Plastic End Cap Proline

Product Information

Specifications

• System Type: Flush Mount Proline
• Material: Aluminium and High-Grade Steel
• Warranty: 25 years
• Compliance Standards: AS/NZS 1170.2:2021, AS/NZS 1170.1:2002
  (R2016), AS/NZS 1170.0:2002

Product Usage Instructions

1. Introduction

The Flush Mount Proline system by Schletter Australia is
designed for flush mount photovoltaic applications in various
environmental conditions. The system consists of fasteners securing
Proline rails that support PV modules.

2. Safety Instructions

Before starting the assembly, read and understand all safety
instructions provided in the manual. Ensure compliance with
regional and national standards, building regulations, and accident
prevention regulations.

3. Setup and Components

Refer to the installation manual and bill of materials carefully
before commencing any installation work. The system components are
made from durable materials such as Aluminium and High-Grade Steel
to withstand adverse site conditions.

4. Installation Instructions

Sections 3 and 4 of the manual provide detailed installation
instructions for assembling the mounting system. Follow the
step-by-step guide for a safe and secure installation process.

5. Warranty Compliance

It is essential to follow the manual instructions to comply with
the product warranty. Any improper use, incorrect assembly, or
modifications may void the warranty.

FAQ

Q: What is the warranty period for the Flush Mount Proline

system?

A: The system comes with a 25-year warranty.

Q: What standards does the system comply with?

A: The system complies with Australian Standards: AS/NZS
1170.2:2021 for wind actions, AS/NZS 1170.1:2002 (R2016) for
imposed loadings, and AS/NZS 1170.0:2002 for general
principles.

Q: What materials are used in the components of the

system?

A: The components are made from Aluminium and High-Grade Steel
for durability.

FLUSH MOUNT PROLINE
INSTALLATION MANUAL V2.3
LAST REVISED ON 19.02.2024

TABLE OF CONTENTS 1.0 Introduction ……………………………………………………………………………………………………………… 2
1.1 Short Description of the system…………………………………………………………………………. 2 1.2 Scope of the Installation Manual………………………………………………………………………… 2 1.3 Appropriate Use/Warnings…………………………………………………………………………………… 2 1.4 Safety Instructions ……………………………………………………………………………………………….. 3 2.0 System Overview …………………………………………………………………………………………………….. 4 2.1 System Setup ………………………………………………………………………………………………………… 4 2.2 Components Details ……………………………………………………………………………………………… 5 3.0 Installation Tools……………………………………………………………………………………………………… 8 4.0 Mounting Instructions …………………………………………………………………………………………….. 9 4.1 Mount Fasteners ……………………………………………………………………………………………………. 9
4.1.1 Roof Hooks ­ Tile Roofs …………………………………………………………………………………. 9 4.1.2 Rapid2+ Pro SML ­ Trapezoidal and Corrugated Roofs…………………………….11 4.1.3 Standing Seam Clamp ­ Standing Seam and Kliplok Roofs ………………….. 12 4.2 Rail Installation ……………………………………………………………………………………………………. 14 4.2.1 Choice of rail ………………………………………………………………………………………………….. 14 4.2.2 Add Rail Splice ……………………………………………………………………………………………….. 14 4.2.3 Add Rail to Fastener ……………………………………………………………………………………… 16 4.3 Module Mounting …………………………………………………………………………………………………. 17 4.3.1 Position Modules ……………………………………………………………………………………………. 17 4.3.2 Secure Modules ……………………………………………………………………………………………… 18 4.4 Accessories …………………………………………………………………………………………………………… 19 4.4.1 Micro/Optimiser Kit Proline ………………………………………………………………………….. 19 4.4.2 Earthing Lug …………………………………………………………………………………………………… 19 4.4.3 Rail Cable Clip…………………………………………………………………………………………………20 4.5 Torque Specifications and Tolerances ……………………………………………………………… 21 4.6 Maintenance …………………………………………………………………………………………………………. 22

