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1. mack BY SOLAR360 INSTALLATION MANUAL 4 Metal Tiled and Tilt Systems 00 n j 3 o ma 1 c O r 4 360Rack InstallationManual Ver4 0 August 12 2013 LEVEL 18 499 ST KILDA RD MELBOURNE VIC 3004 PHONE 1300 600 360 www solar360 com au TABLE OF CONTENT TO INTRODUCTION TECHNICAL SPECIFICATIONS SAFETY AND GENERAL PRECAUTIONS INSTALLATION TOOLS REQUIRED MAIN SYSTEM COMPONENTS INSTALLATION 6 1 Preparation 6 2 Metal Mount Brackets 6 3 Installing Tile Brackets 6 4 Fixing rail 6 5 Rail Joiner 6 6 Installing End Clamps 6 7 Installing Mid Clamps 6 8 Cable Tray 6 9 Earthing TILT SYSTEM INSTALLATION 7 1 Planning and Preparation 7 2 Install Tilt Base Plates 7 3 Setting the Adjustable tilt Arm 7 4 Installing the rail 7 5 Installation of Panels WARRANTY PROVISIONS MAINTENANCE WIND LOAD CONSIDERATIONS 10 1Wind Load Certificate 10 2Technical Drawings Appendix A 04 05 06 08 www solar360 com au 4 0 August 12 TABLE OF FIGURES FIGURE 1 Typical Wind Design drawing FIGURE 2 Drive screws into batten FIGURE 3 Use of corrugated roof leveller FIGURE 4 Align Arm with valley of tile and tighten Screws FIGURE 5 Adjust arm with valley and height of tile and tighten Locknut FIGURE 6 Grind tile if necessary to accommodate thickness of Tile Bracket Arm F
2. 24 25 27 28 26 29 29 30 36 38 1 INTRODUCTION The 360Rack Solar PV mount system was designed with the following key objectives a Make it amongst the quickest systems to install on the market b Minimise assembly work by the installer c Offer features compliant with the latest standards d Low cost e Provide System support and design capability Pre assembly of parts and in box solutions as well as offering a completely integrated earthing system facilitates ease of installation Flexibility is designed into each component allowing for a range of panel thickness to be accommodated and full adjustability without the use of packers on Tile Brackets The Tilt system offers quick and easy installation without setting angles and is designed to sit on top of the roof ridges The Anodised Aluminium rail has been designed to accommodate the smallest possible area without compromising on strength it incorporates features such as integrated cable management to promote compliance to the latest AS 5033 requirements The system is compliant with the AS NZS1170 2 2011 standard for wind actions including the proposed 2012 amendments Further assurance is offered through a 10 year product warranty www solar360 com au Ver4 0 August 12 S um 2 TECHNICAL SPECIFICATIONS Pitched roofs 15 50 Degrees Flat Roofs 0 10 Degrees All types Except Longline A B and C Upto 10 Mtrs 31 50 mm
3. THIS DESIGN IS FOR SYSTEMS NO GREATER THAN 10m HIGH 1 BASE PLATE ALLOWS FOR MOUNTING BETWEEN BATON LOCATE THIS SYSTEM TOWARDS THE CENTER AREA OF ROOF WHERE PITCHES OF 600 1200 IF PITCH 15 GOOMM THEN A POSSIBLE PANELS MUST BE AT LEAST 0 5 ETRS AWAY FROM ROOF CREST OR FURTHER SCREW CAN BE UTILISED AT THE CENTER OF THE EDGES BASE PLATE ROOF STRUCTURE MUST BE DESIGNED TO ACCEPT THE WEIGHT OF SYSTEM 2 SCREWS ARE EITHER 14 10 75MM FOR TIVBER FIXING OR PITCHED ROOF CALCULATIONS ARE BASED ON ROOF FITCH OF 15 DEGREES MB ROOF ZIPS FOR METAL BATONS OR GREATER FLAT ROOF CALCULATIONS ARE BASED ON A TILT ANGLE OF 4 IF METAL BATONS HAVE A WALL THICKNESS OF LESS THAN UPTO 25 DEGREES NOT INCLUDING ROOF PITCH 0 75MM THEN TWO FIXINGS PER BATON SHOULD BE USED NOT FOR INSTALLATION ON PRE CYCLONE STANDARD BUSLDINGS TO ENSURE COMPLIANCE DESSSN ASSIGNED IMPORTANCE LEVEL 2 5 DEFINED IN THE BUILDING CLASS 1 10 WITH A 25 YEAR DESIGN LIFE STRUCTURES AT THIS LEVEL ARE EXPECTED NOT TO COLLAPSE BUT MAY SUSTAIN SUBSTANTIAL DAMAGE UNDER THE EXTREME CONDITIONS NOMINATED INSTALLER TO ASESS WHETHER THE DESIGN 15 SUITABLE IN APPLICATIONS THAT ARE NOT COVERED IN THESE DESIGN GUIDELINES IF NECESSARY INDEPENDENT ENGINEERING ADVICE MAY BE NECESSARY Revision Table 2 Certification Amendments 11 2 2013 EXPANDED DETAIL Further Relevant test reports etc Certified By 1 Enginearing Calculations are based on Re
4. 6063 T5 otainless Steel on system and Galvanised Roof Screws Stainless Steel BCA AS1170 2 AS5033 2012 AS1664 54100 AS3566 AS1866 10 Years According to BCA requirements 3 SAFETY AND GENERAL PRECAUTIONS This document s primary focus is the description of installation for the 360Rack mounting system It is not intended to discuss safety hazards in detail as it is expected that all businesses have their own Safety Hazard documents as part of workplace legislation Where care or attention is required the following symbols will be used throughout the document Indicates a potentially hazardous situation that could result in death or serious injury Indicates a potentially hazardous situation that may result in minor or moderate injury Indicates a very important procedure that may cause delays in installation if not careful A Nes gt gt Wwww solar360 com au Ver4 0_August 12 s aaa Wind actions Although detailed guidelines are provided at the back of this manual regarding design constraints and how to install to ensure compliance with the certification it is important to realise that all installation possibilities are not covered by the certification Solar360 realise that it is important in some instances to provide individual certification By the use of a standard marketing material an installer can input individual project variables which result in an output of recommendations to ensu
5. ASSIGNED IMPORTANCE LEVEL 2 AS DEFINED THE BCA BLEEDING CLASS 1 10 WITH 25 YEAR DESIGN LIFE STRUCTURES AT THES LEVEL ARE EXPECTED NOT TO COLLAPSE MAY SUSTAIN SUBSTANTIAL DAMAGE UNDER THE EXTREME CONDITIONS NOMINATED INSTALLER TO ASESS WHETHER THE DESIGN 15 SUITABLE IN APPLICATIONS THAT ARE NOT COVERED IN THESE DESIGN GUIDELINES IF NECESSARY INDEPENDENT ENGINEERING ADVICE MAY BE NECESSARY 1 RAIL SECTION A 2 Metal Roof Base Plate 3a End Clamp D 3b Mid Clamp E OSJ T5 Aluminum extrusion T5 Aluminum axirusion 8083 T5 Aluminum extrusion BOCES Aluminum aruon 3380 amp 2080 mm Typical Revision Table Rev 2 Certification Amendments 11 2 2013 Further Relevant test reports etc Certified By 1 Engineering Calculations are based on Report 5380 Engineering Worksheet xis Craig Shackleford EC 36632 6 2 2013 2 Tile Maun amp ng system Force Test report TROO1_TilePulllest_22Nov12 mE 10 3 Drawing Metal Roof Components METAL ROOF SYSTEM CONNECTION DETAILS CiN Wood screw 14 10 695 Type 17 Embecment Jimm Product Description Panel Typical SOLAR PANEL RAIL MOUNTING SYSTEM Manufacturers Name Soler 360 A B N 9B 147 183 488 Lvl 18498 St Kilda Red Melbourne VIC 3004 Ausiralia Phone 1300 800 380 Truss top cord or Rafter at iima max centres Design Criteria BASIC WIND DESIGN CRITERIA Metal Roof Cladding AS 1170 2 2002 Including Amendment 1 REGION
