Clenergy PV-ezRack SolarRoof SADL Bracket A1 User manual

SADL Bracket A1 on Kingspan Roof
Code-Compliant Planning and Installation Guide V 1.0
Complying with AS/NZS1170.2-2011 AMDT 2-2016

Installation Guide / SolarRoof™ SADL Bracket A1
1Code-Compliant Planning and Installation Guide V1.0 - Complying with AS/NZS1170.2-2011 AMDT 2-2016
Introduction
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List of contents
Introduction
Planning
Tools and Components
System Overview
Installation Instruction
Certification Letter
Product Warranty
01
02 - 04
05
06
07 - 08
09 - 22
23
The Clenergy PV-ezRack® SolarRoof™ has been
developed as a universal PV-mounting system for roof-
mounting on pitched and flat roofs. SADL bracket A1
is another innovative Tin roof interface, specified for
Kingspan KS1000 RW trapezoidal roof panel. SADL
bracket A1 has been tested on the roof panel above
in a National Association of Testing Authorities (NATA)
accredited lab.
Please review this manual thoroughly before installing
PV-ezRack® SolarRoof™. This manual provides:
1) Supporting documentation for building permit
applications relating to PV-ezRack® SolarRoof™
Universal PV Module Mounting System,
2) Planning and installation instructions.
The PV-ezRack® SolarRoof™ parts, when installed in
accordance with this guide, will be structurally sound
and will meet the AS/NZS1170.2:2011 Amdt 2- 2016
standard.
During installation, and especially when working on the
roof, please comply with the appropriate Occupational
Health and Safety regulations. Please also pay attention
to any other relevant State or Federal regulations.
Please check that you are using the latest version of the
Installation Manual, which you can do by contacting
Clenergy Australia via email at [e-mail] or
contacting your local distributor in Australia.
- Introduction -
Complying with all applicable local or national
building codes, including any that may supersede this
manual.
Ensuring that PV-ezRack and other products are
appropriate for the installation and the installation
environment.
Using only PV-ezRack parts and installer-supplied
parts as specified by the PV-ezRack project plan.
(substitution of parts may void the warranty and
invalidate the letter of certification).
Recycling: Recycle according to the local relative
statute.
Removal: Reverse installation process.
•Ensure that there are no less than two professionals
working on panel installation.
Ensure the installation of related electrical equipment
is performed by licenced electricians.
Ensuring safe installation of all electrical aspects of
the PV array. This includes adequate earth bonding of
the PV array and PV-ezRack® SolarRoof™ components
as required in AS/NZS 5033-2014 AMDT 2 2-2018.
Ensuring that the roof, its rafters/purlins, connections,
and other structural support members can support
the array under building live load conditions.
Ensuring that screws to fix interfaces have adequate
pull-out strength and shear capacities as installed.
Maintaining the waterproof integrity of the roof,
including the selection of appropriate flashing.
Verifying the compatibility of the installation
considering preventing electrochemical corrosion
between dissimilar metals. This may occur between
structures and the building and between structures,
fasteners and PV modules, as detailed in AS/NZS
5033: 2014.
Verifying atmospheric corrosivity zone of installation
site by referring to AS 4312-2008 or consulting local
construction business to determine appropriate
products and installations.
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The installer is solely responsible for:

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- Planning -
Planning
Most of Australia is designated Region A which
indicates a Regional Wind Velocity of 43 m/s with
wind average recurrence of 200 years.
Some areas are designated Region B (52 m/s). Local
authorities will advise if this applies in your area.
Region C areas (64 m/s) are generally referred to as
Cyclonic and are generally limited to northern coastal
areas. Most Region C zones end 100km inland.
Some areas are designated Region B (52 m/s). Local
Region D (79 m/s) is Australia's most extreme Cyclonic
Region, located between the town of Carnarvon and
Pardoo Station in Western Australia.
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Wind regions are pre-defined for the whole of Australia by the Australian Standard 1170.2. The Wind Region is an
independent factor of surrounding topography or buildings.
Region Definition:
Determine the wind region of your installation site
Determine the Terrain Category
You will need to determine the terrain category to ensure the installation meets the required standard.
Terrain Category 1 (TC1) – Very exposed open terrain with very few or no obstructions, and all water surfaces, e.g. flat,
treeless, poorly grassed plains; open ocean, rivers, canals, bays and lakes.

