FLUSH MOUNTED INSTALLATION MANUAL - Sol …sol-distribution.com.au/SOLRACK/Installation...

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FLUSH MOUNTED INSTALLATION MANUAL

V1.0 DECEMBER 2014

SOLRACK INSTALLATION MANUAL

Version 1 (December 2014)

Thank you for choosing the SOLRACK Solar Flush Mounting System.

SOLRACK solar roof mounting system incorporates stainless steel and extruded aluminium

components which combine to form a strong solar panel framing system, adaptable to

numerous types of roof structures.

The rationalization of components through the design of SOLRACK provides ease of ordering

and installation which ultimately saves costs.

SOLRACK Solar Flush Mounting System has been assessed and approved by a chartered

structural engineering company in order to comply with:

AS/NZS 1170.0:2011 – Structural Design Actions Part 0: General Principles

AS/NZS 1170.1:2002 A2-2009 – Structural Design Actions Part 1: Permanent, imposed and

other actions

AS/NZS 1170.2:2011A2-2012 – Structural Design Actions Part 2: Wind actions

AS1664 – Rules for the use of Aluminium in Structures (SAA Aluminium Structures Code)

SOLRACK Solar Flush Mounting System comes with a 10 year warranty and a 5 year finish

warranty.



Table of Contents

INTRODUCTION ............................................................................................................................ 4

INSTALLER’S RESPONSIBILITIES ............................................................................................... 5

PLANNING FOR INSTALLATION .................................................................................................. 7

Step 1: Determine the terrain category ..................................................................................... 7

Step 2: Determine the wind region of the site .......................................................................... 8

Step 3: Determine the height, installation zone and array layout .......................................... 10

Installation Zone................................................................................................................... 10

Array Layout Planning ......................................................................................................... 12

Step 4: Determine the Maximum Flush

Module Leg Spacing .............................................................................................................. 14

Commercial Buildings ......................................................................................................... 14

Residential Buildings ........................................................................................................... 15

Step 5: Determine the type of fasteners and minimum number of fasteners to be used ...... 17

Buildex- Stainless Steel Roofing Fasteners ........................................................................ 17

Fastener Notes:.................................................................................................................... 18

INSTALLATION STEPS ............................................................................................................ 19

Overview of System Components ........................................................................................... 19

Rail Kit Components ............................................................................................................ 19

Installation Tools .................................................................................................................. 20

Installation Instructions ............................................................................................................ 20

Fixing Tile Brackets onto Tiled Roofs .................................................................................. 20

Fixing Rails on Tile Brackets ................................................................................................ 22

Fixing Tin Feet onto Tin Roofs ............................................................................................. 25

Installing Rails on Tin Feet ................................................................................................... 25

Installing Solar Panels on to the Rails ................................................................................. 25

APPENDIX A: SOLRACK Solar Framing System10 year Limited Product Warranty, 5 year

Limited Finish Warranty .............................................................................................................. 28

APPENDIX B: Structural Design Certificate ................................................................................ 29

APPENDIX C: Fastener Pullout Strengths .................................................................................. 30

APPENDIX D: Certified Flush Module Component Drawings .................................................... 31





INTRODUCTION

This manual is designed exclusively for SOLRACK Solar Flush Mounting System.

The manual gives the instructions for a simple and safe installation process. If the installer

adheres to the steps explained in the following sections, SOLRACK Solar Flush Mounting

System will be successfully installed and capable of sustaining the load conditions as

specified in AS/NZS 1170 and AS1664.

SOLRACK Solar Flush Mounting Systems have structural certificates based on the following

conditions. Please ensure all the following conditions are satisfied before proceeding.

Maximum solar panel size = 1.690m x 0.992m

Maximum flush module support spacing to be chosen according to Tables 1-4.

Minimum four support clamps to rail per solar panel.

Solar panels are to be installed on the building roof only.

The terrain is categorized as either 2.5,3 or 4. Please find the details of terrain categories

in Step 1 section.

