Installation Manual
Contents
1. Installation Instruction 1 Determine the positions of the roof hooks according to your plans Remove the roof tiles at the marked positions or if possible simply lift them up slightly 2 Fix the roof hooks to the rafter using 6 x 80 mm timber screws 3 The roof hook must not press against the roof tile If necessary shim the roof hook with wood 4 1f necessary use an angle grinder or hammer to cut a recess in the tile that covers the roof hook at the point where the roof hook comes through so that the tile lies flat on the surface If grooved tiles are used it will also be necessary to cut a recess in the lower tile 5 Caution Do not use fitted roof hooks as a ladder as this extreme point load could damage the tile below Page 8 of 11 Radiant PV RoofTopRac planning and Installation Guide V1 5 RooftopRac installation manual Version 1 5 updated Apr 2013 6 Variation for installation on corrugated metal In the case of corrugated roof cladding wave support are used instead of roof hooks Drill through the roof cladding at the planned location and screw the timber screw into the purloins Then mount the brackets 7 Cross section of a wave support installation Take special care that the timber screw tightly fastens the sealing washer without damaging the roof cladding When performing the installation take care that the thread of the wood screw not cover the long hole in the bracket 8 Installation o2. Radiant PV RoofTopRac planning and Installation Guide V1 5 Radiant PV RoofTopRac System Planning and Installation With Australia AS NZS1170 gm e S gt The PV RoofTopRac System has been developed as a universal system for roof mounting on pitched roofs The use of patented pending aluminium base rails Click In Clamp and Base Rail Pre Clamp technology eliminates custom cutting and enables particularly fast installation Please review this manual thoroughly before installing your PV RooffopRac system This manual provides 1 supporting documentation for building permit applications relating to PV RoofTopRac Universal PV Module Mounting system 2 planning and installation instructions for RooftopRac The installer is solely responsible for 1 Complying with all applicable local or national building codes including any that may superseded this manual 2 Ensuring that Rack and other products are appropriate for the particular installation and the installation environment 3 Ensuring that the roof its rafters connections and other structural support members can support the array under building live load conditions this total assembly is hereafter referred to as the roof rafter assembly 4 Using only rack parts and installer supplied parts as specified by rack substitution of parts may void the warranty and invalidate the letter of certification on page 2 5 Ensuring that lag screws have adequate pullout stren
3. 1 Determine the wind region of your installation site in accordance with AS NZS1170 2 2011 4 wa sS A ean Toi h r Me i so 2 hy N T GPSS A 3 b ho J P Ade ie Af a i 4 A P ae an N Bhad 3 n e gt oe a ER UR A T r k i i J Y oe t ANS a A A i PE te ber a ii Moreland PN Amerson hy A Ye prieten nS l ky A i Sy CE Ni g p Wa Lice Wy i S m j 4 ty won eos Warne Yg ha 9 y LEN r Aa le wrens woembs ho wi faj Y W 6 h w i r F i N p _ r f i e A E f Pj x A fa Fy A b i l J f 4 j f n f A r pue L Jj i f r E m j I L kor aj if m ffs a a A f 4 af a D 6a p r r 4 a y Region Definition Wind regions are pre defined for all of Australia by Australian Standard 1170 The Wind Region has nothing to do with surrounding topography or buildings Most of Australia is designated Region A which indicates a Regional Ultimate Basic Wind Velocity of 45msec Some areas are designated Region B 57msec Local authorities will advise if this applies in your area Region C areas 66msec are generally refered to as Cyclonic and are generally limited to northern coastal areas Most Region C zones end 100km inland Region D 80msec Australia s worst Cyclonic Region between Carnarvon and Pardoo in Western Australia 2 Determine the height of the of your installation site This document provides suffi
