RAKED MOUNTED INSTALLATION MANUAL - Sol …sol-distribution.com.au/SOLRACK/Installation Manual/SOLRACK Manual... · AS/NZS 1170.1:2002 A2-2009 ... Clamping area for modules (check

RAKED

RAKED MOUNTED INSTALLATION MANUAL

V1.0 DECEMBER 2014

SOLRACK INSTALLATION MANUAL Version 1 (December 2014)

Thank you for choosing the SOLRACK Solar Tilt Mounting System.

SOLRACK solar roof mounting system incorporates stainless steel and extruded aluminum components which combine to form a strong solar panel framing system, adaptable to numerous types of roof structures.

The rationalization of components through the design of SOLRACK provides ease of ordering and installation which ultimately saves costs

SOLRACK Solar Tilt Framing System has been assessed and approved by a chartered structural engineering company in order to comply with:

AS/NZS 1170.0:2011 – Structural Design Actions Part 0: General Principles AS/NZS 1170.1:2002 A2-2009 – Structural Design Actions Part 1: Permanent, imposed and other actions AS/NZS 1170.2:2011A2-2012 – Structural Design Actions Part 2: Wind actions AS1664 – Rules for the use of Aluminium in structures (SAA Aluminium Structures Code)

SOLRACK Solar Tilt Mounting System comes with a 10 year warranty and a 5 year finish warranty.


Table of Contents

INTRODUCTION ........................................................................................................................................................ 3

INSTALLER’S RESPONSIBILITIES ........................................................................................................................... 4

PLANNING FOR INSTALLATION .............................................................................................................................. 5

Step 1: Determine the wind region of the site ...................................................................................................... 5

Step 2: Determine the height, installation zones and array layout ....................................................................... 6

Installation Zone................................................................................................................................................. 6

Array Layout Planning ....................................................................................................................................... 8

Step 3: Determine the Maximum Tilt Module Leg Spacing .................................................................................. 9

Commercial Buildings ....................................................................................................................................... 9

Residential Buildings ......................................................................................................................................... 9

Step 4: Determine the type of fasteners and minimum number of fasteners to be used .................................. 10

Buildex- Stainless Steel Roofing Fasteners .................................................................................................... 11

Fastener Notes:................................................................................................................................................ 11

INSTALLATION STEPS ........................................................................................................................................ 12

Overview of System Components ....................................................................................................................... 12

Rail Kit Components ........................................................................................................................................ 12

Tilt Leg Components ....................................................................................................................................... 13

Installation Tools .............................................................................................................................................. 14

Installation Instructions ........................................................................................................................................ 14

Fixing the Legs on to the roof .......................................................................................................................... 14

Mounting the Rail to the Legs .......................................................................................................................... 15

Installing Solar Panels on to the Rails ............................................................................................................. 16

APPENDIX A: SOLRACK Solar Framing System10 year Limited Product Warranty, 5 year Limited Finish Warranty .................................................................................................................................................................. 18

APPENDIX B: Structural Design Certificate……..……………………………………………………….………………19

APPENDIX C: Fastener Pullout Strengths………………………………………………………..……………………..23

APPENDIX D: Certified Tilt Module Component Drawings……………………………………………………………26


INTRODUCTION

This manual is designed exclusively for SOLRACK Solar Tilt Mount System.

The manual gives the instructions for a simple and safe installation process. If the installer adheres to the steps explained in the following sections, SOLRACK Solar Tilt Mount System will be successfully installed and capable of sustaining the load conditions as specified in AS/NZS 1170 and AS1664.

SOLRACK Solar Tilt Mount Systems have structural certificates based on the following conditions. Please ensure all the following conditions are satisfied before proceeding.

