Rooftop Installation Manual
Contents
1. Australian www sunlock com au Made IN CEOCILICU OI oi scite e lait oaia a a Dc ene oh Dollar aoleu alta malul aici E aia atu Dalai ala 3 Safety and Installer Responsibilities mnne nene ne enma eee ne mona eaene mamona naenenanoeaenaes 4 Handling aN GIS tau ng SU n LOC sas ei ouale ta ne at aa i aa 4 Wingand Cimate DEST sis uliul ali aia an a ui aia nu ta ti al 4 Technical Speciiic all OI S ata cacao eseu ae oaia sueta isi aalzaui ui Saua ului oeiracigti i e 5 ANU UIC 20 PUS A aan eset nee Ai fs nt ti it al aaa vea ae ia At ante an D FS I S ee esterases T setat E E EET E A la le E aaa A E A E aa ta e e ai D Tecnmical Specia OS a o at la d e ata Dat tei sa D Before MStar a lut i Pta ele eo aaa 6 Receptor GOOOS ace EREI RR caret shart denen REP ONE ENE RR RR NIC N NR PRR E RI IRI 6 Tools IREGUIFGO POE Sta LEUL OY si ae aaa zinc ia Gidea inveti a Ea iale Ea Ea iu net tace ae a 7 SUNLOCK Component DESCHIDUONS sssri Ra oaia te mai iat lea 8 SUNL OCK Component Dimensions sectional ieee cen 10 Designing Your Framing System issa iati sanda pai a alia Oa oil aci d mai alea ta 12 Procedure to Select Rall Spacing xknssncutt ara ta tite baiat t nia ie tal db e n 12 Fixing Locations and Array Placement mnu nenea nenea maena mona nna mana nana naenanaass 13 PIXI WIT ROOM MNStall LATION Z ONC o ace aiaot iaca it le i ti et ta a 13 Procedure to Select Fixing CeNIres wis im cani cite n Era on ti te an e o i2. H All Round Procedure to Select Fixing Centres 1 Assess and record your terrain category page 16 for the installation site 2 Use these results to determine the fixing centres from the Lookup Tables for Fixing Centres page 16 You will also need to know building height and roof area dimensions to establish the edge exclusion zone when looking up the fixing centre value this is covered in the section Fixing within Roof Installation Zone page 13 The edge exclusion zone specifies the minimum distance fixings can be installed from the edge of the roof 3 Verify that the substructure and attachment method Is sound and suitable as explained in Installation page 17 Note if using screws other than the provided all screw fasteners must conform to corrosion resistance Class 4 Australian Standard 3566 Note A topographic factor of MT 1 0 has been assumed which applies for buildings on level or near level ground The spacing value refers to the maximum allowed spacing Worked Example 1 Assume the installation site is a house In Toorak Victoria This is determined as wind region A through the use of the wind region maps page 15 2 Terrain falls within Category 3 TC3 due to the presence of numerous closely spaced obstructions buildings 3m to 5m high in the residential building zone page 16 3 Check the planned array installation dimensions are not within the edge exclusion zone of the roof 4 Assuming th
3. buildings up to 200m in height Suitable for roof slopes in the range from 0 to 65 Significantly higher strength to weight ratio than other framing products providing improved efficiency due to greater frame spans inherent corrosion resistance resulting in low ongoing maintenance and an extended product life Complies with Australian New Zealand Standard on Wind Actions AS NZS1170 2 2011 Optional anodised finish standard is mill finish Australian design and manufacture Technical Specifications Material 6106 16 Aluminium Extruded Tensile strength a el aii Yield 210 MPa Module thickness 30 to 58mm Roof slope 0 to 65 Building height Up to 200m Mounting structure Timber or steel Roof types Flat or pitched steel and tile concrete or terracotta Before Installing CAUTION Refer to the section Designing Your Framing System before attempting installation Failure to correctly establish the requirements of the proposed installation site is dangerous and will void the framine warranty Receipt of Goods Check that the SunLock equipment is undamaged and that the order is complete Check for correct quantities of the following items Rails slightly more than twice the length of the proposed solar array in linear metres End clamps a minimum of 4 per row of panels fitted at the ends Mid clamps 2 for every gap between neighbouring panels e g 10 for an array of 6 panels in a single
