SunLock PoleLock User manual

PoleLock Installation Manual
Version 4.1 - updated December 2020
www.sunlock.com.au
Australian
Made

PoleLock Installation Manual - Version 4.1 (updated Dec 2020)
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Introduction .................................................................................... 3
Safety and Installer Responsibilities ........................................... 4
> Wind Loading ........................................................................................... 4
> Footings ................................................................................................... 4
> Handling .................................................................................................. 4
Tools Required .............................................................................. 5
Typical Installation ........................................................................ 6
Installation ...................................................................................... 7
> Mounting Pole .......................................................................................... 7
> Pivot Assembly ........................................................................................ 8
> Frame Assembly ...................................................................................... 8
> Total Assembly ........................................................................................ 9
> Multiple Panel Installation ....................................................................... 10
Maintenance and Cleaning .......................................................... 11
Warranty Conditions .................................................................... 11
References .................................................................................... 12
Contact Details ............................................................................. 12
Certificate of Compliance ............................................................ 12

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Thank you for choosing the PoleLock solar
photovoltaic (PV) module pole-mounted framing
system, part of the SunLock family of solar framing
products. PoleLock is suitable for a wide variety of
commercial and remote installations.
PoleLock is backed by a 10-year warranty and
compliant with the Australian / New Zealand
Standard on Wind Actions (AS/NZS1170.2.2011).
PoleLock can support one or two modules on one
pole. More modules can be supported by joining
several PoleLock frames together in a line.

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Wind Loads
PoleLock complies with AS/NZS1170.2.2011 on Wind
Actions, as per the following table:
1 Panel
Frame
2 Panel
Frame
Multiple
Frame
Wind Region
A, B
A
A, B
Terrain Category
2, 3, 4
2, 3, 4
2, 3, 4
Topographic Factor Mt
1.0, 1.2
1.0
1.0
AS/NZS1170.2.2011 provides guidance on determining the
wind pressures applicable to your PoleLock installation site,
taking in local terrain and topography. Sufficient guidance is
given in this document, but you may wish to procure a copy
of these standards if your company installs Australia wide.
If you are unsure about complying with standards, or if you
are not qualified to install this product, please consult either
SunLock or a registered structural engineer.
Footings
The footings for PoleLock have been designed by a
registered structural engineer, and are appropriate for
natural ground, not topsoil, fill, or disturbed ground.
Check that the soil at the install location is appropriate for
this footing design. If it is not appropriate, you will need to
get the footing checked by a registered structural engineer.
Handling
The materials used in the PoleLock frame can have sharp
corners or edges. Wear personal protective equipment such
as safety glasses, hearing protection and gloves during
cutting and handling.
Included Towns:
Region A:
> Callytharra Springs
> Gascoyne Junction
> Green Head
> Kununurra
> Lord Howe Island
> Morawa
> Toowoomba
> Wittanoom
> Bourke
Region B:
> Adelaide River
> Atherton
> Biloela
> Brisbane
> Christmas Island
> Collinsville
> Corindi
> Geraldton
> Ivanhoe
> Kyogle
> Marble Bar
> Mullewa
> Norfolk Island
> Torres Strait Islands
> Wyndham

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Socket and Ratchet (A M10 socket and ratchet
for tightening supplied fasteners)
Angle Grinder (If required, an angle grinder with an
aluminium cutting blade can be used to trim the SunLock
channel to the desired length)
Hand Drill (An electric hand drill for drilling holes in
the base of the mounting post)
Drill Bits (A 6mm & 13mm drill bit is required to drill
holes in the mounting post)
Anti-galling Lubricant (if required, anti-
galling lubricant may be required to aid
in the tightening of stainless steel
fasteners)
Ring Spanner (A M10 ring spanner for
tightening supplied fasteners)
Hex Key (A 6mm hex key / driver bit is
required to secure the SunLock channel
to the channel feet)
Gloves (For handling SunLock framing, as
aluminium can develop sharp corners)