Wind region to be determined according to Figure 1

Maximum Building Height (h) is 20 m.

Building roof pitch ≥10° to ≤ 30°

Minimum steel purlin thickness to be 1.5mm for commercial applications.

Minimum steel purlin/batten thickness to be 0.75mm for residential applications.

Important Considerations Related to SOLRACK Installation

SOLRACK Solar Flush Mounting System is not responsible from any fault caused by the

installer.

Ensure to carry an inspection of the installation site and the roof space before installation.

Building heights over 20 m are outside the design parameters of this document and

should be analysed and be verified by the Certifying Engineer.

It is strongly recommended that all the connections and fasteners are checked against

failure immediately after a 5 year ARI (Average Recurrent Interval) wind event or annually,

whichever comes first.

SOLRACK carries no responsibility for solar panels/frames certified by others.

304 Stainless Steel should not be used in a marine environment or in an environment

above 50 – 60 0

C with chlorides present. The use of 316 Stainless Steel is recommended



in these conditions.

The manual is not applicable for snow or earthquake loads (AS/NZS 1170.4) and

represents installations designed for wind loads only.

INSTALLER’S RESPONSIBILITIES

Please read the following points carefully before beginning any installation. Take a moment to

familiarize yourself with all system components. During the installation, be sure to observe the

appropriate safety regulations and please pay attention to the relevant regulations of your

local region.

Use only SOLRACK components as specified by the SOLRACK manual. Any substitution

or modification of SOLRACK components may void the warranty certification.

Ensure that the SOLRACK roof mounting system is appropriate for each installation and

the installation environment.

Ensure that the roof rafter/purlin assembly (rafters, purlins, connections and other

structural support members) can support the array under building live and dead load

conditions.

Comply with all current standards that are relevant for each installation (Note: This

document does not include loadings for snow or earthquake loads and represent

installations designed for wind loads only).

Comply with the module manufacturer’s installation procedures.

Maintain the waterproof integrity of the roof, including use of the appropriate flashing.

Ensure all components of the SOLRACK railing system are correctly earthed.

Ensure that all screws have adequate pull-out strength and shear capacity ratings (Read

‘Planning Step 6: Fastener Types’ and ‘Appendix B: Fastener Data’ for guidance).

Ensure that waterproof integrity of the roof is maintained by selecting appropriate flashing

and fasteners.

Ensure that all dissimilar metals are electrically separated to prevent galvanic corrosion.

Ensure that all components on the roof are securely fastened.

Ensure all electrical aspects of the PV array have been safely installed.

Note that this document is prepared on the assumption that the wind loads are the maximum

loads affecting the installation. Please verify that other environmental factors, such as snow

loads, do not constitute a threat for the installations.



Please make sure the roof on which the SOLRACK Solar Mounting System will be installed

have the capacity to resist the combined Dead Load and Live Load of the solar system

components.



PLANNING FOR INSTALLATION

Step 1: Determine the terrain category

Before starting any installation, the terrain category has to be identified as the forces exerted

by the wind on panels vary with terrain category.

In Australia there are 6 different terrain categories specified by AS/NZS 1170:

Terrain Category 1 (TC1): Very exposed open terrain with few or no obstructions.

Limited-sized water surfaces at serviceability and ultimate wind speeds in all wind

regions, e.g. flat, treeless, poorly grassed plains; rivers, canals and lakes; and

enclosed bays extending less than 10 km in the wind direction.

Terrain Category 1.5 (TC1.5): Open water surfaces subjected to shoaling waves at

serviceability and ultimate wind speeds in all wind regions, e.g. near-shore ocean

water; large unenclosed bays on seas and oceans; lakes; and enclosed bays

extending greater than 10 km in the wind direction.

Terrain Category 2 (TC2): Open terrain, including grassland, with well-scattered

obstructions having heights generally from 1.5 m to 5 m, with no more than two

obstructions per hectare, e.g. farmland and cleared subdivisions with isolated trees

and uncut grass.

