Solar Roof Mounting System Installation Manual

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 Description 7

6 System overview 9

7 Designing the module field 10

8 Code-compliant AS/NZS 1170 planning 11

9 Installation 15

10 Warranty 21

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 Solar Roof Mounting System Installation Manual

1. General information

Thank you for choosing the Grace solar roof mounting system. Made from custom-built aluminum extrusions
and components, Grace Solar’s innovated design and improved frame strength greatly simplify solar panel
installation. The easy installation four steps make the D-Modules can be put into the D Rail on any position
quickly. So, the D-Modules is pre-assembly with the clamp to save your install time.

Tilt-in Align Up Fasten

Easy installation four steps

Grace solar’s versatile design makes it suitable for a wide variety of building types and zones including
residential, commercial and remote environments.

Gracesolar is backed by a 10-year warranty and is compliant with the Australian/New Zealand Standard on
Wind Actions (AS/NZS1170.2.2011).

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2. Safety and Installer Responsibilities

2.1 Handling and Installing Grace solar ››»

It is critically important that safety practices are observed when installing
 Do not throw or roughly handle any Grace solar components.
 Do not bring Grace solar system into contact with sharp or heavy objects.
 Do not modify Grace solar 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
Caution
which Grace solar components is fixed. Roofs or structures with
Installation of this
rotten/rusted bearers, undersized bearers, excessively spaced bearers,
product is to be
or any other unsuitable substructure cannot be used with Grace solar
performed only by
components, and installation on such structures will void the warranty,
professionally
and could result in death or serious injury.
trained installers.
Any attempt by an
2.2 Wind and Climate Design
unqualified person
AS/NZS1170.2.2011 provides guidance on determining the wind pressures
to install this
applicable to your Grace solar system install site, taking into account roof
product could
shape and geographic location. Sufficient guidance is given in this document,
result in death or
but you may wish to procure a copy of these standards if your company
serious injury.
installs Australia/New Zealand wide.
 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
Grace solar system order.

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3. Technical Specifications

3.1 Applications
 Commercial and residential buildings
 Marine applications and remote areas

3.2 Features
 6005-T5 Aluminum extrusion
Caution  Innovated designed of the D-Modules, which can be pre-assembly with
Refer to the the clamp, make the installation easy and quick.
section “Designing  Suitable for difference conditions and the most solar panels at present
Your System” market.
before attempting  Significantly higher strength-to-weight ratio than other framing products,
installation. Failure providing improved efficiency due to greater frame spans, inherent
to correctly corrosion resistance resulting in low ongoing maintenance and an
establish the extended product life.
requirement of the  Complies with Australian/New Zealand Standard on Wind Actions,
proposed AS/NZS1170.2.2011
installation site is  Anodized finish
dangerous and will
void the framing 3.3 Material
warranty.
Tensile strength
Material
Ultimate Yield
6005-T5 Aluminum
260MPa 240Mpa
Extruded
Stainless Steel 304 635MPa 235MPa
Stainless Steel A2-70 700MPa 450Mpa

3.4. Installation condition

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.

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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 grinder;
For terracotta tile roof installation, and angle grinder
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

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5. Components Description

GD-Rail
 hold each panel row
 length can be customized
 6005-T5 extruded aluminum

Standard Rail Length

808~826mm wide 990~1020mm wide panels
panels
2560mm
3405mm 4200mm

GD Rail Splice Kit

 Extend GD Rail to any length as required by the
quantity or width of the solar panels

Inter Clamp Kit for Framed Modules

 Fit between two panels
 Fastened with a 6mm Allen key
 Standard pre-assembly for the usual panels with
thickness 30~35, 35~40, 45~50, 57~60mm

End Clamp Kit for Framed Modules

 Hold the edge of each end panels
 Fastened with a 6mm Allen key
 Standard pre-assembly for the usual panels with
thickness 30, 35, 40, 46, 50, 57mm

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Variety of Roof Hook

Stainless Steel Roof Hook 1 #
 Fix to the rafter below Roman tile roof
 Include 3pcs st6.3x60 wood screws

Stainless Steel Roof Hook 2 #

 Fix to the rafter below flat tile roof
 Include 2pcs st6.3x60 wood screws

Stainless Steel Roof Hook 3 #

 Side fix to the rafter below Roman tile roof
 Include 3pcs st6.3x60 wood screws

Stainless Steel Roof Hook 4#

 Fix to the rafter on slate tile roof
 Include 3pcs st6.3x60 wood screws

Aluminum Tin Roof Hook 5#

 Fix to the purlin on tin roof
 Include 1pcs st6.3x80 wood screws

Stainless Steel Roof Hook 6#

 Fix to the rafter below Roman tile roof
 Include 3pcs st6.3x60 wood screws

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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  Site specifics

① GD Rail ② GD Rail Splice (Optional)

③ Inter Clamp ④ End Clamp
⑤ Roof hook

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7. Designing the module field

Below, the distances between roof connections for a portrait installation are specified. Clamp-on roof hooks
need to be installed in specific distances, depending on the distance of rafters and the stoical conditions.

