DPA Solar - Roof Mount Installation Guide V1 · 2018-04-18 · 4. Install Panels Follow the instructions below. (i) Install an end panel first using 2 x end clamps. Tighten nuts to

DPA Solar Racking Solutions

Roof Mount Installation Guide V1.4d

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Roof Mount Installation Guide V 1.4d

Contents

Introduction...................................................................................................................................3Planning..........................................................................................................................................4InstallationSteps..........................................................................................................................10

1. Planning/Layout........................................................................................................................................102a. TileRoofInstallation...................................................................................................................................112b. TinRoofInstallation....................................................................................................................................123. InstallRails/Splices....................................................................................................................................134. InstallPanels...............................................................................................................................................14

Grounding&CableClips...............................................................................................................15

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Introduction DPA Solar racking when installed in accordance with this guide and applicable building regulations will be structurally adequate and meet the requirements of AS/NZS1170.

It is important to note that the installer is responsible for the following:

• Complying with all applicable local or national building codes, including any that may supersede this manual;

• Complying with all electrical, health and safety and other applicable regulations as applicable to the location;

• Ensuring that DPA Solar racking and other products are appropriate for the particular installation and the installation environment;

• Ensuring that the roof, its rafters, connections, and other structural support members can support the array under building live load conditions;

• Ensuring that all screws and fixings have adequate pullout strength and shear capacities as installed and are installed in accordance with applicable standards;

• Ensuring that loads other than wind are considered in the design. This document addresses only wind loads on the assumption that wind produces the maximum load factor affecting an installation. Verify that other local factors, such as snow loads and earth quake effects, do not exceed the wind loads.

• Maintaining the waterproof integrity of the roof, including selection of appropriate flashing;

• Fitting galvanic isolation where required to protect against dissimilar metals corrosion; and

• Ensuring safe installation of all electrical aspects of the PV array.

This product is Warranted to be free from defective material and workmanship for a period of 10 years. Please contact DPA Solar for full warranty details.

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Planning Wind regions as defined by Australian Standard 1170 are as follows and illustrated in Figure A:

• Most of Australia is designated Region A which indicates a Regional Ultimate Basic Wind Velocity of 45m/sec.

• Some areas are designated Region B (57m/sec). Local authorities will advise if this applies in your area.

• Region C areas (66m/sec) are generally referred to as Cyclonic and are generally limited to northern coastal areas. Most Region C zones end 100km inland.

• Region D (80m/sec) Australia's worst Cyclonic Region between Carnarvon and Pardoo in Western Australia.

This document applies to installations in regions A, B & C (wind classifications C1 – C3) at roof heights of up to 10m (three storeys). Region D sites require individual analysis and design.

Figure A: Wind Regions

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Terrain Categories are defined by Australian Standard 1170 into Categories 1, 2, 3 and 4. Category 1, is the most exposed, associated with large open areas, such as airports or large fields. Category 4, is the most protected, associated with High density metropolitan, city buildings. This installation guide is applicable to Terrain Categories as low as 2.5, hence no greater exposure than the following scenarios, are allowed:

• Level wooded country / forests

• Centres of small towns, suburban areas

• High density metropolitan, city buildings

The wind force on the roof is dependant on the height of the roof. This factor is Mz,cat, as defined by AS1170. To simplify different roof heights, single storey (height<4m), double storey (height<7m), triple storey (height<10m), groups have been adopted. The roof height is measured from natural ground level to the centre between ridge and eave. Other multipliers such as Mt (topograghy) and Ms (shielding) have been adopted as 1.0. If topography is such that Mt >1.0, spacings should be re-calculated, as those listed may not be sufficient. If shielding is available, then Ms will only reduce, and the spans listed will become conservative.

