INSTALLATION MANUAL - Rexel Energy Solutions
Contents
1. Hail Hosemary ile MId Clamp Hail Joiner Twist Lock Gable Tie LOCKSOLAR Rack in a Box Bracket Roofing Screw al i ii cmd 3 E di e ai E ndi Pp oecurity Head Screw 0 CONTACT DETAILS T 0207 256 4159 F 0207 256 4050 E enquiries locksolar com Level 17 Dashwood House 69 Old Broad Street London EC2M 1S UK www locksolar com LOCRSOLAR Rack in a Box SECURE e VERSATILE e MOUNTING Q LOCKSOLAR Rack in a Box2. Installation Height Rack in a Box 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 Box for installations higher than 10 metres above ground level then you may 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 Q LOCKSOLAR Rack in a Box 4 3 Solar Panel Layout Rack in a Box is a modular system to which a range of solar panel modules can be mounted Rack in a Box clamps the solar panel modules to parallel rails that are aligned with and tied structurally to the existing roof structure Rack in a Box 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 Box 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 20 of installation height Distance B edge of panel to roof perimeter must be a minimum of 20 of Y and 20 of installation height Layouts that will locate the solar panel modules closer to the roof edges will require engineering verification Please consult your Rack in a Box di
3. cable into integrated cable slot Note Integrated cable slot will accommodate 2 cables Q LOCKSOLAR Rack in a Box 5 4 2 Twist Lock Cable Ties Assembly steps 1 Position cable tie so that it runs parallel to rail and insert boss into rail clipping groove 2 Maintaining some pressure rotate clip 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 5 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 aBox 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 LOCKSOLAR Rack in a Box 9 6 End Clamps Assembly steps 1 Determine the thickness of your solar panel module 2 Start by assembling the 1st set of end clamps on each of the mounting rails The end clamps are designed to suit a variety of sola
4. ctural design requirements of most worldwide standards 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 RACK IN A BOX SYSTEM BY AN UNQUALIFIED INDIVIDUAL COULD RESULT IN INJURY OR DEATH The installer is solely responsible for e Complying with all applicable local and national building codes e Ensuring that the Rack in a Box and other products used in the installation are appropriate for the particular installation and the installation environment e 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 e 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 e 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 e 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 Q LOCKSOLAR Rack in a Box 2 0 PRODUCT RANGE The Rack in a Box system comes co
5. en 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 9 2 Mounting Rail Installation 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 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 9 3 Joining Mounting Rails Rail Joiner In circumstances where large arrays of solar panels are being installed Rack in a Box provides a means for joining mounting rails The rail joiner does not replace the need for the roofing brackets Hoof mounting brackets must be attached on either side of the joint within a distance of 200mm Assembly steps 1 The rail joiner comes preassembled with fasteners for your convenience 2 Assemble the joiner to the mounting rails ensuring that the joiner spans equally over both rails and that the bolts are located either side of the Joint 3 Tighten the bolts applying a torque of 8Nm 2 LOCKSOLAR Rack in a Box 0 4 Cable Management Features Rack in a Box incorporates a number of cable management features 0 4 1 Integrated Cable Track Assembly steps Push loose
6. nl Q LOCGKSOLAR Rack in a Box INSTALLATION MANUAL LOCI SOLAR Rack in a Box 1 0 INTRODUCTION 2 0 PRODUCT RANGE 2 1 Rack in a Box Systems 3 0 PREPARATION FOR INSTALLATION 3 1 Applications 3 2 Tools for Installation 3 3 Additional Materials for Installation 4 0 PLANNING THE INSTALLATION 4 1 oite Locations 4 2 Installation Height 4 3 solar Panel Layout 4 4 General Installation Notes 9 0 INSTALLATION 92 1 Hle Roof Tile Hook Installation 0 2 Mounting Rail Installation O 3 Joining Mounting Rails Rail Joiner 9 4 Cable Management Features 9 4 1 Integrated Cable Track 0 4 2 Twist Lock Cable Ties 9 0 Solar Panel Installation 9 6 EndGlamps O Mid Clamps 60 SYSTEM COMPONENTS 7 0 CONTACT DETAILS OMO 402000 O1 O10101 AA O Q LOCKSOLAR Rack in a Box 1 0 INTRODUCTION Thank you for choosing Lock Solar for your Solar Mounting requirements Lock Solars Rack in a Box M has been designed specifically for harsh weather conditions and uses the highest quality materials in its construction also providing your customer with unequalled security for their valuable solar investment Rack in a Box can be used in rural areas on hill side and hill top sites and in cyclonic regions by including additional roof brackets in the installation These additional brackets come in Rack in a Box Additional mounting kits to suit Rack in a BoxTM is compliant with the stru