6. C Up TO 10m IN HEIGHT TERRAIN CATEGORY 2 Shieiding Factor Ms No Shialding Vorst casa Hall Shape Multiniiar 1 Hatten Fl Hardwaod or F7 Pine Terrain Haight 1 REGIONAL DESIGN WINO SPEED Region D Installation nat nacammancdaed Poagkan wy G3m s 227 kmihr E wiv 154 revi Posgion A wv x bale 158 TRUSS RAF TER Limitations 1 SYSTEM IN ANY CAPACITY IS NOT TO BE INSTALLED IN REGIONS DEFINED AS 7 m LOCAL PRESSURE ZONES BATTEN x 1n n 1 THIS DESIGN IS FOR SYSTEMS NO GREATER THAN 10m HIGH A LOCATE THES SYSTEM TOWARDS THE CENTER AREA OF ROOF WHERE Ll AL 1 1 POSSIBLE PANELS MUST BE AT LEAST 0 6 MTRS AWAY PROM ROOF CREST OR sss 58 ROOF STRUCTURE MUST BE DESIGNED TO ACCEPT THE WEIGHT OF SYSTEM HHH HD PITCHED ROOF CALCULATIONS ARE BASED ON ROOF PITCH OF 15 DEGREES LI B ie OR GREATER FLAT ROOF CALCULATIONS ARE BASED ON A TILT ANGLE OF 00 12005 UPTO 25 DEGREES NOT INCLUDING ROOF PITCH THEBES THEE FOR INSTALLATION ON PRE CYCLONE STANDARD BUILDINGS Pee SEB EN DESIGN 18 ASSIGNED IMPORTANCE LEVEL 2 8 DEFINED IN THE BLALDING oo A A 4 4 55 40 CLASS 1 10 WITH 28 YEAR DESIGN LIFE STRUCTURES AT THES LEVEL ARE la A LET EXPECTED NOT TO COLLAPSE BUT MAY SUSTAIN SUBSTANTIAL DAMAGE cry UNDER THE EXTREME CONDITIONS NOMINATED T Wi INSTALLER TO
7. Install only Cordless To cut small groove for Tile Angle grinder with ceramic or Bracket arm allowing tile to sit diamond coated disc flush SN 5 MAIN SYSTEM COMPONENTS AD 001 amp 2 Universal preassemled mid clamp e Fully adjustable in infinite increments e Ease of assembly spring loaded to remain upright e Integrated earthing AD 003 Preassembled e Slot for height adjustment e Pre adhered rubber isolator e Optional leveller available to ensure vertical alignment www solar360 com au Ver4 0 August 12 S um AD 004 Universal end clamp e Adjustable in finite increments of 31 35 40 45 and 50mm Preassembled with T Bolt washer and Lock Nut AD 005 Preassembled Height and sideways adjustability Height adjustment to cater for tile heights of 30 50mm No need for packers Stainless steel Arm ensures compliance to Wind Region C conditions AD 012 Preassembly and ease of use allows for rapid joining of rails Clear and neat joins that do not compromise rail strenght ntegrated earthing www solar360 com au Ver4 0 August 12 SS NK CAES RESI MR 3380 OR MR 2080 Rail Height minimised to save on cost weight and freight Integrated cable tray system with Aluminium Cable clamps AS5033 compliant Rail lengths of 2080mm allows for 4 panel configurations ease of lifting Anodised AS 014 9 Akit
8. St Kido Ad SOLARA 360 Phana 1300 600 360 Malsauma VIC 3004 Design Criteria BASIC WIND DESIGN CRITERIA AS 1170 2 2002 Including Amendment 1 REGION C Ua TO 10m HEIGHT TERRAIN CATEGORY 2 Shielding Facipr Ms No Shieiding Worst case Hill Shape Mulspliar 1 Terrain Haight Mulspla 1 4 RAIL CLAMP 8063 TS Aluminum extrusion REGIONAL DESIGN WIND SPEED Ragion D Installation not reccmmanded Region wy Gans 227 Region B wy Sms 194 kmihr Region A wy 44a 158 kmihr Limitations SYSTEM IN ANY CAPACITY NOT TO BE INSTALLED IN REGIONS DEFINED AS LOCAL PRESSURE Z NES THIS DESSEN FOR SYSTEMS NO GREATER THAN 10m HH LOCATE THIS TOWARDS THE CENTER AREA OF ROOF WHERE POSSIBLE PANELS MUST BE AT LEAST 0 5 NTRS AWAY FROM ROOF CREST OR EDGES ROOF STRUCTURE MUST BE DESIGNED TO ACCEPT THE WEIGHT OF SYSTEM PITCHED ROOF CALCULATIONS ARE BASED ON ROOF PITCH OF 15 DEGREES OR GREATER FLAT ROOF CALCULATIONS BASED ON A TILT ANGLE OF 28 DEGREES HOT INCLUDING ROOF PITCH NOT FOR INSTALLATION ON PRE CYOLONE STANDARD BUILDINGS DESIGN IS ASSIGNED IMPORTANGE LEVEL 3 AS DEFINED THE BGA BLOG CLASS 1 10 WITH 25 YEAR DESIGN LIFE STRUCTURES AT THIS LEVEL ARE EXPECTED TO COLLAPSE BUT MAY SUSTAIN SUBSTANTIAL DAMAGE UNDER THE EXTREME CONDITIONS NOMINATED INSTALLER TO ASESS WHETHER THE DESIGN 15 SUITABLE APPLICATIONS THAT ARE NOT CO
9. comprising 4 preassembled Tilt frames rail clamps and fastener components to mount 4 panels Panel mount assemblies and rails are to be ordered separately The preassembly of each Tilt frame and ease of Tilt adjustment means that this system is one of the quickest on the market to install On a 5 degree pitch inclinations of between 15 and 30 degrees are achievable in approximately 5 degree increments www solar360 com au Ver4 0 August 12 6 INSTALLATION All installations must be performed in accordance with Clean Energy Council CEC Design and Installation guidelines In this respect the site planning preparation positioning and orientaion of the PV system must follow these guidelines Where there is any conflict between this document and the provisions of the CEC guidelines the later shall take precedence It follows that the instructions below only considers the actual Installation methodology associatted with the 360Rack system 6 1 Preparation After considering layout and planning job consult with wind design data at back of this document to ascertain the correct number of mounts required for the rail length being used Tip Try to plan job in groups of 2 or 4 panels the rail lengths are designed to cater for panels of nominal 800 and 1000mm without cutting Rail lengths can be joined to make any continuous length upto 12 5mtrs www solar360 com au Ver4 0 August
10. installed according to manufacturer s guidelines The following pages compose of the compliance documents of the 360Rack system to AS1170 2 The associated drawings define the parameters of how the system should be installed for various roof types The installer should become familiar with these documents and ensure that installation complies with the parameters imposed General limitations and design principles Claims under the Warranty must be received by Solar360 within the Warranty Period without exception The original purchaser The following installation limitations of the system shall apply 1 Installed in a location with a Wind Region of no greater than Region C 2 Height of roof level above ground shall not exceed 10 metres 3 System is to be located towards centre of roof Edges of solar panels to be at least 500mm from crest or edge of roof 4 Roof structures and roof elements including battens rafters trusses etc are to be designed and or verified by an suitably qualified person to accept the superimposed loads of the system 9 Pitched roofs of between 15 to 50 degrees Flat roofs of 1 to 5 degrees for tilt frames with an angle of 25 degrees 6 Not to be installed on pre cyclone designed buildings 7 Design is based Importance Level 2 accordance with BCA Building Class 1 to 10 with 25 year design life 9 If any of the above limitations do comply the installer shall seek independent engineering c