WE SUPPORT SOLAR

P a g e 1 | 23

1.0 Introduction
1.1 Short Description of the system
Schletter Australia offers a wide array of solutions for flush mount photovoltaic (PV) applications suitable for nearly any environmental condition. The solar mounting systems are designed for strength and ease of installation using high quality products to meet or exceed applicable local and international standards.
The system consists of fasteners securing Proline rails which support PV modules. The pre-assembled components, slide in rail joiners without the use of screws and click in module clamps accounts for the industry leading installation times and ease of installation.
The components are made from Aluminium and High-Grade Steel allowing durability in adverse site conditions. The system comes with a 25-year warranty that is complaint with Australian Standards: AS/NZS 1170.2:2021 for wind actions, AS/NZS 1170.1:2002 (R2016) for imposed loadings, and AS/NZS 1170.0:2002 for general principles.
1.2 Scope of the Installation Manual
The manual aims to provide information on safety warnings, mounting system setup and components for installation of PV modules in pitched metal roofs.
Section 1 and 2 focuses on introduction and an overall overview of the mounting system. Section 3 and 4 focuses on installation instructions on the appropriate methods for assembling the mounting system.
Please refer to the installation manual and bill of materials carefully before commencing any installation or maintenance work. All necessary information regarding installation and maintenance should be provided. For further questions, please contact Schletter Australia.
The content of this manual should be followed to comply with product warranty.
1.3 Appropriate Use/Warnings
The mounting system acts as a support structure for the installation of photovoltaic modules. Any other and/or additional use or incorrect assembly (for example: use of third-party components) or nonobservance of tolerance specifications are considered as improper use and exclude any liability of the manufacturer. Any use under conditions other than those assumed in the planning is also considered as improper use and leads to the loss of any liability claims against the manufacturer.
This applies if the system is used under other load, climatic and/or corrosion conditions than originally assumed. Schletter Australia is in no case responsible for damages to the product itself or consequential damages caused by the product which are the result of an inappropriate handling of the product.
Schletter Australia is not responsible for outages or faults resulting from modifications made by the customer or other individuals. There is no entitlement to the availability of previous versions or to the refitting of delivered components to the current series status.

WE SUPPORT SOLAR

P a g e 2 | 23

1.4 Safety Instructions Read and understand these safety instructions carefully before starting the assembly and keep them safely at hand. Comply with all regional and national valid standards, building regulations and accident prevention regulations.
Break hazard! PV modules may be damaged if stepped on.
Planning, installation and commissioning of the solar power system must only be performed by qualified technical personnel. Improper execution can result in damage to the system and endanger individuals.
Electrical current hazard! Installation and maintenance of the PV modules must only be performed by qualified technical personnel. Observe the safety instructions issued by the PV module manufacturer!
Falling hazard! Working on the roof as well as ascending and descending poses a risk of falling. It is vital to observe accident prevention regulations and use appropriate fall protection equipment. PV mounting systems are not suitable as climbing aids or fall protection.
Injury hazard! Falling objects pose a risk of injury to people. Prior to installation, set up barriers in the hazard area to warn people nearby.
It is the obligation of the operator to ensure that all parts of the mounting instructions are kept within easy reach on the PV-plant for the fitters at any time.
As personnel, only persons who can be expected to carry out their work reliably can be admitted. Persons whose responsiveness is affected, e.g., by narcotics, alcohol, or medication, are NOT permitted.

WE SUPPORT SOLAR

P a g e 3 | 23

2.0 System Overview
2.1 System Setup An overview of the roof-top parallel system as shown in figure below, subject to changes based on project specific requirements.
3
4