4. clamp suits the growing number of panels with a standard 38mm height and simplifies and speeds up the install process Clamp Minimum Maximum mm mm Low 30 42 Med 34 46 High 46 58 End clamp dimensions Adjustable end clamps allow the easy modification of the clamp to suit almost any panel frame height Diagram shows the medium clamp in the minimum and maximum positions Note Minimum of two fins must be engaged 18 mm Mid clamp dimensions There are two mid clamp assemblies with different lengths of cap screw 1a suitable for 30 mm 40 mm thick solar panels 1b suitable for 40 mm 50 mm thick solar panels Note Other panel thickness accommodated by special orders Designing Your Framing System The installation site roof height roof material roof angle the size and quantity of solar panels and the number of module rows used will determine the dimensions quantity and layout of framing components required for installation This section of the document should be used before installation to determine critical job specifications 1 Rail 2 End clamp 3 Mid clamp 4 L foot The term Spacing refers to the distance between the parallel rails dimension Y on the figure above The spacing of the rails is determined by the spacing of the battens purlins beneath The term centres refers to the distance between mounting points of the roof dimension X The distance between centres can be reduced an
5. provisions of the Standard Building Codes and in accordance with accepted engineering practice and principles This certification is subject to the limitations imposed on the system as detailed in the Manual This document does nol constitute certification of the existing roof structure to which the mounting system is to be fixed Adequacy of the existing structure should be determined on site by the installer prior to installation This certificate shall not be construed as relieving any other party of their responsibilities liabilities or contractual obligations Rob O Reilly GE MIL Aus CPEag PER Sinuctural RPE For and on Behalf of Partridge Partners Pry Lid 1200 1 0063 AN en li Lamy
6. the L facing towards the ridge of the roof Secure the L foot roof mounts with the roof screws Use the supplied isolation washers between the base of the L foot and the roof surface Installing Tile Brackets Installation of the Sunlock Adjustable Tile Bracket requires no special tools only a 13mm socket spanner and the 6mm internal hex driver Allen key normally used for SunLock framing Expose the timber rafters where the SunLock Tile Brackets are to be attached by sliding or removing tiles at a suitable spacing Loosely assemble the tile brackets ready for adjustment Place the first tile bracket on a rafter and adjust the elevation to a low and flush fit Use a 13mm socket to secure the bolt assembly Generally the other brackets on the roof can be adjusted to the same elevation position L foot fits to the crest b For a steel roof with hidden fixings clip type roofing 1 Lift the sheets of steel to expose the structure beneath 2 Using a marker mark out the precise locations of the structure below the roofing material and clip the roof back in place 3 Place L feet on the markings and screw down with supplied isolation washers between the base of the foot and the roof surface Attach the tile brackets to the rafters using the supplied screws To prevent splitting the timber pre drill the screw holes at an inward facing angle This is especially important for hardwood rafters
7. unsuitable substructure cannot be used with SunLock and installation on such structures will void the warranty and could result in death or serious Injury Wind and Climate Design AS NZS1170 2 2011 provides guidance on determining the wind pressures applicable to your SunLock install site taking into account roof shape and geographic location Sufficient guidance is given in this document but you may wish to procure a copy of these standards if your company installs Australia New Zealand wide REMEMBER average wind speeds are higher for structures mounted closer to the roof perimeter zone edge Refer to Fixing within Roof Installation Zone for more information Make sure your installation complies with local and national building codes Take into account relevant design parameters wind speed exposure and topographic factor when determining the loading for the installation If alternative fasteners are used to fix the framing to the roof assuming supplied fasteners are unsuitable for any reason all screw fasteners must conform to corrosion resistance Class 4 Australian Standard AS3566 and be of equal or greater strength to those supplied with your SunLock order Technical Specifications Applications Commercial and residential buildings Marine applications and remote areas Features 6106 16 Aluminium extrusion Ripple design on L foot and tile brackets Increases joint strength Suitable for