11. 12 6 2 Metal Mount Brackets Install Brackets with Galvanised 17 10x65 Screw provided driven into batten In some cases Truss or rafter Tip An impact driver that requires no pre drilling best performs this function Tip For roofs with exposed fixings determine where the roof mounts will be positioned based on position of existing roof screws Tip For a steel roof with hidden fixings determine where the battens are by using a stud finder or by feel i e standing along the valley section of the roofing material until firmness is felt This point can be marked and the procedure repeated until a straight line of markings is determined Tip Do not remove existing roof screws Instead install on unused crest In order to avoid slippage of the screw point it is prudent to _ indent roof sheet with point of screw by giving a tap with a hammer LL Il 31 E to top of screw head Tip Fix the bracket in place with the upright section facing towards the ridge of the roof Tip The bracket comes preassembled with T Nut and rubber base seal No other washer or seal is required ibn an Ban er LH m Vl Tip For corrugated systems and particularly fussy customer or installer an optional component can be purchased to ensure that the L foot sits perfectly square to the roof surface See Diagram below Figure 3 Use of corrugated roof leveller www solar360 com au Ver4 0 August 12 6 3 Installing
12. 6 2 2013 1 Engineering Calculations are based Report 5380 Engineering Worksneet xls 2 Mounting system Force Test TROO1 TilePullTest 22Nov12 METAL ROOF SYSTEM COMPONENTS Product Name Product Description SOLAR PANEL RAIL MOUNTING SYSTEM Wood Screw Manufacturer s Name 14 10x65 17 Min Emboedment 3 0mm ABN 98147 163 488 Lvi 18 4569 51 Kiida Malian VIC IWH SOLAR ism Design Criteria BASIC WIND DESIGN CRITERIA AS 1170 2 2002 Including Amendment 1 REGION C Ua TO 10m HEIGHT TERRAIN CATEGORY 2 Shielding Factor Ms No Shielding Worst casa Hill Shape Multiplier 1 Tarrain Haight 1 D Installation necommanced Region C wv gamis 227 ken wv Rajan A wv dams 156 km Lirnitations SYSTEM CAPACITY ES HOT TO BE INSTALLED IN REGIONS DEFINED AS LOCAL PRESSURE ZONES THES DESIGN 15 FOR SYSTEMS NO GREATER THAN 10m HIGH LOCATE THES SYSTEM TOWARDS THE CENTER AREA OF ROOF WHERE POSSIBLE PANELS MUST BE AT LEAST 0 5 MTRS AWAY PROM ROOF CREST OR EDGES ROOF STRUCTURE MUST BE DESIGNED TO ACCEPT THE WEIGHT OF SYSTEM PITCHED ROOF CALCULATIONS ARE BASED ON ROOF PITCH 15 DEGREES GREATER FLAT ROOF CALCULATIONS ARE BASED ON A TILT ANGLE OF UPTO 25 DEGREES NOT INCLUDING ROOF PITCH HOT FOR INSTALLATION ON PRE CYCLONE STANDARD BLILDENGS DESIGN S
13. ASESS WHETHER THE DESIGN 19 SLATABLE IN APPLICATIONS BATTEN THAT ARE NOT COVERED IN THESE DESIGN GUIDELINES IF NECESSARY x n nn A INDEPENDENT ENGINEERING ADVICE MAY BE NECESSARY Revision Table TYPICAL METAL ROOF SYSTEM HOLD DOWN LAYOUT oe Further Relevant test reports etc Certified By Craig Shackleford EC 36632 6 2 2013 Engineering Calculations are based on Report 5360 Engineering Worksheelxis Page jof 8 2 Tile Mounling system Force Test epon TRON TilePulITest Z2Nov12 10 4 Drawing Metal Roof Connection Details n ILED ROOF SYSTEM COMPONENTS Product Deseription SOLAR PANEL RAIL MOUNTING SYSTEM Manufacturers Name Solar 360 147 153 458 i Lvl 18498 St Kilda Rd Melboume VIC 3004 Ausiralig Phone 1300 600 380 BASIC WNO DESIGN CRITERIA Min Wood screws 14 10x39mm ype 1 TERRAIN CATEGORY 2 Mim Embedment 30mm Ls c MM Place 10mm in from each side of rafter Hil Shape Multiglier 1 and angle slightly in towards centre E REGIONAL DESIGN WIND SPEED Ragion D Installation nal recommended Ragion 227 kamihr Region wiv Sim s 164 km h Ragion A wv 44m s 158 lomo Limitations 1 SYS7EMIN ANY CAPACITY 15 NOT TO BE INSTALLED IN REGIONS DEFINED AS LOCAL PRESSURE ZONES 2 THIS DESIGN IS FOR SYSTEMS NO GREATER THAN 10m HIGH 34 LOCATE THES SYSTEM TOWARDS THE CENTER AREA OF ROOF WHERE POSSIBLE PA
14. BO idF 153 408 Hin Embeonment 30mm Lvi 18 488 St Kida Ad Place l me im From each sie oF rafter Vic anna and angle slightly I towards centre lin Phone 1300 600 260 Truss top cord Rafter t l20 mm nox centres Design Criteria BASIC WIND DESIGN CRITERIA AZ 1170 2 2002 inducing Amendment 1 REGION C Up TO t m HEIGHT Tied Roof LDlasacing TERRAIN CATEGORY 2 Shislding Factor Ms Shialding Worst casa Shape Multipfer 1 Tarrain Haight 1 REGIONAL DESIGN WIND SPEED nid T B Fi H F7 P D ET Ln atten orc rue Region C wy B3mis 227 kmhr 22 Region wiv 194 kir L Region wh 158 Limitations nax1200 1 SYSTEM IH ANY CAPACITY 15 NOT TO BE INSTALLED IH REGENS DEFINED AS TRUSS RAF TER LOCAL PRESSURE ZONES THIS DESIGN 16 FOR SYSTEMS NO GREATER THAN 10m HIGH LOCATE THIS SYSTEM TOWARDS THE CENTER AREA OF ROOF WHERE POSSIBLE PANELS MUST BE AT LEAST 0 5 MTRS AWAY PROM ROOF CREST OR EDGES ROOF STRUCTURE MUST BE DESIGNED TO ACCEPT THE WEIGHT OF SYSTEM PITCHED ROOF CALCULATIONS ARE BASED ON ROOF PITCH OF 15 DEGREES QR GREATER FLAT ROOF CALCULATIONS ARE BASED ON A TILT ANGLE UPTO 25 DEGREES NOT INCLUDING ROOF PITCH HOT FOR INSTALLATION ON PRE CYCLONE STANDARD BUILDINGS DESIGN 15 ASSIGNED IMPORTANCE LEVEL 2 AS DEFINED IN THE BCA DING CLASS 1 10 WITH A 25 YEAR
15. DESIGN LIFE STRUCTURES AT THIS LEVEL ARE EXPECTED NOT TO COLLAPSE BUT MAY SUSTAIN SUBSTANTIAL DAMAGE UNDER THE EXTREME CONDITIONS NOMSNATED INSTALLER TO ASESS WHETHER THE DESIGN I8 SLNTABLE APPLICATIONS THAT ARE MOT COVERED IN THESE DESIGN GUIDELINES IF NECESSARY INDEPENDENT ENGINEERING ADVICE MAY NECESSARY oO Further Relevant test reports etc Dani Certified By Page 5 B 1 Enginaering Calculations based on Report 5380 EngineeringWorksheet Mama R Smsidino age sal s Craig Shackleford EC 36632 6 2 2013 2 Tile Mounting sy lem Force Test report TROO1 TilePullTest 22N0v12 OOOO 10 6 Drawing Tile Roof Connection Details Date of Approval 11 02 2013 DX 2 CC WE 8 LLL Two 2 14 10 39 Typa 17 Screws par BATTEN Plate TYPICAL SYSTEM LAYOUT 3380 208mm Panels Product Description 2080 1000mm Panels SOLAR PANEL RAIL MOUNTING SYSTEM 2080 1000mm Panels Manufacturers Narne Sclar380 59 147 153488 18 4559 5t Kida Fui E E BASIC WIND DESIGN CRITERIA 1170 2 2002 Including Amandmani 1 REGION C Up TO 10m IN HEIGHT TERRAN CATEGORY 2 Shisiding Factor Ma Mo Shielding Does ces Hill Shape Multiplier 1 Terrain Height Mullipks 1 REGIONAL DESIGN WIND SPEED Region D Instalkason not recommended Region wiv Baris 227 kmi