Terrain Category 2.5 (TC2.5): Terrain with a few trees or isolated obstructions. This

category is intermediate between TC2 and TC3 and represents the terrain in

developing outer urban areas with scattered houses, or large acreage developments

with fewer than ten buildings per hectare.

Terrain Category 3 (TC3): Terrain with numerous closely spaced obstructions having

heights generally from 3 m to 10 m. The minimum density of obstructions shall be at

least the equivalent of 10 house-size obstructions per hectare, e.g. suburban housing

or light industrial estates.

Terrain Category 4 (TC4): Terrain with numerous large, high (10 m to 30 m tall) and

closely-spaced constructions, such as large city centers and well-developed industrial

complexes.



Please note that this manual is only valid for the terrains 2.5, 3 and 4. Please contact Sol-

Distribution if the terrain category is different than these categories.

Step 2: Determine the wind region of the site

The first step in planning an installation is to determine the wind region of the installation site.

If the installation is in Australia or New Zealand, please refer to figure 1: the wind region map

AS/NZS 1170 found in AS/NZS 1170 for Australia.

Wind regions are independent of the building characteristics and the surrounding

topography. Wind Regions C and D are referred to as cyclonic regions and installations in

these regions should be assessed by a structural engineer before proceeding with

installation.

Figure 1. Wind Region Map (Reference: AS/NZS 1170.2:2011)





Step 3: Determine the height, installation zone and array layout

Installation Zone

The height ‘h’, breadth ‘b’ and depth‘d’ of the building is shown in both figure 2 and 3. The

height of the roof is equal to the distance from ground to the mid height of the roof as

illustrated in Figure 2. It is important to obtain engineering advice for buildings over the

maximum height of 20m

The installation zone for the SOLRACK Solar Flush Mounting System can be different

depending on the aspect ratio of the enclosed building. If the building is relatively short and

has aspect ratios h / b ≤ 0.5 and h / d ≤ 0.5, refer to Figure 2. If the building is relatively tall

and has aspect ratios h / b > 0.5 and h / d > 0.5, refer to Figure 3.

Note that‘s’ denotes the gap between the underside of the panel and the roof. S has to be a

minimum of 50mm and a maximum of 300mm.

Figure 2. Roof Installation zone when both h/b≤0.5 and h/d≤0.5



The

installation zone in Figure 3 has an edge zone of a minimum distance of 0.1b and 0.1d.

Installers should generally not install in the edge or corner zones. More information on the

spacing of the rafters and the use of edge zones can be found in the following section.

Figure 3. Installation zone when either h/b>0.5 or h/d>0.5



Array Layout Planning

The purpose of planning the array layout is to ensure that the roof has sufficient space for the

chosen configuration. The available roof area has to be calculated with the following

considerations:

Roof Type (Corrugated metal, tile, klip lok or others)

Purlin or rafter spacing

SOLRACK rail orientation – along the roof or across the roof

Module orientation – portrait or landscape (check Figure 4)

Module height and width

Mid clamp spacing :17mm for each SOLRACK mid clamp

Clamping area for modules (check module manufacturer’s installation manual for

acceptable clamping area)

Shading from nearby obstructions; check any trees or buildings that could potentially

create shading on the solar panels. Try to avoid shading by choosing the roof area which

has minimum risk of shading.

Figure 4 demonstrates the module orientation. Portrait orientation denotes that the short side

of the module is installed parallel to the supporting rail, whereas landscape denotes that the

long side of the module is installed parallel to the supporting rail.



Figure 4. Orientation of the solar panels with respect to the rails



Step 4: Determine the Maximum Flush Module Leg Spacing

Commercial Buildings

Table 1 is used to determine the maximum rail support spacing of the SOLRACK Solar Flush

Mounting System within the middle and end zones of the roof shown in Figure 2 (both h/b≤0.5

and h/d≤0.5).


Mounting System within the middle, inner and edge zones of the roof shown in Figure 3

(either h/b>0.5 or h/d>0.5).

