INSTALLATION MANUAL
Contents
1. LOCKSOLAR Rack in a Box 2 0 PRODUCT RANGE The Rack in a Box system comes conveniently packaged in a box starting from 3 and 4 panel installations All the compo nents you need to successfully install your system in most metropolitan and regional areas are included 2 1 Rack in a Box Systems The Rack in a Box system is available in modular kits to suit both 3 and 4 panel installations and to suit either tin or tile roofs Each kit comes with 2 rails and enough mounting components to suit most applications Additional mounting kits to suit high wind cyclonic regions are available for purchase as accessories Product Code Description Rail Length mm RIB 2560 5MTN Rack in a BoxTM 2560mm Tin Roof Kit 2560 RIB 2560 3MTL Rack in a BoxTM 2560mm Tile Roof Kit 2560 RIB 3410 4MTN Rack in a BoxTM 3410mm Tin Roof Kit zao RIB 3410 4MTL Rack in a BoxTM 3410mm Tile Roof Kit 3400 2 2 Accessories Product Code Description RIB ADD TN Rack in a BoxTM Additional Mounting Kit Tin Roof RIB ADD TL Rack in a BoxTM Additional Mounting Kit Tile Roof RIB CT Rack in a BoxTM Additional Clip in Cable Loop Tie Kit RIB 5410 4MTL Rack in a BoxTM 3410mm Tile Roof Kit As recommended for high structural requirements such as cyclonic high wind regions terrain or topographic factors LOCKSOLAR Rack in a Box 5 0 PREPARATION FOR INSTALLATION 3 1 Applications Rack in2. LOCKSOLAR Rack in a Box INSTALLATION MANUAL 1 0 2 0 2 1 2 2 5 0 5 1 5 2 5 5 4 0 4 1 4 2 4 5 AA 5 0 9 1 0 2 0 9 0 4 0 0 0 0 1 INTRODUCTION PRODUCT RANGE Rack in a Box Systems Accessories PREPARATION FOR INSTALLATION Applications Tools for Installation Additional Materials for Installation PLANNING THE INSTALLATION Site Locations Installation Height Solar Panel Layout General Installation Notes INSTALLATION Tin Roof L Bracket Installation Tile Roof Tile Hook Installation Mounting Rail Installation Joining Mounting Rails Rail Joiner Cable Management Features Integrated Cable Track 5 5 2 Twist Lock Cable Ties 5 6 5 7 5 8 6 0 7 0 8 0 Solar Panel Installation End Clamps Mid Clamps SYSTEM COMPONENTS STANDARDS CONTACT DETAILS Om 0 NN O d di di di di A A A O LOCKSOLAR Rack in a Box 1 0 LOCKSOLAR Rack in a Box INTRODUCTION Thank you for choosing LOCK SOLAR for your solar panel installation The LOCK SOLAR Rack in a Box has been designed specifically for Australian conditions and uses the highest quality materials in the construction The Rack in a Box system provides you with unequalled security for your valuable solar investment The Rack in a Box can be used in rural areas on hill side and hill top sites and in cyclonic regions within Australia by including additional roof brackets in the installation These additional
3. a BoxTM is designed for installation on residential and commercial buildings in standard marine or remote areas Rack in a BoxTM is designed for mounting solar panel modules to flat or pitched tin or tile roofs 3 2 Tools for Installation You will need the following tools for installing the Rack in a BoxTM system SIIIISS Cordless drill Grinder with stone disk for tile roof installation only Protective gloves and clothing Security driver Various wood screw drivers including Phillips head driver and Torx head drivers akRW fh 3 5 Additional Materials for Installation Rack in a BoxTM comes with just about everything you need to install the solar module panels however in order to ensure the watertight integrity of the roof you will need waterproofing materials Other tools and materials may be required to ready the roof structure for installation LOCKSOLAR Rack in a Box 4 0 PLANNING THE INSTALLATION Rack in a BoxTM has been configured to meet a large percentage of common installation sites around Australia Additional components are available to extend the performance of the sustem to suit unusual sites and installations These consist of additional roof brackets tile brackets that are used to hold the installation to the roof structure Please consult your Rack in a BoxTM distributor for assistance in these situations 4 1 Site Locations Locations in Australia are subject to different win
4. brackets come in Rack in a Box Additional Mounting kits to suit The Rack in a Box is compliant with the structural design requirements of Australian New Zealand standard AS 1170 2 and comes with a 12 year warranty WARNING INSTALLATION OF THE RACK IN A BOX SYSTEM IS INTENDED TO BE PERFORMED BY PROFESSIONALLY TRAINED INSTALLERS ONLY ANY ATTEMPT TO INSTALL THE THE RACK IN A BOX SYSTEM BY AN UNQUALIFIED INDIVIDUAL COULD RESULT IN INJURY OR DEATH The installer is solely responsible for Complying with all applicable local and national building codes Ensuring that the Rack in a Box and other products used in the installation are appropriate for the particular installation and the installation environment Ensuring that the roof structure its rafters connections and other structural Support members can withstand the installation of the Rack in a Box and solar panel modules under live building load conditions Ensuring only Rack in a Box parts are used in the installation Substitution of parts could lead to a failure in the Rack in a Box system Ensuring that the roof attachments of the roof mounting brackets have sufficient pullout and shear capacities as installed Maintaining the watertight integrity of the roof Ensuring safe installation of all components of the system Verifying that other loading factors including water ice snow and seismic loads do not affect the installation