16. EME CONDITIONS NOMINATED Various combretions of components may be used bul must nat cause any undue Applicable for Tilt system on metal cladded Roof INSTALLER TO ASESS WHETHER THE DESIGN 15 SUITABLE IN APPLICATIONS atrass on the rail base plates brackets or the struciure being apolied THAT ARE NOT COVERED IN THESE DESIGN GUIDELINES IF NECESSARY End Clampos amp Mid Clamps are be ussi to suit panal rauinements 1 For fixing ip Metal cladded roofs refer io Page 8 INDEPENDENT ENGINEERING ADVICE MAY SE NECESSARY Joiners can be used bo add mans rail lengths as long as the aporopriale quantity of 2 All bolts and washers ara ip bo Stainless Steal A2 and mounts are used Part lengths also alowed with appropriaie scaling scale up fa all scrgws are be Galzanized or a minimum of Class 4 nearest whole number of Assemblies Finish Rev 2 Certification Amendments 11 2 2013 Certified By Craig Shackleford EC 36632 6 2 2013 Signature Date of Approval 11 02 2013 Further Relevant test reports stc Page 6 of 8 1 Engineering Calculations are based on Report S360 EngineeringWorksheet xis 2 Tile Mounting system Force Test report TRON T sPulTast 22Ncw12 Deaign Engineer Mame 10 7 Drawing Tilt System Layout Product Name TILED ROOF SYSTEM COMPONENTS 360Rack Product Description SOLAR PANEL RAIL MOUNTING SYSTEM Manufacturers Name Solara ABH 147 163 208 Lui 18490
17. H 25 YEAR DESIGN LIFE STRUCTURES AT THIS LEVEL ARE bible atiached 2 Forfbing to Tila roofs rofar io Pages EXPECTED NOT TO COLLAPSE BUT MAY SUSTAIN SUBSTANTIAL DAMAGE a The first amp Last bracket must be further than 400mm from the ends of the a Al effort must be made fo space the inner brackets evenly maximum spaces of 130mm must not be spaced more than 140mm a Suitable Base plates must be according the rood type or requirements cf 485 UNDER THE EXTREME CONDITIONS NOMINATED IMSTALLER TO ASESS WHETHER THE DESIGN SUITABLE IN APPLICATIONS 3 Al poks and washers are to ba THAT ARE NOT COVERED IN THESE DESIGN GUIDELINES IF NECESSARY Siea A7 and al INDEPENDENT ENGINEERING ADVICE MAY BE NECESSARY be Galzanized or g minimis individual locations of 4 Finish Various combinations of components may ba used but musi nct causa amy undue Applica Corrugaind nting siruss on the basa plains brackets or fe structure baing appliad SN Te 4 Truss top cords or be End Clamps amp Mid Clamps ip ba used to sult panel requiramarnits 1200mm MAX Centres Revision Table Joiners can ba used to bo add more langis as long as the appropriate quantity of ee Rev 2 Certification Amendments 11 2 2013 Further Relevant tesi reports etc Certified By Page 1 of 8 Craig Shackleford EC 36632
18. IGURE 7 Align T Bolt and insert quarter turn will start to lock in place FIGURE 8 Tighten Locknut once in correct position FIGURE 9 Tighten Locknut once in correct position FIGURE 10 Complete by sliding rail in place and tightening Locknut FIGURE 11 Slide top of end clamp out and insert at correct thickness FIGURE 12 Slide Panel against end clamp and tighten Locknut FIGURE 13 Inserting Mid Clamp into rail FIGURE 14 Slide Clamp against panel FIGURE 15 Install remainder of panels 12 12 13 14 14 15 16 16 17 17 18 18 19 19 20 FIGURE 16 Install Reminder of panels and tighten Locknuts FIGURE 17 Sliding Clamp against panel FIGURE 18 Rail Panel and Joiner Earthing respectively FIGURE 19 Tighten Earth Lug Locknut once in place FIGURE 20 Insertion of Earthing wire FIGURE 21 Mid Clamp with Earthing Positions on Even No of Panels FIGURE 22 Mid Clamp with Earthing Positions on Odd No of Panels FIGURE 23 Typical Wind Design drawing FIGURE 24 Fixing Tilt Base to roof FIGURE 25 Set Extendable arm to desired setting and Lock with pin supplied FIGURE 26 Connect Adjustable arm and Top section together FIGURE 27 Insertion of tilt Rail Clamps FIGURE 28 Tighten Locknuts on clamps once rail is in correct position FIGURE 29 Install Remainder of panels as per previous FIGURE 30 Wind Region Classifications Solar360 website TECHNICAL DRAWINGS Appendix A 20 21 22 22 23 23
19. NELS MUST BE AT LEAST 0 5 MTRS AWAY FROM ROOF CREST OR EDGES ROOF STRUCTURE MUST BE DESIGNED TO ACCEPT THE WEIGHT OF SYSTEM PITCHED ROOF CALCULATIONS ARE BASED ON ROOF PITCH OF 15 DEGREES OR GREATER FLAT ROOF CALCULATIONS ARE BASED ON A TILT ANGLE OF UPTO 25 DEGREES NOT INCLUDING ROOF PITCH NOT FOR INSTALLATION ON PRE CYCLONE STANDARD BUILDINGS DESIGN 15 ASSIGNED IMPORTANCE LEVEL 2 5 DEFINED IN THE BCA BLALDING CLASS 1 10 WITH A 25 YEAR DESIGN LIFE STRUCTURES AT THES LEVEL ARE EXPECTED NOT TO COLLAPSE BUT MAY SUSTAIN SUBSTANTIAL DAMAGE UNDER THE EXTREME CONDITIONS NOMINATED INSTALLER ASESS WHETHER THE DESIGN S SUITABLE IN APPLICATIONS THAT ARE NOT COVERED IN THESE DESIGN GUIDELINES IF NECESSARY ENGINEERING ADVICE MAY Be NECESSARY 6083 Aluminum extrusion 6063 T8 Aluminum extrusion 6063 T5 Aluminum extrusion 6063 T5 Aluminum extrusion 2000 6 Saban Rev 2 Certification Amendments 11 2 2013 Further Relevant test reports etc 4 of 8 Certified By 1 Enginearing Calculations are based on Report 5360 EngmeeringWWorksheat Craig Shackleford EC 36632 6 2 2013 2 Tie Mounting system Force Test report TRO 22 12 10 5 Drawing Tile Roof Components TILE ROOF SYSTEM CONNECTION DETAILS Product Name Product Description Panel Typical SOLAR PANEL RAIL MOUNTING SYSTEM Hin 2 Wood Screws 18 10x358mn Type 17
20. Tile Brackets Install Brackets with Galvanised 17 10x40 Screw provided driven into Truss or rafter not battens Expose the timber rafters by sliding or removing tiles at the required spacing and at multiple points determined by the required amount of brackets The tile bracket arrives pre assembled with fasteners loosely and ready for assembly adjusting Move the tile arm so that it loosely aligns with the Valley of the tile The screws can then be driven into the base plate ensuring that screws are placed on timber rafter approximately 10mm in from edge of timber and driven on a inward angle Slide arm along slots until both in rests in the lowest point valley of D the tile and then fasten M8 Locknut Tip An impact driver that requires no pre drilling best performs this function If timber splits easily then pre drilling may be required Move the adjustable Tile Bracket arm Left Right up down to unsure perfect placement on the valley of the tile and perfect height allowing for the thickness of the tile without the use of packers Once the Tile bracket has been fixed and set in place the tile can be replaced If the tile sits too high over the top of the bracket a section of tile can be removed to accommodate the thickness of the bracket Installer should wear suitable ear and eye protection when using a grinder General Note for Fixing into Steel Purlins For steel roof Purlins M6 Zip screws should be used if ma