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The PoleLock range of frames can support either one or
two modules of various sizes in a portrait orientation. If
required, multiple PoleLock frames can be installed on one
site to provide increased power.
PoleLock has been designed to accommodate the
following panels:
(675mm x 1500mm) ~ 120W - 160W panels
(808mm x 1580mm) ~ 170W - 210W panels
(1000mm x 1680mm) ~ 215W - 250W panels
(1046mm x1556mm) ~ 327W panels
And any panel size up to 2150mm x 1200mm

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Note: PoleLock is certified for use with the following
mounting post:
• 90 DN DuraGal pole (101.6mm outer diameter, 4mm
wall thickness)
• 250 MPa
• 3200mm pole length
Installation
1. Ensure the location is suitable for pole mounted solar
installation.
2. Ensure no building / trees are shading the modules.
3. Dig holes in undisturbed, natural ground with a soil
friction angle of 22 degrees or greater.
1 Panel Frame:
450mm diameter pier, 1200mm deep
2 Panel Frame:
450mm diameter pier, 1400mm deep
600mm diameter pier, 1200mm deep
4. Drill a hole in the end of the mounting pole, insert an
M12 bolt/rod and fasten
5. Place the galvanised pole into the hole ensuring that
the pole sits on a 100mm base of gravel. Fill with the
required amount of 25 MPa concrete. Ensure the
pole is oriented plumb.

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The PoleLock frame consists of two parallel SunLock
channels connected to a central beam through two channel
brackets. This frame is connected to a pivot assembly which
in turn is mounted on the top of a mounting post.
Pivot Assembly
1. Insert each U-bolt through the corresponding holes
in the supporting plate and pivot bracket and loosely
attach the washers and nuts. Slip the assembly over
the top of the mounting pole and tighten. Ensure the
pivot flanges are pointing in the intended northerly
direction.
2. Take the second pivot bracket and slide the pivot
bolt through the mating holes ensuring that both
brackets rotate freely. Loosely tighten all fasteners.
Frame Assembly
1. Take the central beam and fasten the channel
brackets to the ends.
2. Centre and attach the SunLock channel to the
channel brackets by fastening the supplied M8
socket head cap screws.
Attach the pivot bracket to the pole Add the second pivot bracket
Attach the channel bracket to the beam Frame assembly ready to attach to the pivot

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Total Assembly
1. Place the frame assembly on top of the pivot
assembly and tighten all fasteners.
2. Loosely attach the required PV module end-clamps
to the end of the SunLock channels.
3. Loosely attach the module mid-clamps in the centre
of the SunLock channels (2 panel only).
4. Place the solar panel on top of the frame and fasten
down the end clamps, ensuring that the clamps
securely hold down the panel.
5. (2 Panel Only) Attach and fasten the supplied mid
clamps to the other side of the panel.
6. (2 Panel Only) Repeat steps 4 and 5 for the second
panel.
7. Ensure all clamps are sufficiently fastened to prevent
panels dislodging from the frame.
8. Set the desired inclination angle of the solar array by
placing the 30mm M10 bolts through the two sets of
holes in the pivot bracket.
9. Securely tighten all fasteners and ensure that the
assembly is rigid.
Frame—Pivot assembly attachment End Clamps
Mid-Clamps (2 panel only) Set desired inclination angle

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If required, multiple PoleLock frames can be installed on one
site to provide increased power. The PoleLock frames can be
assembled in series to accommodate 3 to 6 panels in wind
region A or B.
The multiple frame installation consists of multiple single or
double panel frames arranged in series, with the channel
ends joined using SunLock channel joiners. Channels can
either be cut to appropriate lengths, using a circular saw with
an aluminium cutting blade, or longer lengths of channel can
be custom ordered.
The number of poles required for installations in wind region A
& B, Mt = 1.0, can be found in the table below.
The chart below is only applicable for the 4 panel size:
(675mm x 1500mm) , (808mm x 1580mm) , (1000mm x
1680mm) , (1046mm x1556mm). Any other size, please check
the Polelock general certificate.
Maximum [A]
Maximum [B]
Wind Region A
2200mm
1050mm
Wind Region B
1700mm
720mm
Number of
Panels
Number of poles
for wind region A
Number of poles
for wind region B
3
2
2
4
2
3
5
3
4
6
3
4
If you wish to assemble an array of more than 6 modules in
wind region B, or for terrain with Mt = 1.2, please contact us
to discuss the correct number of poles required.