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Terrain Category 2 (TC2) – Open terrain, including grassland, with well-scattered obstructions having heights generally
from 1.5m to 5m, 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 some trees or isolated obstructions, terrains in developing outer urban areas
with scattered houses, or larger acreage developments with more than two and less than 10 buildings per hectare.
Terrain Category 3 (TC3) – Terrain with numerous closely spaced obstructions having heights generally from 3m to 10m.
The minimum density of obstructions shall be at least the equivalent of 10 house-size obstructions per hectare, e.g.
suburban housing, light industrial estates or dense forests.
Terrain Category 4 (TC4) – Terrain with numerous larger, high (10m to 30m tall) and closely-spaced constructions
buildings, such as large city centers and well-developed industrial complexes.
If your installation site is not at TC 2, 2.5 or 3, please contact Clenergy to obtain a project-specific engineering certificate
to support your installation.
Determine the Roof Type
This document provides sufficient information for SADL bracket A1 installation on Kingspan KS1000 RW Trapezoidal
Roof Panel having different insulation core thickness (40-120 mm) with an exterior sheet of a minimum 0.42 mm thick. If
your installation is on a different roof type, please contact Clenergy to obtain a project-specific engineering certificate
to support your installation.
Note: Bracket installation is allowed on the full rib of Kingspan roof only. Installation on lap joints must be avoided.
Verify Atmospheric Corrosivity Zone of Installation Site
Please refer to “AS 4312-2008 Atmospheric Corrosivity Zones in Australia” or consult local construction businesses to
verify the corrosivity category of the installation site to determine appropriate products and interface spacing.
Note: Clenergy provided screws for Tin interfaces are suitable for up to C3 corrosive environments only.
Determine the Height of the Installation Site
This document provides sufficient information for the PV-ezRack® SolarRoof™ system installation up to heights of
30 meters. If your installation site is more than 30 meters high please contact Clenergy to obtain a project-specific
engineering certificate to support your installation.
Determine Roof slope
SADL bracket A1 installation on Kingspan KS1000 RW Trapezoidal Roof is certified for roof slopes up to 10°. Please verify
that the Installation site roof slope is between 0° and 10°.
Determine the Installation Area of Roof
Please refer to the generic notes 25, 28 and 29 of the Certification Letter to determine the installation area based
on building height, length, and width. Please be aware at certain building conditions there is an Exclusion Zone for
flush installation, which is the minimum distance between PV solar panel and roof edge of "2 x s", where "s" is the gap
between the underside of the panel and the roof surface.
Determine the Maximum Rail Support Spacing
Please refer to the Certification Letter and Interface Spacing Table. If a project-specific Certification Letter has been
provided, please refer to the support spacing in this letter.

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Verify Maximum Rail End Overhang
Rail end overhang is defined as the distance from the last interface to the end of the panel. The maximum rail end
overhang is 40% of the last interface installed spacing. For example, if the max interface spacing in the generic
engineering certificate is 1800 mm and installed spacing is 1500 mm, the maximum rail end overhang is 600 mm.
Acquire PV Modules Clamping Zone Information
It is important to check PV modules clamping requirements (for example clamp dimensions, clamping distance from
the end of the panel) from PV modules manufacturer before installations, which can help to avoid using the incorrect
size of clamps and help to plan interface's positions on the roof and rail's orientation and position.
- Planning -