21. VERED IN THESE DESIGN GUIDELINES IF NECESSARY INDEPENDENT ENGINEERING ADVICE MA BE NECESSARY if a 1 RAIL SECTION 2 TILT ASSEMBLY 3a END CLAMP 3b MID CLAMP Sees nee Toli 6063 T5 Aluminum extrusion 6063 T5 Aluminum extrusion 083 TS Aluminum extrusion Rev 2 Certification Amendments 11 2 2013 Further Relevant test reports etc Certified By 1 Engineering Calculations are based on Report 8360_EngineeringWoresheat Craig Shackleford EC 36632 6 2 2013 2 O Date of Approval 11 02 2013 Product Name Tilt Frame Side Profile Product Description SOLAR PANEL RAIL MOUNTING SYSTEM Manufacturers Name 147 165 468 Lid 180199 Z3 Ri Melbourne VC 3004 Arala Phone 1300 380 Design Criteria BASIC WIND DESIGN CRITERIA Wood Scres AS 11702 2002 Including Amandmant 1 14 10x75 Type 17 t REWON C Up TO 10m IN HEIGHT Min Embedment Jmm TERRAIN CATEGORY 2 Shielding Factor Shielding Worst Hall Shape Mubtioier 1 Terrain Height Multiple 1 REGIONAL DESIGN WIND SPEED D Installation nal recommended Ragion C wiy 227 Batten F17 Hardwood Metal Roof Cladding Region B wiv 184 mit or F Pine Ragion A why ims 158 krit Limitations Gre j SYSTEM IM ANY CAPACITY TO BE INSTALLED IN REGIONS DEFINED AS Fbings Notes LOCAL PRESSURE ZONES
22. amp against panel into rail and apply so that it sits vertically a quarter turn on the The spring will assist in nut so that the T Bolt maintaining the clamp engages the rail upright during the assembly process Ensure that the protrusions on the earth washer sit underneath the panel Figure 13 Inserting Mid Clamp into rail Figure 14 Slide Clamp against panel Slide the mid clamp against first panel so that there is no gap between the clamp and panel The clamps come in two variants one with earth washer and one without Refer to Earthing section in this document on placement of these components If an earth washer is on the mid clamp please ensure that the washer is correctly aligned and the protruding nibs are between the panel and the rail See Figure 14 Note The mid clamps have some thread locking compound which makes it easy to insert and remove T bolt from rail The nut cannot be hand tightened Mid clamps have a spring which maintains the clamp upright during installation There is no need to hold the clamp when installing next corresponding panel M 0 125 gt www solar360 com au 4 0 August 12 252 po d Install the next panel and tighten the M8 Nut to the recommended torque setting See Figure 15 Butt Panel agains mid clamp ensuring that Earth washers are set undemeath panel Slide panel firmly against mid clamp Figure 15 Install remainder of panels Figure 16 Install Remind
23. d on Importance Level 2 in accordance with Buiksing Classes 1 to 10 with a 25 year design life B If ary of the above Emitations do comply the installer shall seek independent Oompliance I did not prepare the design and certify that the part of the design described as the Building Code of Australia ECA 2010 Volume 2 ASINZS 1864 1 Aluminium Structures Limit State Design ASINZS1170 2 Structural Design Actions Wind Actions AS358686 Screws Salf driling For the building and construction industries 454100 Steel Structures Drawing Pages 1 to 8 Rev 1 Date 25401 2013 Test Report 3660 Mounting System mk1 Tila Bracket Pull Testing Prepared by Richard amp Date 04 12 2012 Date 06 02 2013 Te Loma ey DADA Map 12400 Mad TECHNICAL DRAWINGS Appendix A Product Name s6o0nack Product Description SOLAR PANEL RAIL MOUNTING SYSTEM TYPICAL SYSTEM LAYOUT Nominal amp 8mm x 4 Panels Manufacturer s Name ABN 00 147 163 488 Ll 18 4808 i Rd Melbourne VK 2004 futrala Phonec 1300 600 360 Joiner included for Design Criteria 2060mm Long rails zn BASIC WIND DESIGN CRITERIA AS 1170 2 2002 Including Amerndmant 1 e REGION C Up TO 10m IN HEIGHT TERRAIN CATEGORY 2 Shielding Factor Ms Shielding Worst casa Terrain Height Multipia 1 REGIONAL DESIGN WIND SPEED Ragion D installa amp in not rec
24. e m At without cutting panel widths can be joined to make any continuous length up to 12 5MT Limit imposed due Peeters TR RN He Po to thermal expansion considerations 10 2 Drawing Matal Tilo System Layout M SON gt Www solar360 com au Ver4 0 August 12 22 i 2 1 2222 lt xi 7 22 H m Se 227 oe 7 2 Install Tilt Base Plates Install Tilt Frame base with Galvanised 17 10x75 Screw provided driven into batten In some cases Truss or rafter See Figure 24 Rubber isolators are included in the Tilt frame kit These should be used in between the Tilt base and roof where penetrations are per formed Tip For a steel roof with hidden fixings determine where the battens are by using a stud finder or by feel i e standing along the valley section of the roofing material until firmness is felt This point can be marked and the procedure repeated until a straight line of markings is determined Note The Tilt base has three slots that are used to fix it onto the roof surface In most case the batons are spaced between 800 1200 mm apart and the outer two slots can be used In cyclone areas or where specific building requirements are imposed the spacing maybe 600mm in which case the central slot is also used Note The Tilt assembly consists of three main components the base the top and
25. e arm and Top with pin supplied section together Once the angle is set the Adjustable Tilt arm is connect to the Top Rail section as shown in Figure 26 Tip It is recommended that the M8 Nuts be tightened using a ratchet spanner or Clutch type arill driver The tightening torque is approximately 20 N m To aid in tightening nut a 6mm Allen key is required to prevent the corresponding screw from rotating The remainder of the pivot points should all now be tightened as per procedure above www solar360 com au Ver4 0 August 12 7 4 Installing the rail The rail is held in place by clamps that are supplied with the Tilt assembly The clamps are first paced into the mount rails as shown in Figure 27 fl ee HU Figure 27 Insertion of tilt Rail Clamps Figure 28 Tighten Locknuts on clamps once rail is in correct position The assembly can then be placed on the Tilt Rail arm and the T Bolt on the clamp tightened to clamp the rail in place This procedure is repeated for all the Tilt frame assemblies along the length of the rail See Figure 28 www solar360 com au Ver4 0 August 12 CAs 7 5 Installation of Panels Refer to section 6 iii to 6 vii for reminder of installation Figure 29 Install Remainder of panels as per previous www solar360 com au Ver4 0 Augus 8 WARRANTY PROVISIONS Limited Product Warranty ten 10 year repair replacement or refund remedy Guarant