2

1

Key Components 1 Fasteners 4 End Clamps

2 PRO Line Rails

3 Middle Clamps

Accessories Rail Connector

Rail Caps

Cable Clips

Earth Lugs

WE SUPPORT SOLAR

P a g e 4 | 23

RAILS

2.2 Components Details

ITEM CODE

ITEM DESCRIPTION

120020-04400 Rail Pro35 4400mm

120020-94400 Rail Pro35 4400mm – Black

120021-04400 Rail Pro50 4400mm

100001-002

Roof Hook Universal Proline

108000-000

Roof Hook Standard Proline

PU

IMAGE

200

200

150

24 24

ROOF HOOKS

KLIPLOCK CLAMPS

112012-117

KlipLok Classic EMU

112012-127

KlipLok High Strength EMU

WE SUPPORT SOLAR

66 66
P a g e 5 | 23

MODULE CLAMPS

131020-001

Mid Clamp 30-47mm Proline

100

131020-000

End Clamp 30-47mm Proline

50

131020-901

Mid Clamp 30-47mm Proline Black

100

131020-900

End Clamp 30-47mm Proline Black

50

WE SUPPORT SOLAR

P a g e 6 | 23

WE SUPPORT SOLAR

P a g e 7 | 23

3.0 Installation Tools

Tape Measure

Chalk Line

Marker

Pliers

Angle Grinder

Carpenter’s Square

Rubber Mallet

Torque Wrench

Wrench

Rechargeable Power Drill

Torx® bit (TX 40)

WE SUPPORT SOLAR

P a g e 8 | 23

4.0 Mounting Instructions
4.1 Mount Fasteners
4.1.1 Roof Hooks ­ Tile Roofs
Choice of Roof Hook The choice of roof hook proline generally depends on the height and length of the horizontal arm of the bracket from the rafter fixing point. Proline roof hook ranges as follows:

Standard Roof Hook Proline

Universal Roof Hook Proline

Position Roof Hook I. Select the mounting position along the existing rafters. Remove the roof tile.

II. Grind the bottom tile, if necessary, to remove any raised edges, that allow the roof hook to be correctly oriented maintaining a minimum distance between hook and bottom tile. Use an angle grinder with a diamond wheel for this.

WE SUPPORT SOLAR

P a g e 9 | 23

Only remove the raised edge to the extent that the minimum distance between hook and bottom tile is maintained. This is recommended to be 5mm to account for hook elasticity under load conditions.
Fix Roof Hook to Substructure
I. Screw on the base plate of the roof hooks using 2 of 6.2mm x 80mm, with minimum 36mm embedment into the wooden rafters. The base plate should have one screw in the upper row of holes and another in the bottom.

When ordering the roof hook, make sure the height of the horizontal arm of the bracket has been chosen correctly in relation to the batten height and tile thickness. This is to ensure the minimum distance of 5mm mentioned earlier is achieved.
If the necessary height cannot be reached, use a spacer. The height packed by the spacer is limited by the length of screws thread available after 36mm minimum embedment into the rafters.
Cover Tiles
I. Turn over the removed tile. Use an angle grinder with a diamond wheel to grind the raised edge section which is in line with the roof hook arm. Do not grind any deeper.
II. Cover the tiles. Tiles should ultimately lie down as their natural ingress, to prevent any leakage of rainwater into the roof structure.

WE SUPPORT SOLAR

P a g e 10 | 23

4.1.2 Rapid2+ Pro SML ­ Trapezoidal and Corrugated Roofs I. The Rapid2+ Pro SMLs are positioned on the roof ridges, using string lines for alignment.

Fig 4.1.2A: Rapid2+ Pro SMLs aligned on top of roof

II. Fix the fastener to the roof purlin via the supplied selfdrilling universal screws, 6.2mm x 80mm. Ensure that the screw drilling line of axis is perpendicular to the roofing sheet.

The universal screw works with both timber and steel substructures if the screw embedment requirements are met:

Substructure

Embedment (mm)

F7 Pine Softwood 1.5 BMT Steel

36mm
Complete Penetration – For steel purlins > 1.9mm, predrilled hole of 4.5mm in diameter is recommended

The fasteners must be securely connected to the substructure without deforming the roof ridge.

Fig 4.1.2B: Rapid2+ Pro SMLs being attached using universal screw

The tightening torque must be limited (15Nm) to prevent this deformation and to ensure thermal expansion is not impeded.