1. Height of the module field: module height x number of modules vertically

2. Width of the module field: number of modules horizontally x (width of the module + 18 mm)+32 mm
3. Distance between roof connections vertically (according to the clamping points pre-defined by the module
producer): Quarter-points of the modules, about 1/2 of module height.
4. Distance between roof connections horizontally: Depending on the distance between rafters and on the
static requirements (please see the Chapter 8 on page 11).
5. Distance between modules: 17 mm

When positioning the modules, please take into consideration

 That the values above are
 That dimensions of tiles or other roof covering and the position of the rafters define the precise actual
horizontal distance between roof connections
 That the distance between roof laths defines the precise actual vertical distance between roof
connections.

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8.code-compliant AS/NZS 1170 planning

8.1 Determine the wind region of your installation site

Region Definition:

Wind regions are pre defined for all of Australia by Australian Standard 1170. The Wind Region has nothing
to do with surrounding topography or buildings.
• Most of Australia is designated Region A which indicates a Regional Ultimate Basic Wind Velocity of
45msec.
• Some areas are designated Region B (57msec). Local authorities will advise if this applies in your area.
• Region C areas (66msec) are generally referred to as Cyclonic and are generally limited to northern
coastal areas. Most Region C zones end 100km inland.
• Region D (80msec) Australia's worst Cyclonic Region between Carnarvon and Pardoo in Western
Australia.

8.2. Determine the height of the of your installation site

This document provides sufficient information for Grace solar system installation height less than 10
meters. If your installation site is more than 10 meters in height, please contact Grace solar to obtain
engineering data to support your installation.

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8.3 Determine Roof Installation Roof Areas

The use of this Paragraph (D6) shall be limited to the calculation of wind loads on solar panels with the
following restrictions:
(a) Panels attached to enclosed building with aspect ratios h/d<=0.5 and h/b<=0.5.
(b) Panels be attached parallel to the roof plane.
(c) Panels with a gap of between 50mm and 300mm 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 D8 (roof edge includes ridges with
pitch>=10°.

The aerodynamic shape factor (Cfig) for calculation net pressures for solar panels satisfying the above
conditions, as shown in Figure D8, is given in Table D11. The aerodynamic shape factor (Cfig) contains
local pressure and area reduction effects for calculating net loads on individual panels installed as part of
an array of panels in the areas of the roof identified in Figure D9.

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Solar Roof Mounting System Installation Manual

8.4 Determine the Maximum Rail Support Spacing

a. Please use the following table to determine the GD Rail support spacing for tile roof installations.
1970mm Long Panels fixed to Tiled Roof
Installation
Region A (mm) Region B (mm) Region C (mm) Region D (mm)
Height
Max area of 2 2 2 2
3.0m 2.5m 2.0m 1.5m
one panel
Center Edge Center Edge Center Edge Center Edge
Roof Area
Zone Zone Zone Zone Zone Zone Zone Zone
5 Meters 2010 1420 1390 980 870 610 530 380
10 Meters 1660 1170 1150 810 780 550 480 340
2
 The above figures are based on modules lengths of up to 1970mm, maximum weight of 15Kg/m
 The above spacing applies for fixing through thin sheet purlins (greater than 1.0mm thickness) or a
minimum embedment of 50mm into timber purlins.
 Tile brackets should fixed to the rafter using two 12g mounting screws (M6x60mm)
 For 35mm embedment into timber of fixings into 0.55mm thickness steel for regions A+B remain
unchanged. For regions C reduce the spacing by 15%. For region D reduce the spacing by 35%.
 In case the wooden rafters/trusses you wish to mount on are too thin and the screws would be too
close to the edge of the rafters please pre-drill with a 3~4mm drill in order to avoid the splitting of the
timber ( or use the side mount roof hook).