26. ee statement Solar360 Pty Ltd s goods come with guarantees that cannot be excluded under the Australian Consumer Law You are entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure Solar360 Pty Ltd Solar360 hereby confirms that its 360Rack Solar PV Racking System is compliant with The Building Code of Australia AS NZ 1664 part 1 AS 5033 2012 AS 1866 AS NZ 1170 0 AS NZ 1170 1 AS NZ 1170 2 AS 3566 and AS 4100 as at the date of purchase and comprise of quality components aluminium stainless steel Solar360 warrants that the Racking System is free from faulty parts manufacture or workmanship when installed in accordance with Solar360 s Installation Manual Warranty commencing from date of purchase and will expire within ten 10 years from the date of purchase Warranty Period The Racking System must be installed according to Solar360 s Installation Manual otherwise this Warranty will be void This Warranty is offered to the original purchaser and is not assignable or transferrable The Warranty only applies where during the Warranty Period a defect has arisen in the Racking System wholly or substantially as a result of faulty manufacture parts or workmanship in the Racking System To the max
27. er of panels and tighten Locknuts Tip Check for alignment after installation of second panel Clamp the remainder of the panels and finish off the last panel in the array with end clamps www solar360 com au Ver4 0 August 12 6 8 Cable Tray The 360Rack mount system incorporates a cable tray with proprietary clipping system that avoids the use of cable ties and fulfills the new requirements of AS5033 Please refer to Figure 17 Aluminium clip holds cables in place Figure 17 Sliding Clamp against panel gt gt Wwww solar360 com au Ver4 0_August 12 SSS ESSE A 6 8 Earthing An earth bonding solution is included with the Mounting system this includes See Figure 18 A rail Earthing Lug Mid Clamps with Earthing washers lil Rail Joiners with Earthing washers Figure 18 Rail Panel and Joiner Earthing respectively Figure 19 Tighten Earth Lug Locknut once in place The joiner and mid clamp earthing are integrated into each assembly and automatically are functional by following the previous installation steps for these components The rail earthing lug should be attached to one rail only in any one continuous array of panels Where the array is split another earthing lug must be installed on each array The Rail Earthing lug is preassembled and includes a T bolt assembly and an Earthing washer ready to fit into the rail The T Bolt is inserted as per previous examples and the M8 n
28. ertification for the necessary installation requirements of the system www solar360 com au Ver4 0 August 12 Regional Design Wind Velocity WV Region A WV 44 m s or 158 km hr Region B WV 54 m s or 194 km hr Region C WV 63 m s or 227 km hr Region D Installation not reccomended insets from 50km smooth coastline 100km Derby Broome Wind Region Map Non cyclonic Classification Cyclonic Classification REGION A REGIONC REGION B 8 REGION D 10 1 Wind Load Certificate SHACKELFORD CONSULTING ENGINEERS Structural amp Civil 430A Whitehorse Fead Bakan VIC 3103 STRUCTURAL CERTIFICATION OF 360 RACK SOLAR 360 SOLAR PANEL MOUNTING SYSTEM The following installation limitations of the system shall apply 1 Installed in a location with a Wind Region of no greater than Region C 2 Height of roof level above ground shall noi exceed 10 matres 3 System is to be located towards centre of roof Edges of solar panels to be at least 500mm from crest or edge of roof 4 Roof structures and roof elements including battens rafters trusses etc to be designed and or verified by an suitably qualified person to accept the superimposed loads of the system 5 Pitched roofs of between 15 to 50 degrees Flat roofs of 1 to 5 degrees for tilt frames with an angle of 25 degrees 6 Not to be installed on pre cyclone designed buildings 7 Design is base
29. hr Region wiv mis 194 knr Region wy dimi 158 Limitations MAX 1300 0rmrm 1 SYSTEM IN ANY CAPACITY 15 HOT TO BE INSTALLED IH REGIONS DEFINED AS LOCAL PRESSURE ZONES 2 THIS DESK3N S FOR SYSTEMS NO GREATER THAN 10m HIGH LOCATE THES SYSTEM TOWARDS THE CENTER AREA OF ROOF POSSIBLE PANELS MUST BE AT LEAST 0 5 MTRS AWAY FROM ROOF CREST OR Designs an based on Panel ares of 401000mm 4160mm Rail Longi Fanok having a EDGES surtaca o about 4x1 amp 5mtrs 6 6 soni and Slimm 3380mm Ral jangih ROOF STRUCTURE MUST BE DESIGNED TO ACCEPT THE WEIGHT OF SYSTEM Paris 5 15 senna PITCHED ROOF CALCULATIONS ARE BASED ON ROOF PITCH 15 DEGREES s Footer io nob on Pg B amp 9 or fixings details OF GREATER FLAT ROOF CALCULATIONS ARE BASED CN A TILT ANGLE OF e Each Rail must have a MINIMUM amour of Tit Assemblies par of Rail aa 25 DEGREES MOT INCLUDING AIF PITCH per taba NOT FOR INSTALLATION ON PRE CYCLOME STANDARD BUILDINGS The Grei amp Last brackael must be no than 4DOmm from fe ends of fe rail DESKN ASSIGNED IMPORTANCE LEVEL 2 AS DEFINED IN THE BUILDING effort must be rade bo apos the inner brackets evenly maximum spaces of CLASS 1 10 WITH A 25 YEAR DESK3N LIFE STRUCTURES AT THIS LEVEL ARE 1300enm EXPECTED NOT TO COLLAPSE BRIT MAY SUSTAIN SUBSTANTIAL DAMAGE Raie be apaced more than 1200mm apart UNDER THE EXTR
30. imum extent permitted by law if the Racking System fails to conform to the Warranty during the Warranty Period Solar360 will at its option either repair or replace the Racking System or refund the purchase price for the Racking System as paid by the original purchaser To the maximum extent permitted by law the repair replacement or refund remedy shall be the sole and exclusive remedy and in lieu of all others express or implied and shall not extend beyond the Warranty Period d gt www solar360 com au 4 0 August 12 P p Exclusions and Limitations The Warranty does not apply where damage is caused by other factors including without limitation Alteration repair service or modification of the Racking System without the express prior written consent of Solar360 Removal of the Racking System and reinstallation of it at another site Non compliance with Solar360 s Installation Manual Misuse abuse neglect or accident in storage transportation handling installation application use or service Power failures power surges lighting flood fire vandalism tampering accidental breakage mould discolouration or any acts of God or other events beyond Solar360 s control In addition the Warranty does not cover any cosmetic blemishes for example any blemishes associated with installation normal wear and tear or excessive dirt build up Without detracting from the rights and benefits under the Au