8. Move the tiles back into place Attach the SunLock rails to the Adjustable Tile Bracket uprights and your framing installation is complete 69 mm 50 mm 1 Connecting Rail to Roof Mounts Connect the rail to the roof mounts by inserting the roof mount keylock into the rail channel Make sure the ridged rail surface faces the ridged surface of roof attachments Fasten the cap screw on the keylock 2 3 turns to loosely hold the rail in position 3 Connecting Multiple Rails Join rail segments by inserting the rail joiner into the rail channel 5 Installing End Clamps Insert keylock of the end clamp into the rail channel Using a 6mm hex driver Allen key secure the first solar panel to the railing starting as close to the end of the row as possible A minimum of 50mm between the end of the rail and edge of the first solar panel is required 2 Connecting Rail to Roof Mounts The rail can be adjusted vertically within the roof attachment slot when bolts are loosely fastened 4 Connecting Multiple Rails Fasten cap screws to secure 6 Installing Mid Clamps a Insert the keylock of the mid clamp into the rail channel and position the clamp against the first panel frame Hand tighten the screw 2 3 turns to loosely hold the clamp in position If EarthLock washers are used they should be placed between the SunLock rail and the frame of the panel 7 Installing Mid Clamp
9. arranty and is compliant with the Australian New Zealand Standard on Wind Actions AS NZS1170 2 2011 WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury This symbol is not used for hazards relating to property damage unless there is also a risk of personal injury to this level CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It may also be used to draw attention to unsafe practices that may cause damage to property Safety and Installer Responsibilities INSTALLATION OF THIS PRODUCT IS TO BE PERFORMED ONLY BY PROFESSIONALLY TRAINED INSTALLERS Any attempt by an unqualified person to install this product could result in death or serious injury Handling and Installing SunLock It is critically important that safety practices are observed when installing SunLock Do not throw or roughly handle any SunLock components Do not bring SunLock into contact with sharp or heavy objects Do not modify SunLock components in any way The exchange of bolts drilling of holes bending or any other physical changes not described in standard installation procedure will void the warranty It is the installer s responsibility to verify the integrity of the structure to which SunLock is fixed Roofs or structures with rotten rusted bearers undersized bearers excessively spaced bearers or any other
10. au 14 VO gl 19 E CEI IND LE ap ai O al Aa a 00 nu a atat te daia nt a mau ai 14 Wind Region Map Australia in accordance with AS NZS1170 2 201 1 15 Wind Region Map New Zealand in accordance with AS NZS1170 2 2011 15 Terrain Category Definitions in accordance with AS NZS1170 2 2011 ccceei 16 LOOKUP Tables f r FIXING Centres sis iod cual an ada tnt A a uda iad sai it ai da i 16 In Sata CIO N faza mai San tt 0 leac turzii alui aa iat S 17 Instalung L Feetom Steel ROOTS cainii oi iu are dei ei iu Du a ri tip Da 17 MVSTAUCNG Tte BracKElS scoici taia e a ac nat i at 17 Maintenance and Cleaning isi ac oi a ip ta lo a aid alin 20 Warranty Conaitions si coste at anula lata ude aie di ciur ll ata oi a a ala a alla 20 RETONCING OS i ine ca og il ca 0 E 20 CONTAC Detales a cea dala iata f Sara a ceafa ea ez ele aaliica atei a alia 21 Certiiica te 0l COMpUance css jos taiata coala red Gnu teal cual adica oala dama a 21 Introduction Thank you for choosing the SunLock solar panel roof mounting system Made from custom built aluminium extrusions and components SunLock s streamlined design and improved frame strength greatly simplify solar panel installation Offering a high level of adjustability for module width and depth SunLock s versatile design makes it suitable for a wide variety of building types and zones including residential commercial and remote environments SunLock is backed by a 10 year w