Maximum solar panel size = 1.690m x 0.992m Maximum tilt module leg spacing to be chosen according to leg spacing Tables 1 and 2. Minimum four support clamps to rail per solar panel. Solar panels are to be installed on the building roof only. Wind region to be determined according to Figure 1 Maximum Building Height (h) is 20 m. Maximum tilt module pitch shall be 5⁰- 30⁰ Commercial building roof pitch < 50 Residential building roof pitch ≥10° to ≤ 30° Minimum steel purlin thickness to be 1.5mm for commercial applications. Minimum steel purlin/batten thickness to be 0.75mm for residential applications. Important Considerations Related to SOLRACK Installation

SOLRACK Solar Tilt Mount System is not responsible from any fault caused by the installer. Ensure to carry an inspection of the installation site and the roof space before installation. Building heights over 20 m are outside the design parameters of this document and should be analysed

and be verified by the Certifying Engineer. It is strongly recommended that all the connections and fasteners are checked against failure immediately

after a 5 year ARI (Average Recurrent Interval) wind event or annually, whichever comes first. SOLRACK carries no responsibility for solar panels/frames certified by others. 304 Stainless Steel should not be used in a marine environment or in an environment above 50 – 60 0C with

chlorides present. The use of 316 Stainless Steel is recommended in these conditions. The manual is not applicable for snow or earthquake loads (AS/NZS 1170.4) and represents installations

designed for wind loads only.


INSTALLER’S RESPONSIBILITIES

Please read the following points carefully before beginning any installation. Take a moment to familiarize yourself with all system components. During the installation, be sure to observe the appropriate safety regulations and please pay attention to the relevant regulations of your local region.

Use only SOLRACK components as specified by the SOLRACK manual. Any substitution or modification of SOLRACK components may void the warranty certification.

Ensure that the SOLRACK system is appropriate for each installation and the installation environment. Ensure that the roof rafter/purlin assembly (rafters, purlins, connections and other structural support

members) can support the array under building live and dead load conditions. Comply with all current standards that are relevant for each installation (Note: This document does not

include loadings for snow or earthquake loads and represent installations designed for wind loads only). Comply with the module manufacturer’s installation procedures. Maintain the waterproof integrity of the roof, including use of the appropriate flashing. Ensure all components of the SOLRACK railing system are correctly earthed. Ensure that all screws have adequate pull-out strength and shear capacity ratings (Read ‘Planning Step 6:

Fastener Types’ and ‘Appendix B: Fastener Data’ for guidance). Ensure that all dissimilar metals are electrically separated to prevent galvanic corrosion. Ensure that all components on the roof are securely fastened. Ensure all electrical aspects of the PV array have been safely installed. Note that this document is prepared on the assumption that the wind loads are the maximum loads affecting the installation. Please verify that other environmental factors, such as snow loads, do not constitute a threat for the installations.

Please make sure the roof on which the SOLRACK Solar Mount System will be installed have the capacity to resist the combined Dead Load and Live Load of the solar system components.


PLANNING FOR INSTALLATION

Step1:Determinethewindregionofthesite

The first step in planning an installation is to determine the wind region of the installation site. If the installation is in Australia or New Zealand, please refer to figure 1: the wind region map AS/NZS 1170 found in AS/NZS 1170 for Australia.

Wind regions are independent of the building characteristics and the surrounding topography. Wind Regions C and D are referred to as cyclonic regions and installations in these regions should be assessed by a structural engineer before proceeding with installation.

Figure 1. Wind Region Map (Reference: AS/NZS 1170.2:2011)


Step2:Determinetheheight,installationzoneandarraylayoutInstallationZone

. The height ‘h’, breadth ‘b’ and depth ‘d’ of the building is shown in both figure 2 and 3. The height of the roof is equal to the distance from ground to the mid height of the roof as illustrated in Figure 2. It is important to obtain engineering advice for buildings over the maximum height of 20m

The installation zone for the SOLRACK Solar Tilt Mount System can be different depending on the aspect ratio of the enclosed building. If the building is relatively short and has aspect ratios h / b ≤ 0.5 and h / d ≤ 0.5, refer to Figure 2. If the building is relatively tall and has aspect ratios h / b > 0.5 and h / d > 0.5, refer to Figure 3.

Note that ‘s’ denotes the gap between the underside of the panel and the roof.

Figure 2. Roof Installation zone when both h/b> 0.5 and h/d>0.5


The installation zone in Figure 3 has an edge zone of a minimum distance of 0.1b and 0.1d. Installers should generally not install in the edge or corner zones. More information on the spacing of the rafters and the use of edge zones can be found in the following section.