4. requires 2 rails with fixing as per table above The above spacing applies for fixing through Klip Lok roof Fix Klip lok clamp recommend torque is 25Nm RADIANT BASE RAIL MIDDLE CLAMP f 4 iy x A S E 3 SECTION A KLIP LOK CLAMP EXISTING KLIP LOK ROOF END CLAMP KLIP LOK CLAMP FIXING 4 Verify acceptable Rail End Overhang Rail End Overhang must equal 50 percent or less of foot spacing Thus if foot spacing is 1200mm the Rail End Over hang can be up to 600mm In this case two feet can support a rail of as much as 2400mm 1200mm between the feet and 600mm of overhang at each end 5 Determine Roof slope PV RoofTopRac system can be used for roof slope up to 60 degrees Please verify the Installation site roof slope should be between 0 degrees and 60 degrees Page 5 of 11 RooftopRac installation manual Version 1 5 updated Apr 2013 6 Determine Roof Installation Roof Areas A typical procedure in calculating the maximum building height for the installation of solar panel is given above If you know the building height terrain category wind region and roof pitch then you can determine the edge distance as well A roof can be divided into two zones the internal zone and the edge zone The width of these outer zones can be determined based on the length width and average height of the building If fixings are located in the internediate or edge zones then the maxi
5. ADIANT s Limited Warranty covers only its Product and not any related items Page 11 of 11 RooftopRac installation manual Version 1 5 updated Apr 2013
6. ETAIL As below figure MAXIMUM RAFTER SPACING S EXISTING RAFTER END CLAMP ALU ROOFHOOK ALU ROOFHOOK D Oo 9 p a o O 4 6 MIDDLE CLAMP TIMBER SCREWS EXISTING RAFTER SECTION A SECTION B Page 3 of 11 RooftopRac installation manual Version 1 5 updated Apr 2013 Radiant PV RoofTopRac planning and Installation Guide V1 5 Please use the following table to determine the base rail 40 support spacing for sheet metal roof installations MAXIMUM FIXING IN mm SPACING FOR TIMBER BATTENS PURLINS FOR TIN ROOFS ROOF ZONE Installation Height Region A amp B mm Region C amp D mm 1250 1160 1400 1020 Internal zone 1100 Edge zone Please use the following table to determine the base rail 34 support spacing for sheet metal roof installations MAXIMUM FIXING IN mm SPACING FOR TIMBER BATTENS PURLINS FOR TIN ROOFS ROOF ZONE Installation Height Region A amp B mm Region C amp D mm 1150 1090 1300 a O Internal zone 1050 Edge _ 10Meters 600 zone The above figures are based on modules lengths of up to 2000mm maximum weight of 29Kg 2000mm modules requires 2 rails with fixing as per table above The above spacing applies for fixing through thin sheet purlins greater than 1 0mm thickness or a minimum embedment of 50mm into timber purlins Based on an embedment depth of 35mm fixing into the battens the spacings remain unchanged for
7. cient information for PV RoofTopRac system installation height less then 20 meters If your installation site is more than 20 meters in height please contact Radiant to obtain engineering data to support your installation Page 2 of 11 RooftopRac installation manual Version 1 5 updated Apr 2013 Radiant PV RoofTopRac planning and Installation Guide V1 5 3 Determine the Maximum Rail Support Spacing Please use the following table to determine the base rail 40 support spacing for tile roof installations MAXIMUM RAFTER SPACING S IN mm FOR TILE ROOFS ieee anes Bdge 20 Meters 690 sso aso 3 Please use the following table to determine the base rail 34 support spacing for tile roof installations MAXIMUM RAFTER SPACING S IN mm FOR TILE ROOFS Region A mm Region B mm Region C mm aie Bdge 10 Meters 70 6o 20 Meters 600 so minimum embedment of 50mm into Timber purlins Tile brackets should fixed to the rafter using two timber screws 6 3x80mm The above figures are based on modules lengths of SOLAR PANELS up to 2000mm maximum weight of 29Kg 2000mm modules requires 2 rails with fixing as per P table above Ciy P p E gaala aaia 4 FIXINGS PER PANEL The above spacing applies for fixing through thin ey _ psc pipiens sheet purlins greater than 1 0mm thickness ora FS 7 2 x 6 3 14G Fi z TIMBER SCREWS d 50mm INTO RAFTER EXISTING RAFTER PANEL FIXING D