11. d therefore the number of points of contact increased to increase the wind load rating The overhang between the L foot and the end of the rail dimension W must be less than 200mm Procedure to Select Rail Spacing The length of overhang from rail to panel end dimension Z should not be less than 10 nor exceed 25 of the total length of the panel Always refer to the solar panel manufacturers s product installation manual For tin roof installations where the purlin spacing is less than 750mm a third rail should be used in the middle of the outer rails to avoid unevenly increasing the wind load on the purlins Fixing Locations and Array Placement Fixing within Roof Installation Zone Inner areas of the roof encounter lower wind speeds than those encountered along the edges This inner area Is called the installation zone and is considered a safe install location The fixings of the frame must be within this zone Note The panels themselves can extend beyond the installation zone provided the fixings are within the perimeter The installer must check and confirm that the roof structure battens purlins are in good condition and can withstand the extra loads created by the PV system DETERMINING THE WIDTH OF THE EDGE EXCLUSION ZONE The width of the edge exclusion zone is determined by calculating each of the following values and then using the smallest 0 2xB 0 2xD H Average Height J Minimum of 0 2B 0 2D or
12. e Frame from Energy Matters Purchaser or where the Purchaser is an installer or builder who on supplies the Frame to another party to that other party End User This warranty is not transferable Where an End User wants make a claim under this warranty the End User must in the first instance contact the installer or builder from whom the Frame was purchased All warranty claims must be made in writing and addressed to the Customer Service Officer Energy Matters PO Box 5265 South Melbourne Victoria 3205 and accompanied by proof of purchase of the Frame in a form acceptable to Energy Matters This warranty will not apply to any claims received by Energy Matters after the expiration of the Warranty Period Energy Matters makes no warranties express or implied other than the warranties made herein and specifically disclaims all other warranties representations and conditions to the extent permitted by law To the extent permitted by law in no circumstances will Energy Matters be liable for direct indirect special or consequential damages arising from a defective Frame or for any damage or injury to persons or property Energy Matters s aggregate Liability if any in damages or otherwise will not exceed the Invoice value of the Frame at the time of purchase from Energy Matters Any provision contained in this warranty which is prohibited or unenforceable in any jurisdiction will be deemed to be ineffective to the extent of
13. e does not conform to this warranty during the Warranty Period Energy Matters will at its option either repair or replace the Frame or pay the cost of having the Frame repaired or replaced To the extent permitted by law Energy Matterss total liability under this warranty will in no circumstances exceed the repair or replacement of the Frame or payment of the cost of having the Frame repaired or replaced In the event of replacement of the Frame any remaining part of the Warranty Period will be transferred to the replacement Frame This warranty will not apply to any defect or damage to the Frame arising directly or indirectly from 1 shipment or storage of the Frame 2 improper installation maintenance repair or use of the Frame 3 normal wear and tear 4 misuse neglect abuse accidental damage or modification to the Frame 5 failure to observe the instructions set out in the System Manual or 6 power failure power surges lightning fire explosion flood extreme weather conditions environmental disasters or other causes outside Energy Matterss control as determined by Energy Matters in its sole discretion This warranty does not cover and under no circumstances will Energy Matters be liable for any costs associated with the removal shipping handling or re installation of the Frame or the costs of sending personnel to any site to repair or replace the Frame This warranty is only provided to the original purchaser of th