The tables correspond to installation of solar panel of maximum dimensions 1.690m length x

0.992m width with a hold down fastener on each leg with a minimum pull-out strengths of

4.68kN per fastener from 1.5mm thick steel purlin.

(Check Appendix B for pull out strengths for roof fasteners to confirm the fasteners to be

used)

Table 2. Maximum Rail Support Spacing of Flush Mount Modules for portrait and

landscape orientations for commercial applications where either h/b>0.5 or h/d>0.5

Central End Central End Central End Central End

<5m 2200 1700 1500 1100 1000 700 600 400

5 to 10m 2200 1600 1400 900 900 600 500 400

10 to 15m 2000 1400 1200 800 800 600 500 300

15 to 20m 1800 1300 1100 800 700 500 400 300

<5m 2900 2500 2300 1800 1800 1200 1100 700

5 to 10m 2800 2300 2200 1700 1600 1100 1000 700

10 to 15m 2600 2200 2100 1500 1400 1000 800 600

15 to 20m 2500 2100 1900 1300 1300 900 800 500

Portrait

Landscape

Wind Region DOrientation Height

Wind Region A Wind Region B Wind Region C

Middle Inner Edge Middle Inner Edge Middle Inner Edge Middle Inner Edge

<5m 2200 1500 1100 1400 900 700 900 600 400 600 400 300

5 to 10m 2000 1300 1000 1300 800 600 800 500 400 500 300 200

10 to 15m 1800 1200 900 1100 700 500 700 500 300 400 300 200

15 to 20m 1700 1100 800 1000 700 500 700 400 300 400 300 200

<5m 2800 2300 1900 2200 1600 1200 1600 1100 800 1000 600 500

5 to 10m 2700 2200 1700 2100 1400 1100 1500 1000 700 900 600 400

10 to 15m 2500 2100 1500 1900 1300 900 1300 900 600 800 500 400

15 to 20m 2400 1900 1400 1800 1200 900 1200 800 600 700 500 300

Wind Region C Wind Region D

Portrait

Landscape

Orientation HeightWind Region A Wind Region B

Table 1.Maximum Rail Support Spacing of Flush Mount Modules for portrait and landscape orientations for commercial

applications where both h/b≤0.5 and h/d≤0.5



Residential Buildings


Mounting System within the middle and end zones of the roof shown in Figure 2 (both h/b≤0.5

and h/d≤0.5).


Mounting System within the middle, inner and edge zones of the roof shown in Figure 3

(either h/b>0.5 or h/d>0.5).

The tables correspond to installation of solar panels of maximum dimensions 1.690m length x

0.992m width with a hold down fastener on each leg with a minimum pull-out strengths of

2.86kN per fastener from 0.75mm thick steel purlin.

(Check Appendix B for pull out strengths for roof fasteners to confirm the fastener to be

used).

Table 4. Maximum Rail Support Spacing of Flush Mount Modules for portrait and

landscape orientations for residential applications where either h/b>0.5 or h/d>0.5

Please note that the rail end overhang must not be greater than 33 percent (one third of

support spacing) of the Flush Mount System support spacing i.e. if the support spacing is

1200mm, the rail end over hang can be up to 400mm (1200/3 = 400mm)

Please ensure that the roof pitch where the SOLRACK Solar Flush Mounting System to be

installed is within 10 to 300

.