8. f the rails on roof hooks If your Set of rails consists of rails of different lengths always begin with the shortest piece Install the framing for each row of modules loosely on the roof hooks put the base rail slide into klicktop of roofhook and fasten tightly using the nut recommended torque is 18 Nm 10 An optimum adjustment of the vertical and horizontal position can be made by taking advantage of the long hole in the roof hooks and fasten tightly using the nut recommended torque is 18 Nm 11 Position the first frame rails for each row and fasten them temporarily to the roof cladding using a cord Tighten the allen the nuts on the Klicktop nut that are used to fasten the roof hooks hanger bolts recommended torque is 18 Nm Please also pay attention to Figure 10 Page 9 of 11 Radiant PV RoofTopRac planning and Installation Guide V1 5 RooftopRac installation manual Version 1 5 updated Apr 2013 Radiant PV RoofTopRac planning and Installation Guide V1 5 Splice Installation 12 Installation of the splice with base rails to connect multiple rails together put the splices under the rails halfway put other rail on the halfway Fasten the first M10 12 Allen bolt firmly using the Allen key Fasten the other side M10 12 Allen bolt firmly using the Allen key 13 Tighten the second M10 12 Allen bolt using the Allen key Fasten the other side M10 12 Allen bolt firmly using the Allen key The connection is f
9. gth and shear capacities as installed 6 Maintaining the waterproof integrity of the roof including selection of appropriate flashing and 7 Ensuring safe installation of all electrical aspects of the PV array Installation tools 6 mm Allen key Cordless drill Open end spanner set 10 13 mm required only for mounting with hanger bolts Torx 30 AW 30 bit Angle grinder with stone disk Power Cord If necessary timber to shim the roof hooks Sp ER ae ee Page 1 of 11 RooftopRac installation manual Version 1 5 updated Apr 2013 Radiant PV RoofTopRac planning and Installation Guide V1 5 Code Compliant Planning This document is designed to support for installations using PV RooffopRac Module Mounting System manufactured by Radiant Co Ltd Follow the six steps below and the installation instructions section to install PV RoofTopRac in compliance with the AS NZS1170 Before proceeding note the following This document addresses only wind loads on the assumption that wind produces the maximum load factor affecting an installation Verify That other local factors such as snow loads and earth quake effects do not exceed the wind loads Give precedence to any factor that does Wind loads are considered to act on the entire projected area or may be perpendicular to any surface The roof on which the PV RoofTopRac will be installed must have the capacity to resist the combined Design Dead Load and Live Load per Footing
10. inished PV Module Installation 14 Put the module end clamp inset the base rail tightly against the module and fasten tightly using the Allen bolt recommended torque is 15 Nm 15 Put module middle clamp inset the rails from above place it firmly against the module and fasten loosely approx 2 3 turns Now inset the next module against the previously installed module and tighten the inter module clamp using the Allen key recommended torque is 15 Nm 16 Put rail cap into the base rail Continue mounting the modules as described in steps 14 to 16 until all modules are installed The installation is finished Page 10 of 11 RooftopRac installation manual Version 1 5 updated Apr 2013 Radiant PV RoofTopRac planning and Installation Guide V1 5 15 Years Standard Warranty Terms and Conditions RADIANT International RADIANT warrants to the original purchaser Purchaser of product s that it manufactures Product at the original installation site that the Product shall be free from defects in material and workmanship for a period of ten 15 years except for the anodized finish which shall be free from visible peeling or cracking or chalking under normal atmospheric conditions from the earlier of 1 the date the installation of the Product is completed or 2 30 days after the purchase of the Product by the original Purchaser The Warranty does not apply to any foreign residue deposited on the fin