31. ing System does not cause the beginning of new Warranty terms nor shall the original terms of this Warranty be extended oolar360 has the right to deliver another type different in size colour shape and or power in the event that Solar360 has discontinued producing the Racking System or limited stock in question at the time of the claim If any part or provision of the Warranty is held invalid void or unenforceable that will not invalidate the remaining parts or provisions of the Warranty which shall remain in full force www solar360 com au Ver4 0 August 12 SS PNE 9 MAINTENANCE The main components are all made from either Aluminium or Stainless steel and there are no moving parts Anodising of the Aluminium surface provides extra assurance against corrosion Incorporation of dual redundancy in thread locking also increases reliability By design the system does not require any maintenance In marine environments or areas subject to high pollution rinsing with clean water may be performed at recommended intervals supplied by panel supplier 24 NEN www solar360 com au Ver4 0 August 12 NNNM 10 WIND LOAD CONSIDERATIONS In order to claim Renewable Energy Certificates REC s an installer must sign off that the mounting system complies with the requirements of buildings and structures in relation to Wind Loads imposed according to AS1170 2 The mounting system must also be
32. lock in place Figure 8 Tighten Locknut once in correct position Tip It is recommended that the M8 Nuts be tightening using a ratchet spanner or Clutch type drill driver The tightening torque should be around 20 N m Do not use a impact driver for these as the torque on these are not adjustable and often in excess of 150 N m Es A s Wwww solar360 com au Ver4 0 August 12 x p d C H H J 2 6 5 Rail Joiner Slide rail into place and tighten M8 Locknut Figure 9 Tighten Locknut once in correct position Figure 10 Complete by sliding rail in place and tightening Locknut The corresponding rail simply slides into the joiner and butted against the other rail The assembly is then held in place while tightening the M8 Locknut See Figure 10 Tip It is recommended that the M8 Nuts be tightened using a ratchet spanner or Clutch type drill driver Please see previous note regarding tightening torque Note The Joiner assembly incorporates serrated washers that will penetrate the Aluminium rails and create the earth bond between the two lengths of rail This is part of the mount system Earth Bonding Rail lengths should be limited to 12 5mts to avoid thermal expansion affects Tip Rail Length RL formula RL n x w n 1 20 100 where n no of panels w width of panels This allows for 20mm overhang on each side www solar360 com au Ver4 0 August 12 SS CANNES 6 6 In
33. ommendad Region C wi Gams 227 kmihr i Region B wiy S amp mis 194 km hr Ragion wiy damia 158 Typical Fana Outline TYPICAL SYSTEM LAYOUT 3 1000 h1850 x d50 Nominal 100mm x 4 Panels Limitat m ons 1 SYSTEM IN ANY CAPACITY 18 NOT TO BE INSTALLED IN REGIONS DEFINED AS LOCAL PRESSURE ZONES E ool 0 THIS Ge SGN 15 FOR SYSTEMS AG GREATER THAN HIGH _ LE 1 LOCATE THIS SYSTEM TOWARDS THE CENTER AREA OF ROOF WHERE POSSIBLE PANELS MUST BE AT LEAST 0 5 MTRO AWAY FROM ROOF CREST OR EDGES ROOF STRUCTURE MUST DESIGNED TO ACCEPT THE WEIGHT OF SYSTEM Designs based on Panel cf 4x1 000m 41560mm Length Panels having a PITCHED ROOF CALCULATIONS ARE BASED ON ROOF PITCH OF 15 DEGREES surface ansa of aboul 4x1 55mtas 6 6 sqmirs and dxBOBemm 33B8Dnem Rail karih OR GREATER FLAT ROOF CALCULATIONS ARE BASED ON A TILT ANGLE OF Panes area 5 18 UPTO 25 DEGREES NOT INCLUDING ROOF PITCH Tile Base Plate must have MINBAUM of Z TYWO 14 10 Gauge Screws init adeguata 1 to Metal roofs refer HOT FOR INSTALLATION CIN PRE C YCLONE STANDARD BUILDINGS holdings being battens or rafters Metal Base plates 1 one 14 10 Gauge Screw in Pages 2 3 DESIGN 5S ASSIGNED IMPORTANCE LEVEL 2 AS DEFINED IN THE BUILDING a Each Rail must hare the MINIMUM number of Bate Bracke Rail length as CLASS 1 10 WIT
34. port 8360 EngineeringWorksheat xis Craig Shackleford EC 36632 6 2 2013 2 Tila Mounting system Force Test report TRON TilgPulITast Z2Nov12 10 9 Drawing Tilt Roof Connection Details Date of Approval 11 02 2013
35. re compliance to the AS1170 2 standard The output can then be sent to a designated structural engineer that has pre approved the calculations in the spreadsheet for certification An installer must take into account that the mounting system is certified but the roof itself may not be compliant or it is in a State of disrepair Fasteners are supplied with the mounting system and if alternative fasteners are used the installer should consult with the certified drawings at the back of this manual Modification of the mounting system outside of the installation guidelines including drilling of holes deformation and use of inappropriate fixings may make installation un safe non compliant and void the warranty www solar360 com au Ver4 0 August 12 S um 4 INSTALLATION TOOLS REQUIRED Name _______________________ Description Notes 00000 ll Picture Impact Driver or Clutch Drill Used for tightening all mount M8 Locknuts Minimum Torque system M8 Lock Nuts and Roofing 15Nm N B Use Lowest speed Screws only to avoid galling Thread welding 13mm Socket Bit or Ratchet Used for Tightening all mount M8 Locknuts Minimum Torque spanner system M8 Lock Nuts 15Nm 10mm Magnetic Hex driver Bit Used for all Tighten all roof screws Use impact Driver for fast and easy installation without drilling For Tilt Install only T Bar 6mm Used to hold screw while tightening allen key 8 nut For Tiled
36. stalling End Clamps The end clamps are pre slotted to accept panel thicknesses of 30 35 40 45 or 50mm A rubber band prevents the two components that make up the end clamp from coming apart during transport and assembly This can be cut off after installation Pre set the end clamps to the appropriate thickness and place into rail See Figure 11 The T Bolt is inserted as per previous examples Slide Panel against end clamp and tigthen M8 Locknut Allow 10 15mm maximum from edge of rail to start of End Clamp Figure 11 Slide top of end clamp out and insert at correct thickness Figure 12 Slide Panel against end clamp and tighten Locknut Insert the first solar panel to the railing starting as close to the end of the rail as possible design allows for 15mm max Tighten the M8 Nut to the recommended torque setting See Figure 12 Tip If rails were aligned properly the first panel should be set perpendicular to the rail once this is done on the first panel the remainder can be installed without adjustment X E gt gt www solar360 com au 4 0 August 12 252 p d 6 7 Installing Mid Clamps The mid clamps are designed to accommodate any panel thicknesses from 30 52mm without disassembly Place the mid clamp into the rail T Bolt is inserted as per previous and by using hand pressure only turn the nut clockwise so that the T Bolt engages the rail see Figure 13 Insert mid clamp Slide Cl