Central End Central End Central End Central End

<5m 1500 1000 900 600 600 400 400 200

5 to 10m 1300 900 800 600 500 400 300 200

10 to 15m 1200 800 700 500 500 300 300 200

15 to 20m 1100 800 700 500 400 300 200 200

<5m 2600 1800 1600 1100 1100 700 600 400

5 to 10m 2300 1600 1400 1000 1000 700 600 400

10 to 15m 2100 1400 1300 900 800 600 500 300

15 to 20m 1900 1300 1200 800 800 500 500 300

Wind Region D

Portrait

Landscape

Orientation HeightWind Region A Wind Region B Wind Region C

Middle Inner Edge Middle Inner Edge Middle Inner Edge Middle Inner Edge

<5m 1400 900 700 800 500 400 600 400 300 300 200 100

5 to 10m 1200 800 600 700 500 300 500 300 200 300 200 100

10 to 15m 1100 700 500 700 400 300 400 300 200 200 100 100

15 to 20m 1000 700 500 600 400 300 400 200 200 200 100 100

<5m 2400 1600 1200 1500 1000 700 1000 600 500 600 400 300

5 to 10m 2100 1400 1000 1300 900 600 900 600 400 500 300 200

10 to 15m 1900 1200 900 1200 800 600 800 500 400 500 300 200

15 to 20m 1700 1100 800 1100 700 500 700 500 300 400 300 200

Wind Region D

Portrait

Landscape

Orientation HeightWind Region A Wind Region B Wind Region C

Table 3. Maximum Rail Support Spacing of Flush Mount Modules for portrait and landscape orientations for residential

applications where both h/b≤0.5 and h/d≤0.5





Step 5: Determine the type of fasteners and minimum number of fasteners to be used

Tables 5 and 6 determine the correct fasteners to attach the Flush Mount Module to the roof

supports: Timber rafter or truss 0.75mm thick steel purlin/batten for residential applications. A

minimum 1.5mm thick steel purlin or truss for commercial applications. The length of the

fastener will vary according to the roofing profile; however the 65mm length is applicable for

most installations.

Table 5. Dual point for timber and steel drilling (min 1.5mm thick steel purlin-max

2.00mm thick steel purlin)

Table 6.Steel drilling point (above 2.0mm thick steel)

Buildex- Stainless Steel Roofing Fasteners

Table 7. Buildex for use within 1000m of the coast into steel purlins (min 0.75mm thick

steel purlin- max 2.0 mm thick steel purlin)

Table 8. Buildex for use within 1000m of the coast into timber rafters/trusses (min 1.5mm

thick steel purlin- max 2.0 mm thick steel purlin)

C14-14125-D4Z Dual 14 14 125mm Class 4

C14-14150-D4Z Dual 14 14 150mm Class 4

Code Point Gauge TPI Length Finish

C14-1465-D4Z Dual 14 10 65mm Class 4

C14-1050-S4Z SD 14 10 50mm Class 4

C14-1025-S4Z SD 14 10 25mm Class 4

C14-20150-S4Z SD 14 20 150mm Class 4

C14-10100-S4Z SD 14 10 100mm Class 4

C14-10125-S4Z SD 14 20 125mm Class 4

C14-1070-S4Z SD 14 10 70mm Class 4

C14-1080-S4Z SD 14 10 80mm Class 4

Code

C14-1025-S4Z

Point

SD

Gauge

14

TPI

10

Length

25mm

Finish

Class 4



Fastener Notes:

Minimum embedment length into timber to be not less than 36mm.

Never set drill on impact when installing screws, as this will void fastener warranties.

Use Dual Point screws up to 2.0mm thick steel purlins or rafters.

Use Steel Point screws over to 2.0mm thick steel purlins or rafters.

Use Stainless Steel screws within 1000m of the coast.

Use a Minimum 1 off 14gx10 TPI (T17s) roofing fasteners per support leg to a minimum

0.75mm thick steel purlin/batten or pine/ hardwood timber for a residential application.

Use a Minimum 1 off 14gx10 TPI Teks roofing fasteners per support leg to a minimum

1.5mm thick steel purlin for commercial building.



INSTALLATION STEPS

Prior to the installation, ensure that the roof offers sufficient space for the chosen layout. It

should be helpful to include the following considerations when planning the array layout:

Number of modules in the vertical direction x module height (always check the module

manufacturers installation manual)

Number of modules in horizontal direction x (module width + 18 mm) + 32 mm

Distance between modules: 17 mm as per mid clamp.

Spacing between the modules and the roof edges as specified in figure 2 and figure 3.

