submit to the exclusive jurisdiction of the State of California.