The wind force on the roof is also dependant on the roof pitch (angle). The following tables, are based on different angles (interpolation is allowed). The roof cladding is not a function of the wind force applied to the roof. Tin roofs can be as low as 1 deg. Tiled roofs are limited to no less than 15deg. Hence the tables, list options for 1-10,15,20,25,30-45 degrees. An Exclusion Zone exists due to high localised wind pressures at roof ridges and edges. Solar panels should not be installed in the exclusion zone where possible. If it is necessary to install solar panels in the exclusion zone, then refer to especially listed distances between rail supports for the length of rail that is within the exclusion zone. For roofs with pitch 10degrees or less (tin), there is less overall force at the exclusion zone near the ridge, as the basic wind force reduces along the length of the roof. As the wind load co-efficients and exclusion zone are a function of h and d, it should be noted that the following tables are also organized by (d<h) and (d>2h). For values in between, interpolation is allowed. Breadth is generally not critical. Generally speaking, the (d<h) value is appropriate for tall skinny buildings, and the (d>2h) value is appropriate for low level construction. The Exclusion Zone (marked as DIST in the diagram below) is defined as the minimum of:

• 0.2d

• 0.2b

• h

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Region C Wind Classifications Properties within Region C are allocated a wind classification based on a number of factors. These are defined in AS4055 and summarised in the tables in Figure B. All installations at sites with a wind classification of C2 or C3 must be calculated using the “DPA Solar Racking Worksheet” (Excel). Wind classification C4 is not covered. The Region C table at Figure E may be used for wind classification C1.

Figure B: Region C Wind Classifications Figures C-E specify the maximum spacing between rail supports for tile or tin roof installations. Maximum panel dimensions are 1650mm x 1000mm and weight 22kg. For other panel sizes, refer to the “DPASolar Racking Worksheet” (Excel). Note that Figures C-E assume F5 pine or better roof construction. For Zone C it is possible to specify higher grades of construction material using the “DPASolar Racking Worksheet”.

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Rail Support Spacing – REGION A

Installation PITCH Edge Central Ridge

Single storey 1-10 (d<h) 900 1200 900

1-10 (d>2h) 1200 1200 1200

15 (d<h) 900 1200 900

15 (d>2h) 1200 1200 1200

20 (d<h) 1200 1200 1200

20 (d>2h) 1200 1200 1200

25 (d<h) 1200 1200 1200

25 (d>2h) 1200 1200 1200

30-45 (d<h) 1200 1200 1200

30-45 (d>2h) 1200 1200 1200

Double storey 1-10 (d<h) 900 1200 900

1-10 (d>2h) 1200 1200 1200

15 (d<h) 900 1200 900

15 (d>2h) 1200 1200 1200

20 (d<h) 1200 1200 1200

20 (d>2h) 1200 1200 1200

25 (d<h) 1200 1200 1200

25 (d>2h) 1200 1200 1200

30-45 (d<h) 1200 1200 1200

30-45 (d>2h) 1200 1200 1200

Figure C: Support Spacing for Region A

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Rail Support Spacing – REGION B


Single storey 1-10 (d<h) 300 900 300

1-10 (d>2h) 600 900 600

15 (d<h) 600 900 600

15 (d>2h) 600 1200 600

20 (d<h) 600 1200 600

20 (d>2h) 900 1200 900

25 (d<h) 900 1200 900

25 (d>2h) 1200 1200 1200

30-45 (d<h) 1200 1200 1200

30-45 (d>2h) 1200 1200 1200

Double storey 1-10 (d<h) 300 900 300

1-10 (d>2h) 600 900 600

15 (d<h) 600 900 600

15 (d>2h) 600 1200 600

20 (d<h) 600 1200 600

20 (d>2h) 900 1200 900

25 (d<h) 900 1200 900

25 (d>2h) 1200 1200 1200

30-45 (d<h) 1200 1200 1200

30-45 (d>2h) 1200 1200 1200

Figure D: Support Spacing for Region B

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Rail Support Spacing – REGION C (wind classification C1)


Single storey 1-10 (d<h) 300 600 300

1-10 (d>2h) 300 600 300

15 (d<h) 300 600 300

15 (d>2h) 600 900 600

20 (d<h) 600 900 600

20 (d>2h) 600 900 600

25 (d<h) 600 900 600

25 (d>2h) 900 1200 900

30-45 (d<h) 900 1200 900

30-45 (d>2h) 900 1200 900

Double storey 1-10 (d<h) 300 600 300

1-10 (d>2h) 300 600 300

15 (d<h) 300 600 300

15 (d>2h) 600 900 600

20 (d<h) 600 900 600

20 (d>2h) 600 900 600

25 (d<h) 600 900 600

25 (d>2h) 900 1200 900

30-45 (d<h) 900 1200 900

30-45 (d>2h) 900 1200 900

Figure E: Support Spacing for Region C (wind classification C1)

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Installation Steps

The following pages specify the installation steps to be followed for mounting to tin and tile roofs.