Overview of System Components

Rail Kit Components

Figure 5. SOLRACK Solar Flush Mounting Kit Components



Installation Tools

Installation Instructions

Fixing Tile Brackets onto Tiled Roofs

Mark the installation points along the center of the rafters according to the installation

plan.

Remove the roof tiles at the installation points or slightly lift them up if possible

Ensure that tile brackets are aligned with the rafters.

Fix the tile brackets to the rafter using a minimum of two 6.3mm x 60 mm wood screws

Tighten the screws to the brackets

Figure 6.Fixing the tile brackets onto the tile roof

6mm Allen Key

Cordless Drill

Open End Spanner set; 9,10,17,19mm (required only for

mounting with roof screws)

Torx- 30 (AW 30) Bit

Angle Grinder with Stone Disk

Power Cord

Timber to shim the tile brackets (if necessary)

Gloves for handling framing



Ensure the tile bracket does not press against the roof tile. Shim the tile bracket with wood

if necessary.

Figure 7. Make sure that the tile bracket does not press against the roof tile

Use an angle grinder or hammer to cut a recess in the tile bracket, so that the tile lies flat

on the surface. If grooved tiles are used, it will also be necessary to cut a recess in the

lower tile.

Figure 8. Make sure that the tile lies flat on the surface

Never push against the fitted tile brackets or use the tile brackets as a ladder such that

extreme point load might cause damage to the tiles and tile brackets.

Figure 9. Never push against the tile bracket or use it as a ladder



Make sure to cut a recess around the position of the tile bracket for the roofs with plain tile

roof cladding

Figure 10. Make sure to cut the recess around the tile bracket

A titanium zinc metal sheet must be cut to fit on site, with an overlap of at least 20 mm

around the recess, and installed under the tile brackets.

Figure 11. Install a titanium zinc metal sheet under the tile brackets

Fixing Rails on Tile Brackets

Position the G Module in the rail channel and fasten it loosely with 2 or 3 turns of the

screw such that the screws can still be able move in the rail channel.

Slide the screws to their final position in connection with the mid clamp, end clamp or tile

brackets/ roof screws and fasten firmly.

Figure 12. Positioning the G Modules



Install the rails for each row of modules loosely on the tile brackets using an M8 x 25mm

Allen bolt, washers (2 to 3 turns of the screw)

When working with different rail lengths, always begin with the shortest piece.

Adjust the vertical and horizontal position of the rail to an optimum by using the long hole

in the tile bracket and the loose connection of the G Modules.

Figure 13. Slide the rails on the tile brackets through the G modules and adjust the

horizontal and vertical position

Determine if extended rails need to be used according to the installation plan. Connect

rails via splice connector.

Figure 14. Connecting the rails via splice connector

Position the first frame rails for each row and fasten them temporarily to the roof cladding.

Position the earth lugs on each rail by sliding G module through the rail.

Draw the earth cable through the earth lugs and tighten it up using the bolts attached to

the earth lugs



Figure 15. Attaching earth lugs on rails and drawing earth cables through



Apply the same steps for each row of rails and make sure the rails are positioned

according to the planned layout.

Tighten the Allen bolts and the nuts

Figure 16. Apply the same steps for the other rows of rails

Fixing Tin Feet onto Tin Roofs

Tin feet is used for corrugated iron and sheeted roof

Make sure that the screw head tightly fastens the sealing washer without damaging the

roof cladding or water proof roof membrane.

Ensure that the thread of the roof screw does not cover the long hole in the tin foot.

Figure 17. Tin feet installation for corrugated iron roof

Installing Rails on Tin Feet

Apply the same steps in the section ‘Fixing Rails on Tile Brackets’

Installing Solar Panels on to the Rails

Add anti slip protection to the lowest row of modules by fastening M6 x 20 mm bolts to

the lower mounting holes of the module frame using M6 nuts.



Place the first module of the bottom row so that anti-slip protection sits in the rail channel

of the lowest row of rails.