14. e example roof is flat steel tilt legs will be required Refer to SunLock elevated mounting installation manual for more information After determining the building height wind region and terrain category refer to the Lookup Tables for Fixing Centres page 16 to determine appropriate fixing centre values e g the arrow below indicates a measurement of 1140mm for centres Topographic region 1 0 Calculated Fixing Centres ROOF HEIGHT WIND REGION B mm TC2 TC2 TC2 5 TC3 TC4 790 490 580 710 870 670 420 480 550 870 i Ze Ai 580 360 400 360 680 40 CH 100 510 N A N A N A 460 100 amp HE 200 470 N A N A N A 360 Wind Region Map Australia in accordance with AS NZS1170 2 2011 Region A i E Region B y E Region C N Region D Wind regions based on AS1170 2 2002 E Region A6 E Region A7 Region W EH Lee Multiplier NW Lee Multiplier SE Terrain Category Definitions in accordance with AS NZS1170 2 2011 Terrain Category 2 TC2 Site near water or cleared rural land i i with few obstructions to wind Terrain Category 2 5 TC2 5 Terrain Category 2 TC2 Terrain Category 2 5 TC2 5 Site near scattered trees or buildings and near i low obstructions such as crops fields etc Terrain Category 3 TC3 Terrain Category 3 TC3 Site surrounded by trees or buildings lt 4 lt A 3m to 5m high typical suburban site Terrain Category 4 TC4 S
15. ite located in highly built up industrial or inner city areas 10m to 30m obstructions Terrain Category 4 TC4 Lookup Tables for Fixing Centres ROOF HEIGHT WIND REGION A mm WIND REGION B mm Metres TC2 TC2 5 TC3 TC4 TC2 TC2 5 TC3 TC4 H lt 10 790 940 1140 1400 490 080 710 870 10 H 20 670 770 890 1400 420 480 550 870 20 CH 40 580 650 730 1090 360 400 360 680 40 CH 100 510 540 580 740 N A N A N A 460 100 lt H 200 470 490 510 580 N A N A N A 360 ROOF HEIGHT WIND REGION C mm WIND REGION W mm m TC2 TC2 5 TC3 TC4 TC2 TC2 5 TC3 TC4 H 10 N A N A 420 420 610 730 890 1090 10 e H 20 N A N A N A N A 520 600 690 1090 20 CH 40 N A N A N A N A 450 000 060 850 40 CH 100 N A N A N A N A 400 420 450 080 100 CH 200 N A N A N A N A 370 380 400 450 Note The spacing value refers to the maximum allowed spacing Installation Start any roof structure installation by marking the fixing points at the calculated centres and spacing along the proposed length of the array in a parallel row Note A roof interface leg L foot or tile bracket should be mounted within 200mm of each end of each rail nstalling L Feet on Steel Roofs For a steel roof with exposed fixings 1 Determine where the roof mounts will be positioned based on position of existing roof screws Do not remove existing roof screws Instead install on unused crest Fix L feet in place and fix with the upright part of
16. row Roof Interface Legs at least 2 for each panel L feet roof screws and isolation washers for steel roof interfaces tile brackets and rafter screws for tile roofs Refer to Procedure to Select Fixing Centres page 14 Tools Required for Installation T bar Allen Key or 6mm hexagonal driver bit If using Drill or impact driver for driving roof material fixings a 6mm driver bit make sure the cordless power tool used for driving has a hand tight clutch setting anda fine soft impact drive to prevent damage to the fragile glass panels and threads on the SunLock framing LA ai Gloves for handling SunLock framing aluminium For terracotta tile roof installation an angle can develop sharp corners grinder fitted with a continuous edge diamond tipped tile cutting blade gloves hearing protection a face protection mask and a suitably rated breathing protection mask for all people in proximity of grinding SunLock Component Descriptions 1 Rails hold each panel row and are custom designed and Australian made 6106 16 extruded aluminium 2 Joiners extend SunLock Rails to any length as required by the quantity or width of the solar panels 3 L foot roof mounts secure the railing to steel roofs Refer to loading tables below for spacing information The L foot is made from aluminium and must be used with the supplied isolation washer to prevent galvanic corrosion with the roof material 4 Tile bracke