Figure 3. Installation zone when either h/b>0.5 or h/d>0.5


ArrayLayoutPlanning

The purpose of planning the array layout is to ensure that the roof has sufficient space for the chosen configuration. The available roof area has to be calculated with the following considerations:

Roof Type (Corrugated metal, tile, klip lok or others) Purlin or rafter spacing SOLRACK rail orientation – along the roof or across the roof Module orientation – portrait or landscape (check Figure 4) Module height and width Mid clamp spacing :17mm for each SOLRACK mid clamp Clamping area for modules (check module manufacturer’s installation manual for acceptable clamping

area) Shading from nearby obstructions; check any trees or buildings that could potentially create shading on

the solar panels. Try to avoid shading by choosing the roof area which has minimum risk of shading.

Figure 4 demonstrates the module orientation. Portrait orientation denotes that the short side of the module is installed parallel to the supporting rail, whereas landscape denotes that the long side of the module is installed parallel to the supporting rail.

Figure 4. Orientation of the solar panels with respect to the rails


Step3:DeterminetheMaximumTiltModuleLegSpacingCommercialBuildings

Table 1 is used to determine the maximum rail support spacing of the SOLRACK Tilt Mount System within the middle, inner and edge zones of the roof shown in Figure 4 above for a commercial roof with less than 5 deg. pitch and solar panel tilt from 5 deg. to 30 deg.

A solar panel of maximum dimensions 1.690m length x 0.992m width with a hold down fastener on each leg with a minimum pull-out strengths of 4.68kN per fastener from 1.5mm thick steel purlin.

(Check Appendix B for pull out strengths for roof fasteners to confirm the fasteners to be used)

ResidentialBuildings

Table 2 is used to determine the maximum rail support spacing of the Tilt Module system within the middle, inner and edge zones of the roof shown in Figure 4, for a residential roof with less than 5 deg. pitch and solar panel tilt from 5 deg. to 30 deg.

A solar panel of maximum dimensions 1.690m length x 0.992m width with a hold down fastener on each leg with a minimum pull-out strengths of 2.86kN per fastener from 0.75mm thick steel purlin.

(Check Appendix B for pull out strengths for roof fasteners to confirm the fastener to be used).

Middle Inner Edge Middle Inner Edge Middle Inner Edge Middle Inner Edge

<5m 2100 1500 1100 1400 900 700 900 600 400 600 400 300

5 to 10m 2000 1400 1000 1300 800 600 800 500 400 500 300 200

10 to 15m 1800 1200 900 1100 700 500 700 400 300 400 300 200

15 to 20m 1700 1100 800 1000 700 500 700 400 300 400 300 200

<5m 2800 1900 1400 1800 1200 900 1200 800 600 700 500 300

5 to 10m 2600 1900 1400 1800 1200 900 1200 800 600 700 500 300

10 to 15m 2500 1900 1400 1800 1200 900 1200 800 600 700 500 300

15 to 20m 2400 1900 1400 1800 1200 900 1200 800 600 700 500 300

Wind Region C Wind Region D

Portrait

Landscape

Orientation Height

Wind Region A Wind Region B

Table 1.Maximum Rail Support Spacing of Tilt Module for portrait and landscape orientation for commercial applications


Please note that the rail end overhang must not be greater than 33 percent (one third of support spacing) of the Tilt Mount System support spacing i.e. if the support spacing is 1200mm, the rail end over hang can be up to 400mm (1200/3 = 400mm)

Step4:Determinethetypeoffastenersandminimumnumberoffastenerstobeused

Tables 3 and 4 determine the correct fasteners to attach the Tilt Module to the roof supports: Timber rafter or truss 0.75mm thick steel purlin/batten for residential applications. A minimum 1.5mm thick steel purlin or truss for commercial applications. The length of the fastener will vary according to the roofing profile; however the 65mm length is applicable for most installations.

Table 3. Dual point for timber and steel drilling (min 1.5mm thick steel purlin-max 2.00mm thick steel purlin)

Table 4.Steel drilling point (above 2.0mm thick steel)