11. ish All installations in corrosive atmospheric conditions are excluded The Warranty is VOID if the practices specified by AAMA 609 amp 610 02 Cleaning and Maintenance for Architecturally Finished Aluminium www aamanet org are not followed by Purchaser This Warranty does not cover damage to the Product that occurs during its shipment storage or installation This Warranty shall be VOID if installation of the Product is not performed in accordance with RADIANT s written installation instructions or if the Product has been modified repaired or reworked in a manner not previously authorized by RADIANT IN WRITING or if the Product is installed in an environment for which it was not designed RADIANT 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 periods the Product shall be reasonably proven to be defective then RADIANT shall repair or replace the defective Product or any part thereof in RADIANT s sole discretion Such repair or replacement shall completely satisfy and discharge all of RADIANT s liability with respect to this Limited Warranty Under no circumstances shall RADIANT be liable for special indirect or consequential damages arising out of or related to use by Purchaser of the Product Manufacturers of related items such as PV modules and flashings may provide written warranties of their own R
12. mum spacing to the next fixing must be reduced as per the table in the drawings Radiant PV RoofTopRac planning and Installation Guide V1 5 Minimum of 0 2B 0 2D or H All Round PV RoofTopRac Components for Roof Installation Overview of system components Base Rail40 Base Rail 34 RoofHook45 136 166 Wave support for Tin Roof Page 6 of 11 Modules middle Clamp Modules End Clamp galvanised Corrugated Screw 6x80mm with Gaske Base Rail40 60 Splice RooftopRac installation manual Version 1 5 updated Apr 2013 Radiant PV RoofTopRac planning and Installation Guide V1 5 Installation preparation Overview of system components Modules End Clamp Module Middle Clamp Base Rail RoofHook Base Rail Splice Wood screw Planning the module area 1 Number of modules in the vertical direction x module height please check also the installation manual of the manufacturer of the solar module 2 Number of modules in horizontal direction x module width 23 5 mm 30 mm 3 Horizontal spacing of the roof hooks up to 2 0 m 4 Vertical spacing of the roof hooks approx 1 2 to 3 4 of module height 5 Distance between the modules 23 5 mm Caution Installations that are exposed to the wind or are located on the edge or corners of the roof may make it necessary to leave smaller spaces between modules S Page 7 of 11 RooftopRac installation manual Version 1 5 updated Apr 2013
13. region A and B For region C the spacings should be reduced by 10 and for region D the spacings should be reduced by 30 The wave support should be fixed to the purlins under using one timber Screw 6 3x80mm through sheet metal roofs with desk rubber MAX1 3 WAVE SUPPORT SPACING mE Sees E E WAVE SUPPORT oT ee a EXISTING METAL a oe ROOF SHEETING a ka af ed Oa a REFER TO TABLE EXISTING ROOF BATTEN PURLIN 86 3 14G SELF DRILLING SCREW WAVE SUPPORT FIXING WAVE SUPPORT FIXING SIDE VIEW RooftopRac installation manual Version 1 5 updated Apr 2013 SECTION A Page 4 of 11 Oo y y O M A RADIANT BASE RAIL Radiant PV RoofTopRac planning and Installation Guide V1 5 Please use the following table to determine the base rail 40 support spacing for Klip lok roof installations MAXIMUM FIXING IN mm SPACING FOR KLIP LOK CLAMP FOR KLIP LOK ROOFS Region C amp D mm 1120 a 1080 1000 950 560 Edge 540 zone 500 Please use the following table to determine the base rail 34 support spacing for Klip lok roof installations MAXIMUM FIXING IN mm SPACING FOR KLIP LOK CLAMP FOR KLIP LOK ROOFS ROOF ZONE Installation Height Region A amp B mm Region C amp D mm 1400 1020 E PR 1250 1150 1050 850 5 Meters 700 500 Edge 490 zone 15 Meters 590 450 The above figures are based on modules lengths of up to 2000mm maximum weight of 29Kg 2000mm modules
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