antai pitched roof installation version 3.2-001 · as/nzs1170.2:2011 - 7 - 5. components t mounting...
TRANSCRIPT
AS/NZS1170.2:2011 - 1 -
www.fastensolar.com
AS/NZS1170.2:2011 - 2 -
Contents
Chapter Title Page
1 General information 3
2 Safety and Installer Responsibilities 4
3 Technical Specifications 5
4 Tools for Installation 6
5 Components List 7
6 System overview 8
7 Planning the Layout 9
8 Code‐compliant the AS/NZS1170.2:2011 installation planning 10
9 Installation 13
10 Warranty 20
AS/NZS1170.2:2011 - 3 -
1. General information
Fastensol Pitched Roof Mounting Systems
Fastensol Roof Mounted solution, accommodating a wide range of modules, is suitable for most type of
roof. With innovative T‐Rail and T module, enables significantly faster, easier installations, which has been
developed into one of the most versatile mounting solutions in the world, delivering time and cost
effective experience to solar system installers.
Mounting Rail
Easy to be installed
Figure 1: Tilt in the module and easy to be installed
Fastensol Mounting system features series of highly engineered new innovative product, designed with
experienced engineers to the speed of installation.
Fastensol pitched roof solar mounting system is backed by a 10 years warranty and is compliant with
AS/NZS1170.2.2011.
AS/NZS1170.2:2011- 4 -
2. Safety and Installer Responsibilities
2.1 Handling and Installing Fastensol ››»
It is critically important that safety practices are observed when
installing
Do not throw or roughly handle any Fastensol components.
Do not bring Fastensol system into contact with sharp or heavy objects.
Do not modify Fastensol 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 Fastensol components is fixed. Roofs or structures with rotten/rusted bearers, undersized bearers, excessively spaced bearers,
or any other unsuitable substructure cannot be used with Fastensol components, and installation on such structures will void the warranty,
and could result in death or serious injury.
2.2 Wind and Climate Design
Fastensol provides guidance on determining the wind pressures
applicable to your install site, taking into account roof shape and
geographic location.
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 ix 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
Fastensol system order.
Caution
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.
AS/NZS1170.2:2011 - 5 -
3. Technical Specifications
3.1 Applications
Commercial and residential buildings
Marine applications and remote areas
3.2 Features
6005‐T5 Aluminum extrusion
Innovated designed of the Tilt‐in modules, which can be pre‐assembly
with the clamp, make the installation easy and quick.
Suitable for difference conditions and the most solar panels at present
market.
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
Anodized finish
3.3 Material
Material Tensile strength
Ultimate Yield
6005‐T5 Aluminum
Extruded 260 MPa 240 Mpa
Stainless Steel 304 625.55 Mpa 263.8 Mpa
Stainless Steel A2‐70 700 MPa 450 Mpa
3.4. Installation condition
Static calculation according to DIN 1055:2005 with the following
limitations
Roof slope 0° to 60°
Building height Up to 20m
Mounting structure Timber
Roof types Flat or pitched steel and tile
System angle Flushed with the roof
■ Note: if the condition is over the table list, please contact us to confirm.
Caution
Refer to the
section
“Designing Your
System” before
attempting
installation.
Failure to
correctly
establish the
requirement of
the proposed
installation site
is dangerous
and will void
the framing
warranty.
AS/NZS1170.2:2011 - 6 -
4. Tools for Installation
The following tools are required for the installation:
6 mm Allen key or hexagonal driver bit.
If using a 6mm driver bit, make sure the
cordless power tool used for the driving has
a hand‐tight clutch setting a fine (soft)
impact drive to prevent damage to the
fragile glass panels and threads on the
Structure.
Cordless drill;
Drill or impact driver for driving roof
material fixings
Angle Tinder;
For terracotta tile roof installation, and
angle Tinder fitted with a continuous edge
diamond tipped tile0cutting blade; gloves,
hearing protection, a face protection mask,
and a suitably rated breathing protection
mask for all people in proximity of grinding
Gloves;
Protect the hazard of the sharp corners.