b. Please use the following table to determine the base rail support spacing for Tin roof installations.
1970mm Long Panels fixed to Tin Roof
Installation
Region A (mm) Region B (mm) Region C (mm) Region D (mm)
Height
Max area of 2 2 2 2
3.0m 2.5m 2.0m 1.5m
one panel
Center Edge Center Edge Center Edge Center Edge
Roof Area
Zone Zone Zone Zone Zone Zone Zone Zone
5 Meters 985 695 680 480 610 430 370 260
10 Meters 815 575 565 400 550 390 340 240
2
 The above figures are based on modules lengths of up to 1970mm, maximum weight of 15Kg/m
 The above spacing applies for fixing through thin sheet purlins (greater than 0.75mm thickness) or a
minimum embedment of 50mm into timber purlins.
 The L Feet should be fixed to the purlins under using one 12g mounting screw (M6x80mm) through
sheet metal roofs with desk rubber.
 For 35mm embedment into timber of fixing into 0.55mm thickness steel the max panel length should
be reduced to 1700mm and the max spacing reduced by 20%.
 Please note that the screws provided with our products are designed for mounting into wooden
structures.

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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
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

Grace solar 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.

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9. Installation

Install on Roman Tile Roof

1. Remove the roof tiles at the marked
positions or simply lift them up slightly.

2. Input the roof hook to the wooden

beam. Fix the roof hooks with 3x
wood screws (M6x80).

3. Cover the hooks by the removed tile

4. The roof hook must not press against

the roof tile. Place it flat. If necessary,
shim the roof hook with wood.

Wrong Correct
5. 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.

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Install on Plain Tile Roof

6. Mark roof hook installation points,
and cut recesses for hooks into plain
tiles/slate at each installation point.

7. Cut titanium zinc metal sheets to fit

and install them under the roof
hooks. Fix the roof hooks to the
rafter using two 6 x 80 mm wood
screws.

Install on Tin Roof

8. Mark roof hook installation points
and use the power tool to drill the
wood screw through the point to
fasten the L feet with the purlin.

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Install The GD-Rail

9. D-Module quick mount.
Four steps to quick mount the
D-Module into GD-Rail channel.
Move the assembly to
It’s desired final position, and
fastens firmly in place by torque bolt
to 10Nm.

10. Connect the roof hook with the GD

Rail.
a. Insert the D-Module into the
side channel of the GD Rail as
the step 9 shown.
b. Adjust the GD Rail to be level.
c. Fasten the bolt.

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11. GD Rail connect

a. Put the GD Rail Splice into the
side channel of the GD Rail about
75mm, then fasten the M8 Bolt.
b. Put the other GD Rail into the
other side of the GD Rail Splice and
fasten the other M8 bolt.

Install the module

12. Installing anti-slip protection
The anti-lip protection is only
necessary on the lowermost row of
modules. At first, fit two bolts M6*20
and nuts into the lower holes of
each module. Then place the first
module of the bottom row so that
the anti-slip protection sits in the rail
channel of the lowest row of rails

13. Fixing the outer modules by End

clamp.
a. Put the end clamp kit into the
top channel of the GD-Rail as
the step 9.
b. Push the side of module to
firmly against the end clamp
and then fasten the bolt.

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14. Fixing the inter modules by inter

clamp.
a. Put the inter clamp kit into the
top channel of the GD-Rail as
the step 9.
b. Push the Inter-module clamp
firmly against the already fixed
module.
c. Push the next module against
the other side of the
module-inter clamp.
d. Tighten the bolt
15. Installing the further rows of
modules

Cable tie and Grounding

16. Grounding
Please see the Grace solar
Grounding System Installation
Guide

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10. Warranty
Xiamen Grace Solar Technology Co., Ltd. warrants that its Grace Solar Panel Mounting System is free from defects
in materials and workmanship for a period of 10 years from the date on which the Frame is purchased from Grace
Solar, on the terms set out in this warranty.
In the event that the Frame does not conform to this warranty during the Warranty Period, Grace Solar 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, Grace Solar‘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 Grace Solar’s control, as determined by Grace Solar in its sole discretion.
This warranty does not cover, and under no circumstances will Grace Solar 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 Grace Solar panels mounting system (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.
This warranty will not apply to any claims received by Grace Solar after the expiration of the Warranty Period.
Grace Solar makes no warranties, express or implied, other than the warranties made herein, and specifically
disclaim all other warranties, representations and conditions to the extent permitted by law. To the extent
permitted by law, in no circumstances will Grace Solar be liable for direct, indirect, special or consequential
damages arising from a defective Frame or for any damage or injury to persons or property. Grace Solar’s
aggregate liability, if any, in damages or otherwise, will not exceed the invoice value of the Frame at the time of
purchase from Grace Solar.
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.

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