37. stralian Consumer Law Solar360 excludes all liability whether in contract tort including negligence strict liability or by virtue of the breach of any statutory duty or otherwise Solar360 will not be liable whatsoever for any damage to products sold in conjunction with Racking System or any damage resulting from the installation and assembly of Racking System Any claim in relation to another manufacturer s product is to be made to that manufacturer directly To the maximum extent permitted by law Solar360 s aggregate liability if any in damages or otherwise shall not exceed the purchase price paid to Solar360 by the customer Solar360 will not be liable for any labour costs injury damage or any consequential costs associated with replacing the defective Racking System www solar360 com au Ver4 0 August 12 en PNE Making a Warranty claim Claims under the Warranty must be received by Solar360 within the Warranty Period without exception The original purchaser must provide the original proof of purchase and provide all such evidence as may be required by Solar360 to demonstrate the validity of the original purchaser s claim Warranty claims may only be made by or on the behalf of the original purchaser You must notify Solar360 in writing within fourteen 14 business days after the date when the malfunction or defects provided under this Warranty have been found Miscellaneous The repair or replacement of the Rack
38. terial thickness is less than 1mm than consider adding additional screws or use bolts with nuts Alternatively a localized piece of timber can be used to fix into Figure 6 Grind tile if necessary to accommodate thickness of Tile Bracket Arm www solar360 com au Ver4 0 August 12 6 4 Fixing rail Connection of the rail to the roof mounts is simply achieved by aligning T Bolt on mounts with slot on rail and then pushing the T Bolt into the slot Once this is achieved the M8 lock nut can be tightened The T Bolt will lock and bind into the aluminium rail Stainless steel fasteners are particularly susceptible to thread galling During the tightening of the fastener pressure builds between the contacting thread surfaces and breaks down the protective oxide coatings With the absence of the oxide coating the metal high points of the threads are exposed to one another which increases friction The combination of these two events can generate enough heat to fuse and seize the nut and bolt together Lowering the wrench speed during installation and removal can help avoid galling Tip The mounts have vertical slots to allow for alignment of the rail in case of roof not being perfectly flat Tip The ends of the bottom and top rails should be aligned this will make it easier to align Solar panels once they are installed Once Parts are aligned push assemblies together Figure 7 Align T Bolt and insert quarter turn will start to
39. the adjustable tilt arm The later two components are allowed to pivot on the base so that they can be placed out of harm way when fixing the base into the roof material Tip In order to avoid slippage of the screw point it is prudent to indent roof sheet with point of screw by giving a tap with a hammer to top of screw head Tip An impact driver that requires no pre drilling best performs this function The remainder of the Tilt frames can be installed paying particular attention to making sure the frames are aligned General Note for Fixing into Steel Purlins For steel roof Purlins M6 Zip screws should be used if material thickness is less than 1mm then an additional screw must be used at every fixing point Refer to Engineering drawings at end of document E Wwww solar360 com au Ver4 0 August 12 2252 Bp e 2225 Figure 24 Fixing Tilt Base to roof 7 3 Setting the Adjustable tilt Arm The Tilt arm has an inner section that slides up or down with a series of holes that align to give adjustment of nominal 15 20 25 and 28 degrees of extra tilt over and above the exisiting roof surface angle A pin is provided to lock the inner and outer section at the correct angle See Figure 25 27 Slide Lockpin Inner frame in and out slides up and once holes down to reach are aligned desired angle A Figure 25 Set Extendable arm to desired setting and Lock Figure 26 Connect Adjustabl
40. umbers of panels Where Where X denotes the placement of a Mid clamp with earth washer For odd number of panels the required panel Earth washers is given by P 1 x AWhere P No of panels i e In above case No of mid clamps with earth washers required is 5 1 x 1 6 SEH HH amp IEEE UT EREDETE ERREGEK ANN S T JOT AHHH HHH OU EENI ie EI DE O DA FESTE EE EE DOE T EITLEETAIEELT EET Figure 22 Mid Clamp with Earthing Positions on Odd No of Panels Number of Arrays www solar360 com au Ver4 0 August 12 7 TILT SYSTEM INSTALLATION 7 1 Planning and Preparation After considering layout and planning job consult with wind design data at back of this document to ascertain the correct number of Tilt frames required for the rail length being used Try to plan job in groups of 2 or 4 panels the LUI esee FASEA m panel widths are designed erri PEE un E mE fo cater for nominal 800 cee cr and 1000mm panel widths ae ee
41. ut tightened ensuring that the earthing washer is properly aligned with rail slot See Figure 19 E 25 CS I 1 Wwww solar360 com au 4 0 August 12 The Earth cable can then be stripped and inserted into hole whereby the bolt can be tightened against the lug body Guidelines from AS 3000 AS 5033 and AS 4777 should also be incorporated See Figure 20 Strip wire place in lug and tighten screw Assembly may then be coated with Galv spray or Silicone to prevent corrosion Figure 20 Insertion of Earthing wire Figure 21 Mid Clamp with Earthing Positions on Even No of Panels Tip It is recommended that lug be either sprayed with Galv Spray or sealed with Silicone to ensure long term contact of the Earth wire with the Lug frame It also is beneficial to install the Lug underneath one of the panels as to create a shield from environmental effects Layouts The mid clamps come in two variants one with earth washer and one without The clamps with Earth washers are placed in an array depending on the number of panels in the array For Even numbers of panels Where X denotes the placement of a Mid clamp with earth washer For even number of panels the required amount of panel Earthing washers is given by P x A Where P No Of panels Number of Arrays i e In above case No of mid clamp with earthing washers required is 4 x 1 4 p o 7 gt Wwww solar360 com au Ver4 0 August 12 Se y Em ee For Odd n

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