Cord or color pen;
Mark the installation position;
Spirit level
Rule
If necessary, timber to shim the roof hooks
AS/NZS1170.2:2011 - 7 -
5. Components
T mounting rail
√ length can be customized
√ 6005‐T5 extruded aluminum
√ 2560,3400mm for 808‐826mm module
√ 3200,4200mm for 990‐1020mm module
Rail Splice Kit
√ Fastened with a 6mm Allen key
Mid Clamp Kit
√ Thickness 30,35,40,46,50,57mm
√ Fastened with a 6mm Allen key
End Clamp Kit
√ Thickness 30,35,40,46,50,57mm
√ Fastened with a 6mm Allen key
L Feet Bracket
√ EPDM rubber pad
√ 1pc st6.3x85 screw
Tile Roof Hook
√ 3pcs st6.3x85 screw
Klip‐lok 406 & Klip‐lok 700 Clip
√ EPDM rubber pad
AS/NZS1170.2:2011 - 8 -
6. System overview
All components of the system are listed below. The version and quantities of the parts can vary, depending
of
● Type of roof ● Type of module
● Number of modules ● Installation site
AS/NZS1170.2:2011 - 9 -
7. Planning the array layout
Figure 2 Planning the array layout
1. Array height = number of modules in the vertical direction x module height
2. Array width = Number of module in horizontal direction× (module width+17mm)+32mm
3. Vertical spacing between the roof fixings for the supporting rail = approx. 1/2 of module height
4. Distance between the modules = 17mm
AS/NZS1170.2:2011 - 10 -
8. code‐compliant the AS/NZS1170.2:2011 Installation planning
8.1 Determine the wind region of your installation site
Figure 3. Regional boundaries – AS/NZS1170.2:2011
8.2 Determine Roof Installation Roof Areas
Determining the roof installation areas shall be limited to the calculation of wind loads on solar panels
with the following restrictions:
(a) Panels attached parallel to the roof plane. (b) Panels attached to enclosed building with aspect ratios h/d≤0.5 and h/b≤0.5.
AS/NZS1170.2:2011 - 11 -
(c) Panels with a gap of between 50 mm and 300 mm between the underside of the Panel and the
roof(s)
(no pitched frames).
(d) Panels with a minimum distance between panel and roof edge of 2 s where s is the gap between the
underside
of the panel and the roof surface, as shown in Figure 4 (roof edge includes ridges with pitch≥ 10°).
Figure 4. Panel mounted parallel to roof plane
Figure 5. Roof installation zones
AS/NZS1170.2:2011 - 12 -
8.4 Determine the Maximum Rail Support Spacing
a. Please use the following table to determine the T Rail support spacing for tile roof installations.
1670 mm long panel fixed to Tile roof
Height Above
ground(Meters)
Region A Region B Region C Region D
Center Edge Center Edge Center Edge Center Edge
5 2130 1500 1640 1150 1000 725 630 440
10 1940 1370 1360 960 925 655 570 400
√ The above figures are based on 1670mm long panel, maximum weight of 22Kg;
√ 1670 mm long panel required 2 rails with fixing as table above;
√ 2000 mm long panel required 3 rails with fixing as table above;
√ Tiled Roof with roof hook fixed to rafters with minimum of 2 x 12 gauge (5.5mm min diameter, 10 TPI)
screws with
50mm Min. embedment into timber;
√ For 35 mm screw embedment to timber batten, Region A & B remain unchanged, Region C reduce the
spacing by
15%, Region D reduce the spacing by 35 %.
1670 mm long panel fixed to tin roof
Height Above
ground(Meters)
Region A Region B Region C Region D
Center Edge Center Edge Center Edge Center Edg
e
5 1235 870 850 600 535 375 330 230
10 1020 720 700 600 480 340 300 210
√ The above figures are based on 1670mm long panel, maximum weight of 22Kg;
√ 1670 mm long panel required 2 rails with fixing as table above;
√ 2000 mm long panel required 3 rails with fixing as table above;
√ Metal roof with “L” bracket fixed to purlin with minimum of 1 x 14 gauge (5.5mm Min. diameter, 14 TPI
and 10 TPI for
fixing to steel and timber respectively) screw through to 0.75mm Min. BMT steel or 50mm Min.
embedment into timer
purlin;
√ For 35 mm screw embedment to timber batten, Region A & B remain unchanged, Region C reduce the
spacing by
15%, Region D reduce the spacing by 35 %;
√ For 0.6 mm thick steel batten, the max spacing shall reduce by 20 %.
8.5 Verify acceptable Rail End Overhang
Rail End Overhang must equal 50 percent or less of foot spacing. Thus, if foot spacing is 1200mm, the
AS/NZS1170.2:2011 - 13 -
Rail End Over hang can be up to 600mm. In this case, two feet can support a rail of as much as 2400mm
(1200mm between the feet and 600mm of overhang at each end).
8.6 Determine Roof slope
Fastensol system can be used for roof slope up to 60 degrees. Please verify the Installation site roof
slope should be between 0 degrees and 60 degrees.
9. Installation Instruction
9.1 Install the L feet bracket
a. Mark the L foot bracket installation
points.
b. Fasten the L foot bracket with the
purlin using 1 pc st6.3 x 85 wooden
screw; fix other L brackets to the
rafter according to your plans.
■ Note: The EPDM rubber pad play
the role of waterproof.