5. the desired height on each of the brackets then align the ends of the rail and tighten the rail to the brackets Apply a torque of 8Nm to the bolt 5 4 Joining Mounting Rails In circumstances where large arrays of solar panels are being installed Rack in a BoxTM provides a means for joining mounting rails The rail joiner does not replace the need for the roofing brackets Roof mounting brackets must be attached on either side of the joint within a distance of 200mm The joint for the mounting rail does not replace the need for the roof attachment brackets Roof mounting brackets must be located either side of the joint within a distance of 200 mm Assembly steps L The joiner comes preassembled with fasteners for your convenience 2 Assemble the joiner to the mounting rails Ensure that the joiner spans the joint equally and the bolts are located either side of the joint 3 Tighten the bolts Torque the bolts to 8 Nm Q LOCKSOLAR Rack in a Box 5 5 Cable Management Features Rack in a BoxTM incorporates a number of cable management features 5 5 1 Integrated Cable Track Assembly steps L Push loose cable into integrated cable slot Note Integrated cable slot will accommodate 2 to 3 cables Q LOCKSOLAR Rack in a Box 5 5 2 Twist Lock Cable Ties e Assembly steps L Position cable tie so that it runs parallel to rail and insert boss into rail clipping groove 2 Maint
6. the top of the roof D Secure the bracket with the roofing screw LOCKSOLAR 5 2 Tile Roof Tile Hook Installation The mounting rails are attached to the roof structure using the tile hooks Modifications to tiles are required where the tile hooks will be placed Assembly steps 1 2 Mark the installation points over the centre of the rafters Remove the tile from the roof Locate the position of the tile hook such that the tile hook lies in the valley of the lower tile Ensure that the tile hook is located against the up slope edge of the lower tile The tile hook must mount flush to the rafters and lay flat along the valley face of the lower tile Use the shims provided to ensure the best fit Mount the tile hook to the exposed rafter using the supplied wood screws Use at least 3 wood screws per tile hook When replacing the tile the tile hook must lie flat against the lower tiles If necessary cut recesses into the inner face of the tile to accommodate the tile hook and ensure best watertight fit 5 5 Mounting Rail Installation All Rack in a BoxTM systems arrive with the L Brackets and Tile Hooks pre assembled with the mounting rail attachments in order to save you installation time Assembly steps 1 Attach the mounting rail to the roof brackets as shown 2 Make sure that the ridged side of the rail corresponds with the ridges on the mounting bracket 3 Position the mounting rail at
7. torque of 8Nm Q LOCKSOLAR Rack in a Box 5 8 Mid Clamps Assembly steps for solar module thickness of 35mm to 45mm The mid clamps are preassembled with the fasteners for your convenience Attach the mid clamp to the mounting rail Position the mid clamp firmly against the edge of the solar panel 2 5 4 Turn the bolt to achieve a loose fit 5 Slide the adjoining solar panel along the rail and under the mid clamp 6 Ensure that the mid clamp is tight against the solar modules 7 Tighten the bolt applying a torque of 8Nm Assembly steps for solar module thickness of 45mm to 55mm 1 Disassemble the fasteners from the mid clamp assembly and remove the aluminium spacer tube from around the bolt Reassemble the fasteners to the mid clamp Attach the mid clamp to the mounting rail Position the mid clamp firmly against the edge of the solar panel Turn the bolt to achieve a loose fit Slide the adjoining solar panel along the rail and under the mid clamp Ensure that the mid clamp is tight against the solar modules oN O 1 As WD Tighten the bolt applying a torque of 8Nm LOCKSOLAR Rack in a Box 6 0 SYSTEM COMPONENTS Mounting Rail Tile Hook End Clamp Roofing Screw Mid Clamp Twist Lock Cable Tie Rail Joiner Security Head Screw L Bracket 7 0 STANDARDS Australian New Zealand Wind Loading Standard AS NZS1170 2 2002 Wind load testing performed un
8. aining some pressure rotate clip clockwise to vertical locked position 3 Collect excess cable into loops and bend cable tie tail up to hold in place 4 Push cable tie tail through ratchet head and pull to tighten 5 6 Solar Panel Module Installation WARNING ENSURE YOU FOLLOW ANY OF THE RECOMMENDATIONS AND INSTRUCTIONS OF THE SOLAR PANEL MODULE SUPPLIER IN HANDLING AND INSTALLING THE SOLAR PANEL MODULE FOLLOW THE NEXT INSTRUCTIONS CAREFULLY WHEN INSTALLING THE PANELS CORRECTLY USING THE RACK IN A BOX SYSTEM THE SOLAR PANEL MODULES WILL NOT BE DAMAGED Ensure the solar panels are assembled to the Rack in a Box mounting rails one panel at a time Use a suitable means to prevent the panels slipping from the frame during installation Once installed the mounting clamps will hold the solar panels in place Until the clamps are securely installed the solar panels need to be appropriately secured Q LOCKSOLAR Rack in a Box 5 7 End Clamps Assembly steps L Determine the thickness of your solar panel module 2 Start by assembling the Ist set of end clamps on each of the mounting rails The end clamps are designed to suit a variety of solar panel thicknesses from 35mm to 55mm Set the end clamp to the required height 3 The end clamps come preassembled with the fasteners for your convenience 4 Attach the end clamp to the mounting rail D Tighten the end clamp firmly against the solar panel applying a