Figure 18. Add Anti Slip Protection and make sure the slip protection sits in the rail

channel

Slide the module end clamp firmly against the module and fasten tightly using the

Allen key.

Figure 19. Slide the module end clamp firmly against the module and fasten tightly using

the Allen bolt

Ensure to place earth washers to each mid clamp.

Slide the mid clamp into the rails from above, place it firmly against the module and

fasten loosely.

Slide the next module against the previously installed module and tighten the mid

clamp using the Allen key. Ensure that the anti-slip protection sits in the rail channel.



Figure 20. Slide the preassembled inter module clamp then tighten the two modules

using the Allen key

Position the last module of the row in the base rail ad fasten the module using the

module end clamp.

Slide the first module of the next row above the corresponding lower rail. Continue

mounting the module as described in the above steps until all modules are installed.

Test both rails for end to end continuity to ensure that the entire frame is correctly

earthed.

Figure 21. Fasten the last module of the row by using the end clamp and repeat the

steps for the next row



APPENDIX A: SOLRACK Solar Framing System10 year Limited Product

Warranty, 5 year Limited Finish Warranty

SOLRACK warrants to the original purchaser of the SOLRACK framing system that the

framing components at the original installation site shall be free from defects in material and

workmanship for a period of ten years with the exception of the anodized finish, which shall

be free from visible peeling, cracking or chalking under normal atmospheric conditions for

a period of five (5) years, from the earlier of the date the installation of the Product is

completed, or 120 days after the purchase of the Product by the Purchaser (“Finish

Warranty”).

The Finish Warranty does not apply to any foreign residue deposited on the finish. All

installations in corrosive atmospheric conditions are excluded. The Finish Warranty is VOID if

the practices specified by AAMA 609 &

610-02 – “Cleaning and Maintenance for Architecturally Finished Aluminum” are not followed

by Purchaser.

This Limited Warranty shall be VOID if installation of the Product is not performed in

accordance with the SOLRACK written installation manual, or if the Product has been

modified, repaired, or reworked in a manner not previously authorized by SOLRACK, or if the

Product is installed in an environment for which it was not designed. SOLRACK shall not

be liable for consequential, contingent or incidental damages arising out of the use of the

product by purchaser under any circumstances.

If within the specified warranty period the product shall be reasonably proven to be

defective, then the defective product shall be repaired or replaced, or any part thereof, at

SOLRACK sole discretion. Such repair or replacement shall completely satisfy and

discharge all of SOLRACK’s liability with respect to this limited warranty. Under no

circumstances shall SOLRACK be liable for special, indirect or consequential damages

arising out of or related to use by Purchaser of the Product.

SOLRACK’s limited Warranty covers only its solar framing product and not any related items.

For warranty service claims, please contact SOLRACK technical support team at:

[email protected].



APPENDIX B: Structural Design Certificate

Date of Issue: 16/10/2014 3:51 PM

Plant Description: Solar Flush Mount system solar panel mounting structure with SR-03 Light and roof fasteners. Client/Owner:

- Sol Distribution Pty Ltd Site Address: Locations throughout Mainland Australia (Wind Regions A, B, C and D as Per AS/NZS 1170.2:2011). Drawings and Documentation Included in this Certificate:

- The following drawings supplied by Sol Distribution Pty Ltd and nominated in the table below are included in this structural certification for the solar assembly.

Table 1: Certified Drawings

NOTE – The Client shall hold all Material Test Certificates for future reference and subsequent design changes.

The Design was carried out based on the following Standards:

AS/NZS 1170.0:2011 – Structural Design Actions Part 0: General Principles AS/NZS 1170.1:2002 A2-2009 – Structural Design Actions Part 1: Permanent, imposed and other actions AS/NZS 1170.2:2011A2-2012 – Structural Design Actions Part 2: Wind actions Exclusions

Solar Panel/Frame certified by others. Earthquake Code (AS/NZS 1170.4) not considered - Solar panel is not a major building structure. Set-up, instruction and installation manual. 304 Stainless Steel should not be used in a Marine environment or in an environment above 50 – 60 0C with

chlorides present. The use of 316 Stainless Steel is recommended in these conditions. This certification does not include loadings for snow or earthquake loads and represent wind loads only.