9.2 Install the tile roof hook
a. Remove the roof tiles at the
marked
positions or simply lift them up
slightly;
b. Input the roof hook to the wooden
beam. Fix the roof hooks with 3 pcs
st6.3×85 wooden screws;
■ Note: Minimum 2 pcs wooden
screws
AS/NZS1170.2:2011 - 14 -
c. Cover the hooks by the removed
tile.
Note: If necessary, use an angle
grinder or hammer to cut a concavity
in the tile that covers the roof hook at
the point where the roof hook comes
through. (Caution! Must not use fixed
roof hook as a ladder, as this extreme
point load could damage the tile
below)
AS/NZS1170.2:2011 - 15 -
9.3 Install the Klip‐lok roof clamp
a. Mark the installation points of the
clips according to your plans and the
fixing spacing table 7.4;
■ Note: The EPDM rubber pad play
the role of waterproof.
b. Place the fix L feet bracket on the
Klip‐lok clips 700, and connect them
by tightening 2 pcs M8 x 20 Bolt.
■ Note: Please make sure the clips
are in one line.
c. Install the Klip‐lok clips 406 and Fix
L feet bracket same as the installation
of Klip‐lok clips 700.
AS/NZS1170.2:2011 - 16 -
9.4 Install the T rail
a. Tilt in the T‐module
Only Four steps to quick mount the
tilt‐in
T‐module into T mounting rail
channel;
b. Connect the rail
1. Insert the tilt‐in module into the
side channel of the T rail as
the step above shown;
2. Adjust the rail to be level;
3. Fasten the bolt.
■ Fasten firmly in place by torque bolt
to 10Nm.
AS/NZS1170.2:2011 - 17 -
c. Connect the rail splice kits
Installation of the splice to connect
rails together. Slide the splices on the
rear side of the pre‐assembled rails
halfway to the side. Fasten the first
M8 bolt firmly using the Allen key.
Now slide the next rail segment into
the splice. Tighten the second M8
bolt .The connection is finished.
9.5 Intall the module
a. Place the solar module on the rail,
slide the end clamp tightly against
the solar module and fasten tightly
using the Allen bolt.
■ Recommended torque is 8 NM.
b. Slide the pre‐assembled mid clamp
into the rails from above, place
it firmly against the module and
fasten
loosely (approx. 2‐3 turns).
AS/NZS1170.2:2011 - 18 -
c. Now slide the next T module
against
the previously installed module and
tighten the mid clamp using the
Allen key, Take care that the anti slips
protection sits in the rail channel of
the
lowest row of rails;
d. Place the last module in the row on
the
rails (with the first row of modules,
take care that the anti‐slip protection
sits properly in the rail channel) and
fasten the last mid module clamp and
the module end clamp using the Allen
Key.
■ Recommended torque is 8 Nm
e. Finish
AS/NZS1170.2:2011 - 19 -
9.6 Grounding System
Install the rail grounding system
AS/NZS1170.2:2011 - 20 -
10. Warranty
10 years limited Product Warranty, 5 years limited Finish Warranty
Fastensol warrants to the original purchaser (“Purchaser”) of product(s) that it manufactures (“Product”)
at the original installation site that the Product shall be free from defects in material and workmanship for
a period of ten (10) years, except for the anodized finish, which finish shall be free from visible peeling, or
cracking or chalking under normal atmospheric conditions for a period of five (5) years.
1) the date when the installation of the Product is completed;
2) 30 days after the purchase of the Product by the original 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”
(www.aamanet.org) is not followed by Purchaser. This Warranty does not cover any damage to the
Product that occurs during its shipment, storage, or installation.
This Warranty shall be VOID if installation of the Product is not performed in accordance with Fastensol’s
written installation instructions, or if the Product has been modified, repaired, or reworked in a manner
not previously authorized by Fastensol IN WRITING, or if the Product is installed in an environment for
which it was not designed. Fastensol 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 periods the Product shall be reasonably proven to be defective, then
Fastensol should repair or replace the defective Product, or any part thereof, in Fastensol’s sole discretion.
Such repair or replacement shall completely satisfy and discharge all of Fastensol’s liability with respect to
this limited Warranty. Under no circumstances shall Fastensol be liable for special, indirect or
consequential damages arising out of or related to use by Purchaser of the Product.
Manufacturers of related items, such as PV modules and flashings, may provide written warranties of their
own. Fastensol’s limited Warranty covers only its Product, and not any related items.
Thank you for using of Fastensol’s mounting systems, for more information about us, please contact us
at:
Market Office: No.12, Xuelingbeili, Huli District, Xiamen, China
Tel: 0086‐592‐5215070 Fax: 0086‐592‐5215070 E‐mail: [email protected]