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Galvanised steel, aluminium and stainless steel are largely
maintenance free. Only in highly polluted or marine
conditions is rinsing with clean water required during
scheduled panel cleaning.
Sunlock Australia Pty Ltd (trading as Sunlock) warrants that
its PoleLock and SunLock Solar Panel Mounting System
(Frame) is free from defects in materials and workmanship for
a period of 10 years from the date on which the Frame is
purchased from Sunlock Australia Pty Ltd (Warranty Period),
on the terms set out in this warranty.
In the event that the Frame does not conform to this warranty
during the Warranty Period, Sunlock Australia will, at its
option, either repair or replace the Frame or pay the cost of
having the Frame repaired or replaced.
To the extent permitted by law, Sunlock Australia’s total
liability under this warranty will in no circumstances exceed
the repair or replacement of the Frame or payment of the cost
of having the Frame repaired or replaced. In the event of
replacement of the Frame, any remaining part of the
Warranty Period will be transferred to the replacement
Frame.
This warranty will not apply to any defect or damage to the
Frame arising directly or indirectly from:
1. Shipment or storage of the Frame;
2. Improper installation, maintenance, repair or use of the
Frame;
3. Normal wear and tear;
4. Misuse, neglect, abuse, accidental damage or
modification to the Frame;
5. Failure to observe the instructions set out in the System
Manual; or
6. Power failure, power surges, lightning, fire, explosion,
flood, extreme weather conditions, environmental
disasters or other causes outside Sunlock Australia’s’
control, as determined by Sunlock Australia in its sole
discretion.
This warranty does not cover, and under no circumstances
will Sunlock Australia be liable for, any costs associated with
the removal, shipping, handling or re-installation of the Frame
or the costs of sending personnel to any site to repair or
replace the Frame.
This warranty is only provided to the original purchaser of the
Frame from Sunlock Australia (Purchaser) or, where the
Purchaser is an installer or builder who on-supplies the
Frame to another party, to that other party (End-User).
This warranty is not transferable. Where an End-User wants
make a claim under this warranty, the End-User must in the
first instance contact the installer or builder from whom the
Frame was purchased.
All warranty claims must be made in writing and addressed to
the Customer Service Officer, Sunlock Australia Pty Ltd, 7
Audsley Street, Clayton South, Victoria, 3169; and
accompanied by proof of purchase of the Frame in a form
acceptable to Sunlock Australia.
This warranty will not apply to any claims received by
Sunlock Australia after the expiration of the Warranty Period.
Sunlock Australia makes no warranties, express or implied,
other than the warranties made herein, and specifically
disclaims all other warranties, representations and conditions
to the extent permitted by law.
To the extent permitted by law, in no circumstances will
Sunlock Australia be liable for direct, indirect, special or
consequential damages arising from a defective Frame or for
any damage or injury to persons or property. Sunlock
Australia’s aggregate liability, if any, in damages or
otherwise, will not exceed the invoice value of the Frame at
the time of purchase from Sunlock Austrlia.
Any provision contained in this warranty which is prohibited
or unenforceable in any jurisdiction will be deemed to be
ineffective to the extent of such prohibition or unenforceability
and will not invalidate the remaining provisions nor affect the
validity or enforceability of that provision in any other
jurisdiction.
This warranty will be governed and construed in accordance
with the laws of Victoria, Australia and the parties irrevocably
submit to the exclusive jurisdiction of the courts of Victoria.

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AS/NZS1170.2.2011, structural design actions,
Part 2: Wind Actions
For further information contact Sunlock on 1300
655 554 (local call from anywhere in Australia)
or at [email protected]
©Ebulen Consult 2020
POLELOCK POLE-MOUNT GROUND RACKING SYSTEM
STRUCTURAL ENGINEERING CERTIFICATE
SUNLOCK POLELOCK SYSTEM
Prepared for:
Sunlock Australia Pty Ltd
7 Audsley Street,
Clayton South, VIC 3169
December 9, 2020
Ref: E20110157