C14-14125-D4Z Dual 14 14 125mm Class 4C14-14150-D4Z Dual 14 14 150mm Class 4

Code Point Gauge TPI Length FinishC14-1465-D4Z Dual 14 10 65mm Class 4

C14-20150-S4Z SD 14 20 150mm Class 4

C14-10100-S4Z SD 14 10 100mm Class 4C14-10125-S4Z SD 14 20 125mm Class 4

C14-1070-S4Z SD 14 10 70mm Class 4C141080-S4Z SD 14 10 80mm Class 4

Code Point Gauge TPI Length FinishC14-1050-S4Z SD 14 10 50mm Class 4

Middle Inner Edge Middle Inner Edge Middle Inner Edge Middle Inner Edge

<5m 1800 1200 900 1100 700 500 700 500 300 400 300 200

5 to 10m 1600 1100 800 1000 600 500 700 400 300 400 200 200

10 to 15m 1400 900 700 900 600 400 600 400 300 300 200 100

15 to 20m 1300 900 600 800 500 400 500 300 200 300 200 100

<5m 1700 1100 800 1100 700 500 700 500 300 400 300 200

5 to 10m 1700 1100 800 1100 700 500 700 500 300 400 300 200

10 to 15m 1700 1100 800 1100 700 500 700 500 300 400 300 200

15 to 20m 1700 1100 800 1100 700 500 700 500 300 400 300 200

Portrait

Landscape

Orientation Height

Wind Region A Wind Region B Wind Region C Wind Region D

Table 2. Maximum Rail Support Spacing of Tilt Module for portrait and landscape orientation for residential applications


Buildex‐StainlessSteelRoofingFasteners

Table 5. Buildex for use within 1000m of the coast into steel purlins (min 0.75mm thick steel purlin- max 2.0 mm thick steel purlin)

Table 6. Buildex for use within 1000m of the coast into timber rafters/trusses (min 1.5mm thick steel purlin- max 2.0 mm thick steel purlin)

FastenerNotes:

Minimum embedment length into timber to be not less than 36mm. Never set drill on impact when installing screws, as this will void fastener warranties. Use Dual Point screws up to 2.0mm thick steel purlins or rafters. Use Steel Point screws over to 2.0mm thick steel purlins or rafters. Use Stainless Steel screws within 1000m of the coast. Use a Minimum 1 off 14gx10 TPI (T17s) roofing fasteners per support leg to a minimum 0.75mm thick steel

purlin/batten or pine/ hardwood timber for a residential application. Use a Minimum 1 off 14gx10 TPI Teks roofing fasteners per support leg to a minimum 1.5mm thick steel

purlin for commercial building.


INSTALLATIONSTEPS

Prior to the installation, ensure that the roof offers sufficient space for the chosen layout. It should be helpful to include the following considerations when planning the array layout:

Number of modules in the vertical direction x module height (always check the module manufacturers installation manual)

Number of modules in horizontal direction x (module width + 18 mm) + 32 mm Horizontal spacing of the tilt legs Vertical spacing of the tilt legs Distance between modules: 17 mm

OverviewofSystemComponents

RailKitComponents

Figure 5. Rail Kit Components


TiltLegComponents

Figure 6. Tilt Leg Components

Figure 7. Overview of SOLRACK Solar Tilt Mount System


InstallationTools

InstallationInstructions

FixingtheLFeetandFrontLegintotheroof Mark the installation points along the center of the rafters The mounting brackets should align with the rafters. The mounting brackets should be spaced evenly along the length of the mounting rail. Drill holes on the marked points for the mounting screws Align the brackets along the mounting rail Ensure each front leg is comprised of; L Feet, L Connection and G module Tighten the screws to the brackets

Figure 8. Fixing the legs into the roof

6mmAllenKey CordlessDrill OpenEndSpannerset;9,10,17,19mm(requiredonlyfor

mountingwithroofscrews) Torx‐30(AW30)Bit AngleGrinderwithStoneDisk PowerCord Timbertoshimthetilebrackets(ifnecessary) Glovesforhandlingframing


MountingtheAdjustableLegstotheLFeet Align the adjustable legs to the L Feet Attach the adjustable leg to the L Feet by tightening the M8 Bolt and Nut Adjust the length of the leg for the desired angle

Figure 9. Mounting the adjustable legs to the L Feet

MountingtheRailtotheLegs Attach the L connection with G module to the rear legs by tightening the M8 Bolt and Nut Slide the rails through the G modules to the front and rear legs Tighten the rails to the brackets

Figure 10. Rear leg with L Connection and G Module, Front Leg, Side view of G Module-rail assembly

Determine if extended rails need to be used according to the installation plan. Connect rails via splice connector.