1. Planning / Layout Determine the position of the roof hooks / L-feet according to the design requirements specified below and in the preceding tables.

A = refer to Tables C-E

B = approximately 60% of panel length (allow 20% panel overhang past each rail)

C = 375mm maximum overhang

A

B

C

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2a. Tile Roof Installation Follow the steps below for a tile roof installation.

(i) Remove the roof tiles at the required positions or lift them up slightly.

(ii) Fix the roof hook to the roof structure using 2 x Type 17 screws. Ensure minimum 50mm penetration.

The installation of the screws must be in accordance with applicable regulations.

(iii) Replace the tile, ensuring that the roof hook does not press against the roof tile. If required shim the roof hook with a spacer or grind the roof tile.

It is important not to use an installed roof hook as a ladder.

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2b. Tin Roof Installation Follow the instructions below for a tin roof installation.

(i) Install the L-feet using the supplied roofing screws.

Isolator is installed between the L-foot and roof to prevent corrosion.

(ii) Ensure that there is adequate penetration of the screw into the roof timber (minimum 50mm penetration using a Type 17 screw).

Take care not to crush or damage the roofing material by over-tightening the screw.

The installation of the screw must be in accordance with applicable regulations.

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3. Install Rails / Splices Follow the instructions below for a tin roof installation.

(i) Connect the roof hook or L-foot to the rail as indicted. Tighten the nut 10 Nm to secure the rail.

(ii) Install splices between rails that form a single run. Up to 30mm spacing is permitted between rails at the splice if required (ensure the gap is centered in the splice).

(iii) Completed rail installation.

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4. Install Panels

Follow the instructions below.

(i) Install an end panel first using 2 x end clamps. Tighten nuts to 10 Nm.

(ii) Continue along the row installing additional panels using 2 x mid clamps between each adjacent panel. Tighten nuts to 10 Nm.

Complete the row using 2 x end clamps.

(iii) Install additional rows as required to complete the system.

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Grounding & Cable Clips

The available grounding components are listed below. Installation details are provided on the following page. Cable clips are also available to assist with cable management.

Following installation of any grounding components, the installer must ensure continuity through testing.

IMPORTANT NOTE: Bonding jumpers and grounding clips must be installed as panels are installed. They cannot be fitted once panels are in place.

Item Part No. Description

Grounding Clip

DR2-G-GC Stainless steel

Grounding Lug

DR2-G-GL Stainless steel and aluminium

Cable Clip #1

DR2-A-PC01 Clips into rail. Accepts 2 x 4.0 sqmm PV cables.

Cable Clip #2

DR-FSC-CP2 Clips onto panel frame. Accepts 2 x 4.0 sqmm PV cables.

Bonding Jumper

DR2-G-BJ Provides conductivity between rails.

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Grounding Clip Installation: For correct installation, each panel should have at least 4 x teeth embedded (each clip has 4 teeth). See images to the right for the number of clips for even and odd panel configurations.

Tighten clamps to approximately 10 Nm to ensure that teeth fully embed into anodizing to complete a circuit. Grounding clips are single use (cannot be re-used after installation).

Grounding Lug Installation: Install 2 Grounding Lugs at the end of each line of rails and wire to the ground connection for the installation.

Bonding Jumper Installation: Bonding jumpers are installed adjacent each splice as shown, to provide continuity between rails.

NOTE:

Bonding jumpers are not required if other means are in place to ensure continuity between rails.

An alternate arrangement using grounding clips is to install additional grounding clips on the solar panels that cover each rail connection/splice, providing continuity between the rails via the panel frame.

Documents

DPA Solar - Roof Mount Installation Guide V1 · 2018-04-18 · 4. Install Panels Follow the instructions below. (i) Install an end panel first using 2 x end clamps. Tighten nuts to