9. d structural loadings in accordance with the requirements identified in AS 1170 2 Rack in a BoxTM has been designed to be installed in most areas in Australia where installations are located in Regions A and B These areas include all major city and suburban regions of Sydney Melbourne Brisbane Adelaide Canberra Hobart and Perth See figure 1 for wind areas The terrain surrounding the installation has a major impact on the wind loadings that the installation must withstand If you are intending to use Rack in a BoxTM in Cyclonic regions identified as Region C and D then you will need to purchase Rack in a BoxTM Additional Mounting kits to be used in the installation Please contact your Rack in a BoxTM distributor for more information Region A Normal Region E intermediate Region C Tropical Cyclones Ragion D Severe Tropical Cyclones vw Figure 1 Wind Regions Australia AS 1170 If you are intending to use the Rack in a Box in Cyclonic regions identifed as Region C and D then you will need to purchase Rack in a Box Additional Mounting kits to be used in the installation Please contact your Rack in a Box distributor for more information The terrain surrounding the installation has a major impact on the wind loadings that the installation must withstand The Rack in a Box system can be used in rural locations but in some cases may require you to purchase Rack in a Box Additional Mounting kits to be used in the
10. der AS4040 2 1992 LOGKSOLAR Rack in a Box SECURE e VERSATILE e MOUNTING 8 0 CONTACT DETAILS T 1500 199 235 F 1500 779 882 INT 61 41 99 22 777 E enquiries locksolar com www locksolar com 7 LOCKSOLAR Rack in a Box
11. ges will require engineering verification Please consult your Rack in a Box distributor for further information 4 4 General Installation Notes l Mounting rails should align with the spacing of the battens purlins of the roof The spacing between the mounting rails shall not be less than 5090 of the length of the solar panel modules The mounting brackets L Brackets or Tile Hooks should align with the rafters of the roof structure The mounting brackets L Brackets or Tile Hooks shall be spaced evenly along the length of the mounting rail 2 5 4 D The outer most mounting brackets L Brackets or Tile Hooks shall be located within 200mm of the rail ends Q LOCKSOLAR Rack in a Box 5 0 INSTALLATION When referring to the layout of the solar panel modules and the Rack in a BoxTM system identify the positions of the mounting rails and locate the roof structure for attachment 5 1 Steel Roof L Bracket Installation The mounting rails are attached to the roof structure through the roof sheeting Assembly steps L Mark the installation points and ensure that installation points are located over the centre of the rafters 2 Drill pilot holes in the tin roofing for the roofing screw 3 Use the rubber pad supplied in the Rack in a BoxTM kit under each bracket and over the pilot hole to ensure a watertight connection 4 Align the bracket along the line of the mounting rail with the upright towards
12. installation Please contact your Rack in a BoxTM distributor for more information Q LOCKSOLAR Rack in a Box 4 2 Installation Height Rack in a BoxTM has been designed specifically for single storey and two storey buildings up to a maximum height of 10 metres above ground If you are intending to use Rack in a BoxTM for installations higher than 10 metres above ground level then you may need to purchase Rack in a BoxTM Additional Mounting kits to be used in the installation Please contact your Rack in a BoxTM distributor for more information 4 5 Solar Panel Layout Rack in a BoxTM is a modular system to which a range of solar panel modules can be mounted Rack in a BoxTM clamps the solar panel modules to parallel rails that are aligned with and tied structurally to the existing roof structure Rack in a BoxTM needs to be sited within the perimeter of the roof and no closer to the roof edges than as follows An Array that will locate the solar panel modules closer to the roof edges will require engineering verification Please consult your Rack in a BoxTM distributor for further information Figure 2 Installation Perimeter Zones Distance A edge of panel to roof perimeter must be a minimum of 20 of X and 2090 of installation height Distance B edge of panel to roof perimeter must be a minimum of 2090 of Y and 2090 of installation height Layouts that will locate the solar panel modules closer to the roof ed
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