STRUCTURAL DESIGN CERTIFICATE – No: CSM-SC052-2014 Job No: 14S-385

Solar Flush Mount System PC No. Part Name Model / Drawing No.

1. Rail / Roof Hook SFS-SR-03 2 G-Module SR-SP-SF S2 V1.1 3 L Feet SR-SP-SF S3 V1.0 4 Mid Clamp SR-SP-SF S4 V1.0 5 End Clamp SR-SP-SF S1 V1.0 6 L- Connecting SR-SP-SF S8

Page 2 of 3

CSM Group Pty Ltd

Specification of this Structural Certificate Maximum Solar Panel Size = 1.690m x 0.992m. Maximum flush Module support Spacing as per Tables 5.1 through 6.4. Minimum four support clamps to rail per Solar Panel. Solar Panels to be installed on the building roof only. External wind uplift and internal positive wind pressures are considered. Wind Region A, B, C & D has been considered (Refer Tables 5.1 through 6.4). Regional wind speed for 500 year ARI. Building Height (h) conditions based on Terrain Categories except terrain categories TC1, TC1.5 and TC2. Maximum Building Height (h) is 20 m. Maximum roof pitch shall be 10⁰- 30⁰. Minimum Steel Purlin thickness to be 1.5mm for Commercial applications. Minimum Steel Purlin/batten thickness to be 0.75mm for Residential applications.

Details of the Design

Maximum Solar Panel Size : 1.690m x 0.992m

Building Roof Pitch : 10° - 30⁰

Australian Terrain Category : Terrain Categories 2.5, 3 and 4

Wind Region : A, B, C & D (Refer Tables 5.1 through 6.4)

Mounting Conditions onto Rails : Rail fastened to Flush Mount Leg then onto the roof purlins atmaximum spacing as per Tables 5.1-5.4 & Tables 6.1-6.4

Maximum rail support spacing : As per Tables 5.1-5.4 (Commercial) & Tables 6.1-6.4 (Residential)(Based on a maximum pullout force per support leg)

Mounting Conditions onto Solar Panels : Four clamping positions per solar panel back to rails andTwo rails per panel

Minimum purlin thickness for Commercial applications : 1.50mm

Minimum purlin/batten thickness for Residential applications : 0.75mm

Design life of structure : 20 years

CSM group has not carried out any inspection of any installed plant being completed, thus this Certificate Does Not cover Inspection of the plant for each site location.

However, specific building heights over 20m are outside the design parameters within this document and should be specially analysed and be verified by the Certifying Engineer.

It is strongly recommended that all the connections and fasteners should be checked against failure or corrosion immediately after a 5 year ARI wind event or annually, whichever comes first.

The roof on which the solar assembly is to be installed must have the capacity to resist the combined dead and live loads per support clamp.

Page 3 of 3

CSM Group Pty Ltd

If manufactured, constructed and installed in accordance with the abovementioned drawings, specifications, details of the design and OEM Installation Manual, the support structure will be capable of sustaining the load conditions as specified in the Australian standards AS1170.2-2012 and AS1664.

Certifying Engineer

Signature Date: 16/10/2014

Bruce Delahunty Senior Civil/Structural Engineer MIE Aust (Civil/Struct) 3786934BEng, MEng, CPEng, NPER, RPEQ 12227



APPENDIX C: Fastener Pullout Strengths

Page 11 of 21

CSM Group Pty Ltd

Page 12 of 21

CSM Group Pty Ltd



APPENDIX D: Certified Flush Module Component Drawings

Distribution Centre Unit 14, 39 Herbert Street St Leonards NSW 2065

Perth Warehouse Unit 1, 25 Trade Road Malaga WA 6090

Phone 1300 660 483 02 8424 3830

Fax 1300 660 370

Email [email protected]

sol-distribution.com.au

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