Figure 11. Connecting the rails via splice connector


Figure 12. Overview of installed SOLRACK rail system

InstallingSolarPanelsontotheRails

Add anti slip protection to the lowest row of modules by fastening M6 x 20 mm bolts to the lower mounting holes of the module frame using M6 nuts.

Place the first module of the bottom row so that anti-slip protection sits in the rail channel of the lowest row of rails.

Figure 13. Add Anti Slip Protection and make sure the slip protection sits in the rail channel

Slide the module end clamp firmly against the module and fasten tightly using the Allen key.

Figure 14. Slide the module end clamp firmly against the module and fasten tightly using the Allen bolt

Ensure to place earth washers to each mid clamp. Slide the mid clamp into the rails from above, place it firmly against the module and fasten loosely. Slide the next module against the previously installed module and tighten the mid clamp using the Allen

key. Ensure that the anti-slip protection sits in the rail channel.


Figure 15. Slide the preassembled inter module clamp then tighten the two modules using the Allen key

Position the last module of the row in the base rail ad fasten the module using the module end clamp. Slide the first module of the next row above the corresponding lower rail. Continue mounting the

module as described in the above steps until all modules are installed. Test both rails for end to end continuity to ensure that the entire frame is correctly earthed.

Figure 16. Fasten the last module of the row by using the end clamp and repeat the steps for the next row


APPENDIX A: SOLRACK Solar Framing System10 year Limited Product Warranty, 5 year Limited Finish Warranty

SOLRACK warrants to the original purchaser of the SOLRACK framing system that the framing components at the original installation site shall be free from defects in material and workmanship for a period of ten years with the exception of the anodized finish, which shall be free from visible peeling, cracking or chalking under normal atmospheric conditions for a period of five (5) years, from the earlier of the date the installation of the Product is completed, or 120 days after the purchase of the Product by the Purchaser (“Finish Warranty”).

The Finish Warranty does not apply to any foreign residue deposited on the finish. All installations in corrosive atmospheric conditions are excluded. The Finish Warranty is VOID if the practices specified by AAMA 609 & 610-02 – “Cleaning and Maintenance for Architecturally Finished Aluminum” are not followed by Purchaser. This Limited Warranty shall be VOID if installation of the Product is not performed in accordance with the SOLRACK written installation manual, or if the Product has been modified, repaired, or reworked in a manner not previously authorized by SOLRACK, or if the Product is installed in an environment for which it was not designed. SOLRACK shall not be liable for consequential, contingent or incidental damages arising out of the use of the product by purchaser under any circumstances.

If within the specified warranty period the product shall be reasonably proven to be defective, then the defective product shall be repaired or replaced, or any part thereof, at SOLRACK sole discretion. Such repair or replacement shall completely satisfy and discharge all of SOLRACK’s liability with respect to this limited warranty. Under no circumstances shall SOLRACK be liable for special, indirect or consequential damages arising out of or related to use by Purchaser of the Product.

SOLRACK’s limited Warranty covers only its solar framing product and not any related items.

For warranty service claims, please contact SOLRACK technical support team at:

[email protected].

Date of Issue: 16/10/2014 3:42 PM

Plant Description: Solar Tilt Mount system solar panel mounting structure with SR-03 Light rail and roof fasteners. Client/Owner:

- Sol Distribution Pty Ltd

Site Address: Locations throughout Mainland Australia (Wind Regions A, B, C and D as Per AS/NZS 1170.2:2011). Drawings and Documentation Included in this Certificate:

The following drawings supplied by Sol Distribution Pty Ltd and nominated in the table below are included in this structural certification for the solar assembly.

Table 1: Certified Drawings

NOTE – The Client shall hold all Material Test Certificates for future reference and subsequent design changes.

The Design was carried out based on the following Standards:

AS/NZS 1170.0:2011 – Structural Design Actions Part 0: General Principles AS/NZS 1170.1:2002 A2-2009 – Structural Design Actions Part 1: Permanent, imposed and other actions AS/NZS 1170.2:2011A2-2012 – Structural Design Actions Part 2: Wind actions Exclusions

Solar Panel/Frame certified by others. Earthquake Code (AS/NZS 1170.4) not considered - Solar panel is not a major building structure. Set-up, instruction and installation manual. 304 Stainless Steel should not be used in a Marine environment or in an environment above 50 – 60 0C with

chlorides present. The use of 316 Stainless Steel is recommended in these conditions. This certification does not include loadings for snow or earthquake loads and represent wind loads only.