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ER-EC-ST
End Clamp
ER-IC-ST
Inter Clamp
C-U/30/46-G
Universal Clamp with
Grounding Clip
C-U/30/46
Universal Clamp
ER-EC-DU35/40
End Clamp, Dual 35
or 40mm
ER-EC-DU40/46
End Clamp, Dual 40 or
46mm
ER-R-ECO
ECO Rail
ER-SP-ECO
Splice for ECO Rail
ER-I-35
SADL Bracket A1
ER-I-05
Tin Interface
ER-I-05/CM
Tin Interface with Click
Module
ER-I-05A/EZC/ECO
Tin Interface A with
ezClick connection
- Tools and Components -
Tools and Components
Tools
Components
Screwdriver Torque Wrench 5/16″ Hex Socket Tape String & Marker Pen

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Code-Compliant Planning and Installation Guide V1.0 - Complying with AS/NZS1170.2-2011 AMDT 2-2016
SADL Bracket A1 with Tin Interface SADL Bracket A1 with Tin Interface with ezClick connection
System Overview
1. Overview of SADL Bracket A1 on Kingspan Roof
1)End Clamp 2) Inter Clamp 3) ECO Rail 4) Tin interface 5) SADL Bracket A1
Note: Bracket installation is allowed on full rib of the Kingspan roof only. Installation on lap joints must be avoided.
2. Precautions during Stainless Steel Fastener Installation
Improper operation may lead to the deadlock of Nuts and Bolts. The steps below should be applied to stainless steel
nut and bolt assembly to reduce this risk.
2.1 General installation instructions:
(1) Apply force to fasteners in the direction of the thread
(2) Apply force uniformly, to maintain the required torque
(3) Professional tools and tool belts are recommended
(4) In some cases, fasteners could be seized over time. As an option, if want to avoid galling or seizing of thread, apply
lubricant (grease or 40# engine oil) to fasteners prior to tightening.
2.2 Safe Torques
Please refer to safe torques defined in this guide as shown in the figures below. In case power tools are required,
Clenergy recommends the use of low speed only. High speed and impact drivers increase the risk of bolt galling
(deadlock) If deadlock occurs and you need to cut fasteners, ensure that there is no load on the fastener before you cut
it. Avoid damaging the anodized or galvanized surfaces.
(1)
(2)
(3)
(4)
(5)
- System Overview -

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Installation Instruction
1. SADL Bracket A1 Installation
Position the SADL Bracket A1 on Kingspan roof full rib correctly
according to layout plan and press the bracket down to make sure
“shoulder” each side well touch on roof rib.
Release bracket after installing 4 screws.
Screw installation instruction:
1. Use a 5/16" Hex Socket.
2. Use a mains powered or cordless screwdriver with a drive speed of
3,000 RPM maximum.
3. Fit the driver bit into the screw and place it at the fastening position.
4. Apply consistently firm pressure (end load) to the screwdriver until
the screw has fastened.
NOTE:
Screws not exposed to frequent rain should be washed down with
fresh water at least every 6 months to meet the warranty conditions of
Buildex Screws.
According to the installation plan, determine the mounting position and orientation of the Tin Interface depending on
rails running parallel or perpendicular to the roof rib, then fasten the bolt with 16-20 N•m torque.
- Installation Instructions -
2. Tin Interface Installation
Rail running parallel to roof rib Rail running perpendicular to roof rib

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Code-Compliant Planning and Installation Guide V1.0 - Complying with AS/NZS1170.2-2011 AMDT 2-2016
3. Rail Installation
3.1 To connect several rails, slide half of the splice into the rear side of the rail, and fasten the first M8 bolt. Slide
the next rail into the splice and tighten the second M8 bolt. Splice provides the electrical connection between the
2 rails through the pressure bolts. This eliminates the need of using 2 earthing lugs.
Required torque is 10 ~12 N•m.
3.2 Install the Z module into the side channel of ECO Rail as shown in the figure on the right.
- Installation Instructions -
Clearance
106~121mm Clearance
126~149mm
4. PV Module Installation
4.1 Please refer to the PV-ezRack Grounding System Installation Guide for PV modules clamps and grounding lugs
installations.
4.2 The installers must ensure panel clamps are installed flush mounted to the panel frame and apply the correct
torque value of the clamp fastener as shown in this guide.

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Certification

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- Certification -

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