17. s 8 Check Alignment of the Array d _ Slide second panel firmly into place against the After fixing the first 2 panels check that the array is mid clamps and fasten bolts straight If there appears to be a deviation from square e g if the ridge cap shows the row to be falling or rising slightly readjust the panels until they appear square with the roof Alternatively measure the distance from the rail to the edge of the panel 9 Continue Installing Mid Clamps 10 Install End Clamps Continue to clamp the neighbouring panels in the array to the rails end clamps You should have a minimum of 50mm clearance between the edge of the last panel and the end of the rail Tighten all bolts to secure the panels 11 EarthLock Lug Fasten the EarthLock Lug directly to a SunLock rail by placing the insert key in the rail and tightening the cap screw Maintenance and Cleaning 6106 16 aluminium is largely maintenance free Only in highly polluted or marine conditions is rinsing with clean water required during scheduled panel cleaning Warranty Conditions Energy Matters Pty Ltd trading as Energy Matters and Apollo Energy Energy Matters warrants that its SunLock Solar Panel Mounting System Frame is free from defects in materials and workmanship for a period of 10 years from the date on which the Frame is purchased from Energy Matters Warranty Period on the terms set out in this warranty In the event that the Fram
18. such prohibition or unenforceability and will not invalidate the remaining provisions nor affect the validity or enforceability of that provision in any other jurisdiction This warranty will be governed and construed in accordance with the laws of Victoria Australia and the parties irrevocably submit to the exclusive jurisdiction of the courts of Victoria References AS NZS1170 2 2011 structural design actions Part 2 Wind actions AS3566 2011 self drilling screws for the building and construction industries Contact Details Sales and service International 61 3 9697 1950 1300 855 484 Fax 61 3 9697 1919 Local call from anywhere in Australia Email info dsunlock com au Certificate of Compliance Eeginucting Gormwulindts Liter d La bi a e May 20 2011 Energy Matters Pty Lid SS Level 2 101 105 Clarke Street South Melbourne VIC 3205 Attention Mr Jeremy Lawrence CERTIFICATE OF STRUCTURAL ADEQUACY Project Description SunLock Solar Panel Roof Mounting System Rooftop Installation Manual Version 3 May 2011 We Partridge Partners Pty Limited being professional Structural Engineers within the meaning of the Building Code of Australia hereby certify that we have reviewed the structural design of the SunLock Solar Panel Roof Mounting System and associated fixing centres as detailed in the SunLock Rooftop Installation Manual Version 3 updated May 2011 and that this work is in accordance with the relevant
19. ts fix the railing to the rafters below a tile roof and ensure a waterproof finish Each tile bracket includes two 50mm roofing screws yy WL 5 Adjustable tile brackets provide a simple and adaptable method for attaching SunLock framing to tile roofs Additional features allow adjustment of the elevation and side position of the bracket to provide a closer fit for different tile batten heights tile profiles and tile positions Each tile bracket includes two 50mm roofing screws 6 End clamps hold the edge of each end panel and are fully height adjustable to accommodate solar panels of any thickness between 30 and 58mm These are fastened with a 6mm hex driver Allen key 7 Mid clamps fit between two panels and hold the panels to the rails These are fastened with a 6mm hex driver Allen key 8 EarthLock system comprises the EarthLock washer and the EarthLock lug This system provides earth continuity from each panel frame to the rail allowing the quick and effective connection of the array to an earthing cable if required SunLock Component Dimensions 30 mm Rail lengths gt For standard 808mm For wider 990 1005mm wide panels wide panels 2600 mm 2100 mm 3410 mm 3200 mm 4200 mm 53 mm 115 mm 50 mm Tile bracket dimensions Each tile bracket includes two 50mm roofing screws 5 38 mm i i N SU Fixed leg end clamp The fixed height end
Download Pdf Manuals
Related Search