STRUCTURAL DESIGN CERTIFICATE – No: CSM-SC054-2014 Job No: 14S-385

Solar Tilt Mount System, Rail SFS-SR-03 PC No. Part Name Model / Drawing No.

1 Rail / Roof Hook SFS-SR-03 2 G-Module SR-SP-SF S2 V1.1 3 L Feet SR-SP-SF S3 V1.0 4 Mid Clamp SR-SP-SF S4 V1.0 5 End Clamp SR-SP-SF S1 V1.0 6 Support Leg I SR-SP-SF S10 7 Support Leg II SR-SP-SF S9 8 L- Connecting SR-SP-SF S8

Page 2 of 3

CSM Group Pty Ltd

Specification of this Structural Certificate Maximum Solar Panel Size = 1.690m x 0.992m. Maximum Tilt Module Leg Spacing as per Tables 5.1, 5.2, 6.1 & 6.2. Minimum four support clamps to rail per Solar Panel. Solar Panels to be installed on the building roof only. External wind uplift and internal positive wind pressures are considered. Wind Region A, B, C & D has been considered (Refer Tables 5.1, 5.2, 6.1 & 6.2). Regional wind speed for 500 year ARI. Building Height (h) conditions based on Terrain Categories except terrain categories TC1, TC1.5 and TC2. Maximum Building Height (h) is 20 m. Maximum tilt module pitch shall be 5⁰- 30⁰. Minimum Steel Purlin thickness to be 1.5mm for Commercial applications. Minimum Steel Purlin/batten thickness to be 0.75mm for Residential applications.

Details of the Design

Maximum Solar Panel Size : 1.690m x 0.992m

Maximum Module Angle or Pitch : 5° - 30⁰

Commercial Building Roof Pitch : <5°

Residential Building Roof Pitch : ≥10° to ≤ 30°

Australian Terrain Category : Terrain Categories 2.5, 3 and 4

Wind Region : A, B, C & D (Refer Tables 5.1, 5.2, 6.1 & 6.2)

Mounting Conditions onto Rails : Rail fastened to Tilt Module Leg then onto the roof purlins atmaximum spacing as per Tables 5.1, 5.2, 6.1 & 6.2.

Maximum Tilt Module Leg spacing : As per Tables 5.1 & 5.2 (Commercial) and 6.1 & 6.2 (Residential) (Based on a maximum pullout force per support leg)

Mounting Conditions onto Solar Panels : Four clamping positions per solar panel back to rails andTwo rails per panel

Minimum purlin thickness for Commercial applications : 1.50mm

Minimum purlin/batten thickness for Residential applications : 0.75mm

Design life of structure : 20 years

CSM group has not carried out any inspection of any installed plant being completed, thus this Certificate Does Not cover Inspection of the plant for each site location.

However, specific building heights over 20m are outside the design parameters within this document and should be specially analysed and be verified by the Certifying Engineer.

It is strongly recommended that all the connections and fasteners should be checked against failure or corrosion immediately after a 5 year ARI wind event or annually, whichever comes first.

The roof on which the solar assembly is to be installed must have the capacity to resist the combined dead and live loads per support clamp.

Page 3 of 3

CSM Group Pty Ltd

If manufactured, constructed and installed in accordance with the abovementioned drawings, specifications, details of the design and OEM Installation Manual, the support structure will be capable of sustaining the load conditions as specified in the Australian standards AS1170.2-2012 and AS1664.

Certifying Engineer

Signature Date: 16/10/2014

Bruce Delahunty Senior Civil/Structural Engineer MIE Aust (Civil/Struct) 3786934 BEng, MEng, CPEng, NPER, RPEQ 12227

APPENDIX B: Structural Design Certificate

APPENDIX C: Fastener Pullout Strengths

Page 11 of 21

CSM Group Pty Ltd

Page 12 of 21

CSM Group Pty Ltd

APPENDIX D: Certified Tilt Module Drawings

2:1

1:1

Documents

RAKED MOUNTED INSTALLATION MANUAL - Sol …sol-distribution.com.au/SOLRACK/Installation Manual/SOLRACK Manual... · AS/NZS 1170.1:2002 A2-2009 ... Clamping area for modules (check