7. nveniently packaged in a box All the components you need to suc cessfully 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 multiple panel installations on a variety of different roof types Each kit comes with 4 rails and enough mounting components to suit most applica tions Product Code Description RIB 2400 1 KW UK Rack in a Box Mounting Kit includes 4 x 2390mm Rails 4 x Joiners 4 x End Clamps 8 x Mid Clamps 5 x Twist Lock Cable Ties 1 x Drill Bit RIB ROSEMARY TILE Rack in a Box Tile Hook for Rosemary Tiles RIB PAN TILE Rack in a Box Tile Hook for Pan Tiles RIB SLATE TILE Rack in a Box Tile Hook for Slate Tiles Q LOCKSOLAR Rack in a Box 3 0 PREPARATION FOR INSTALLATION 3 1 Applications Rack in a Box is designed for installation on residential and commercial buildings in standard marine or remote areas It 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 Box system Cordless drill Grinder with stone disk for tile roof installation only Protective gloves and clothing Lock Solar Security Head Drill Bit supplied with each box Various screw drivers including Phillips head driver oR WMS 3 3 Additional Materials for Installa
8. r panel thicknesses from 32mm 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 torque of 8Nm LOCKSOLAR Rack in a Box O Mid Clamps AY Assembly steps for solar module thickness of 32mm to 45mm 1 The mid clamps are preassembled with the fasteners for your convenience 2 Attach the mid clamp to the mounting rail 3 Position the mid clamp firmly against the edge of the solar panel 4 Turn the bolt to achieve a loose fit D 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 e Heassemble the fasteners to the mid clamp 3 Attach the mid clamp to the mounting rail 4 Position the mid clamp firmly against the edge of the solar panel o Turn the bolt to achieve a loose fit 6 Slide the adjoining solar panel along the rail and under the mid clamp 7 Ensure that the mid clamp is tight against the solar modules Tighten the bolt applying a torque of 8Nm 6 0 SYSIEM COMPONENTS Mounting
9. stributor for further information 4 4 General Installation Notes 1 Mounting rails should align with the spacing of the battens purlins of the roof 2 Ihe spacing between the mounting rails shall not be less than 50 of the length of the solar panel modules 3 The Tile Hooks should align with the rafters trusses of the roof structure 4 All Tile Hooks should be used and shall be spaced evenly along the length of the mounting rail 5 The outer most Tile Hooks shall be located within 200mm of the rail ends 9 0 INSTALLATION When referring to the layout of the solar panel modules and the Rack in a Box system identify the positions of the mounting rails and locate the roof structure for attachment 2 1 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 Mark the installation points over the centre of the rafters trusses e Hemove the tile from the roof 3 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 4 The tile hook must mount flush to the rafters trusses and lay flat along the valley face of the lower tile 9 Mount the tile hook to the exposed rafter using the supplied wood screws Use at least 2 wood screws per tile hook 6 Wh
10. tion Rack in a Box 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 Q LOCKSOLAR Rack in a Box 4 0 PLANNING THE INSTALLATION Rack in a Box has been configured to meet a large percentage of common installation sites around the United Kingdom Additional components are available to extend the performance of the system to suit unusual sites and installations These consist of additional roof brackets that are used to hold the installation to the roof structure Please consult your Rack in a Box distributor for assistance in these situations 4 1 Site Locations Locations in the United Kingdom are subject to different wind structural loadings and Rack in a Box complies in accordance with the requirements of European standards These areas include but are not limited to all major city and suburban regions of England Ireland Scotland and Wales The terrain surrounding the installation has a major impact on the wind loadings that the installation must withstand f you are intending to use Rack in a Box M in Cyclonic regions 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 4 2
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