1.
General Information
1.Introduction
Thank you for choosing Newsunpower
BPSolar sistem solar mounting system. Made from custom-built aluminum
extrusions and components, BPSolar
Newsunpwer's
sistem innovative design and improved frame strength
greatly simplify solar panel installation. The easy 4 steps installation makes the Tilt-in modules
able to be put into NSBP
NSP Rail in any position quickly. So, the Tilt-in modules are pre-assembled with
the clamps to save your installing time.
Tilt In Align Lock
Four Steps, Easy Installation!
BPSolar sistem versatile design makes it suitable for a wide variety of building types and zones
Newsunpower's
including residential, commercial and remote environments.
BPSolar sistem solar mounting system is backed by a 10-year warranty and is assessed in
Newsunpower
accordance with the Australian/New Zealand Standard on Wind Actions (AS/NZS1170.2.2011,
inclusive of Amendament #2 (DECEMBER 2012)).
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Installation Manual 19--4104
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2. Safety and Installer Responsibilities
2.1. Safety and Installer Responsibilities
It is critically important that safety practices are observed when installing
2.1.1 Do not throw or roughly handle any Newsunpower
BPSolar sistem components.
2.1.2 Do not bring Newsunpower
BPSolar sistem system into contact with sharp or heavy objects.
2.1.3 Do not modify Newsunpower
BPSolar sistem 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.
2.1.4 It is the installer's responsibility to verify the integrity of the structure to which
Newsunpower
BPSolar sistem components are fixed. Roofs or structures with rotten/rusted bearers, undersized
bearers, excessively spaced bearers, or any other unsuitable substructure cannot be used with
Newsunpower
BPSolar sistem components, and installation on such structures will void the warranty, and could
result in death or serious injury.
2.1.5 It is the installer's responsibility not to overload the existing structures due to the weight
and additional wind load (liplift) of installation.
2.2. Safety and Installer Responsibilities
AS/NZS1170.2.2011 provides guidance on determining the wind pressures applicable to your
Newsunpower
BPSolar sistem solar mounting system install sites, taking into account the roof shapes and
geographic locations. Sufficient guidance is given in this document, but you may wish to procure a
copy of these standards if your company installs Australia/New Zealand wide.
2.2.1 REMEMBER average wind speeds are higher for structure mounted closer to the roof
perimeter zone (edge). Refer to 'Fixing within Roof Installation Zone' for more information).
2.2.2 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.
2.2.3 If alternative fasteners are used to fix the mounting 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 Newsunpower
BPSolar sistem mounting system order.
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Installation Manual 19--4103
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3. Technical Specifications
3.1. Applications
3.1.1 Commercial and residential buildings
3.1.2 Marine applications and remote areas
3.2. Features
3.2.1 6005-T5 Aluminum extrusion
3.2.2 Innovative design of the Tilt-in modules, which can be pre-assembled with the clamp,
making the installation easy and quick.
3.2.3 Suitable for different conditions and the most solar panels at present market.
3.2.4 Significantly higher strength-to-weight ratio than other mounting products, providing
improved efficiency due to greater lifespans, inherent corrosion resistance resulting in low on-
going maintenance and an extended product life.
3.2.5 Assess in accordance with Australian/New Zealand Standard on Wind Actions,
AS/NZS1170.2.2011(inclusive of Amendament #2 (DECEMBER 2012)).
3.2.6 Anodized finish
3.3. Materials
Tensile Strength
Materials
Ultimate Yield
Extruded
260MPa 240MPa
6005-T5 Aluminum
Stainless Steel 304 670MPa 300MPa
3.4. Materials
Roof Slope 0°—60°
Building Height up to 20m
Mounting Structure Timber
Roman tile, Flat tile, Asphalt shingle/Slate tile,
Roof Types
tin and irregular sheet metal,etc.
System Angles Flushed with the roof
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Installation Manual 19--4102
4. Instalation
4. Tools for Installation
tools
The following tools are required for installation:
No. Tool Name Usages/Notes Pics
If using a 6mm driver bit, make
sure the cordless power tool used
for the driving has a hand-tight
6 mm Allen key or
1 clutch setting a fine (soft) impact
hexagonal driver bit.
drive to prevent damage to the
fragile glass panels and threads on
the structure.
Drill or impact driver for driving
2 Cordless drill
roof material fixings,
For tile roof installation, and angle
grinder fitted with a continuous
edge diamond tipped tile Ocutting
blade; gloves, hearing protection, a
3 Angle grinder
face protection mask, and a
suitably rated breathing protection
mask for all people in proximity of
Grinding.
4 open-end wrench For fastening the bolts.
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Installation Manual 19--4101
5.System
7. Moduleplanning
field planning
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
tolerance of conditions.
L 1. Height of the module field: module height x number of modules vertically
L 2. Width of the module field: NO. of modules horizontally x (width of the module+18 mm)+32 mm
L 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.
L4. Distance between roof connections horizontally: Depending on the distance between rafters
and on the fixing requirements.
L5. Distance between modules: 17 mm
When positioning the modules, please take into consideration that
• the values above are
• dimensions of tiles or other roof covering and the position of the rafters define
the precise actual horizontal distance between roof connections
• the clamping points of modules defines the precise actual vertical distance
between roof connections.
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6.Instalation
9. Installation
Tile Roof Hook Installation:
1. According to system planning, to
determine the hooks installation
directions and positions.
Move away the roof tiles at the marked
position or simply lift them up slightly.
(See right pic.)
2. Input the roof hook to the marked
wooden beam.
Fix the roof hooks with 3x wood screws
(St6.3*14G*80) by Cordless drill.
(See right pic.)
3. Where the beam which for supporting
hook handle is too high for the hook to
lean on, shim the roof hook with wood
board till the corner of the hook handle
is in same level with the tile.
(See right pic.)
Wrong Correct
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8. Always install from the shorest when
the rails are not in the same lengths. Using
M8X25mm hexagonal socket head
bolt,locking washers,and tilt-in Module to
install all rails on the hooks (Do not fasten
in order to facilitate the adjustment of rails
later on).(See right pic.)
9. To adjust rails position.
Take advantage of the loose connection
between long hook hole,tilt-in module and
hexagonal socket head bolt to adjust the
rails in horizontal and vertical
directions.When the position of rails are
well adjusted,fasten the hexagonal socket
head bolts with hexagonal driver bit.
(See right pic.)
10.To install rail splice kit.
When rails are not long enough,rail splice
kit can be used to connect multiple rails
together.When connecting,slide half of
splice to one rear side of the pre-
assembled rail,then put next rail into the
other side of the splice kit. When come
togeter,fix 2 hexagonal socket head bolts
into the rail splice with cordless drill.
(See right pic.)
Solar Module Installation:
11. Before the installation of solar
modules, an anti-lip protection should
be installed on the bottom row of
modules for the security. Therefore,bolts
are required to be fastened on holes
near the bottom frame of the
module.Such protection can prevent the
modules from dropping. Refer the right
picture to for the details.
(See right pic.)
12. To install end clamp kit.
Slide the end clamp kit,firmly stick to the
side of module,then use the hexagonal
driver bit to fasten the bolt.
(Recommend torque force:8 N·m)
(See right pic.)
13. To install inter clamp kit.
Slide the inter clamp kit between 2
modules into the right position,
then use the hexagonal driver bit to
fasten the bolt.
(Recommend torque force:8 N·m)
(See right pic.)
14. Complete the installation of the
whole pitched roof solar mounting
system.
(See right pic.)
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