Schletter Advantage
In comparison to other mounting systems, this fastener has the advantage that it uses a long base to distribute further the applied load on the roof sheet. This minimizes the stress on the roof sheet and guarantees optimized stability. The fastener can be used for both metal and timber substructures.
The height adjustable multi-adaptor allows for rail adjustment across uneven roofs. It also helps to achieve good clearance between panels and roof sheets for heat dissipation.
The UV resistant EPDM rubber inlay on the bottom of the fastener guarantees water tightness.

WE SUPPORT SOLAR

P a g e 11 | 23

4.1.3 Standing Seam Clamp ­ Standing Seam and Kliplok Roofs
Choice of Seam Clamps The choice of seam clamp depends on the correct identification of the Kliplok roofing sheet at site. Based on the roofing sheet the following clamps can be used:

Kliplok Classic

Kliplok High Strength

Connect Standing Seam Clamp
I. Once the appropriate seam clamp is selected, position the seam clamps on the roof as per the rail installation plan.
II. Secure the seam clamps to the roof by tightening the single M8 bolt (14Nm), as shown in Fig 4.1.3A.
Please limit tightening torque to recommended settings to avoid deformation of the standing seams and to ensure that thermal expansion of the metal sheets is not impeded.
Roofing sheet manufacturers recommend to avoid fixing fasteners on lapjoints.

Fig 4.1.3A: Securing seam clamp to roofing sheet

Schletter Advantage
The single bolt tightening combined with pre-assembled EMU adaptor makes the system fast and easy to install.
The seam clamps can be adjusted for either Lysaght Classic or High Strength roof applications.
The seam clamps come pre-assembled fit for the roofing sheet at site: Classic or High-Strength.
The multi adaptor can be easily adjusted to run rails parallel and perpendicular to the standing seam of the roofing sheet, as shown below:

WE SUPPORT SOLAR

P a g e 12 | 23

Multi adapter orientation for running rail perpendicular to standing seam

Multi adapter orientation for running rail parallel to standing seam

WE SUPPORT SOLAR

P a g e 13 | 23

4.2 Rail Installation
4.2.1 Choice of rail The Proline rails come in standard sizes of 4400mm. Based on required spans and site conditions, the rails come in the following dimensions:

Pro35
4.2.2 Add Rail Splice I. To increase the array length, rails can be spliced together using rail joiners [Fig 4.2.1A].
II. Insert half of internal splice into first rail, push until it reaches midpoint where the stop tab is located under the splice [Fig 4.2.2B].
III. Add second rail to opposite end until it fully reaches the middle stop plate. This should lock both rails together forming a longer array [Fig 4.2.2C].
No screws are required, saving installation time.
It is recommended to limit array lengths to a maximum of 20m, due to thermal expansion limitations, for fixing to substructure.
However, this should be limited to 10m for fixing in roofing sheets (for example: Kliplok clamps).
The rail joiners are for single use application only.

Pro50 Fig 4.2.1A: Rail Joiner

WE SUPPORT SOLAR

P a g e 14 | 23

Fig 4.2.2B: Joiner connecting Proline rails

Fig 4.2.2C: Rails secured together via Proline joiner

WE SUPPORT SOLAR

P a g e 15 | 23

4.2.3 Add Rail to Fastener
I. Position the bottom (rectangular channel) of Proline rails on top of the multi adaptor hook fit for Proline rails, as shows in Fig 4.2.3A.
II. Push down the length of rail spliced together on the EMU Proline hooks. so that the hook clips into the bottom channel of the rail.
Notes:
Please note that, the multi adaptor hook should be oriented as shown in Fig 4.2.3A i.e. the hook that is closer to the wall, is fit for Proline rails.
The multi adaptor comes pre-assembled with Rapid2+ Pro SML, roof hooks and seam clamps. This means one fastening method can be used across all the flush mount fasteners.
If necessary, adjust the rails to the desired height to compensate for roof unevenness before tightening the bolt.
III. Do not tighten until the rail has been positioned to rest correctly on top of the fastener hook, as shown in Fig 4.2.3B.
IV. Secure by tightening the bolt on the fasteners using recommended torques (14Nm).

Fig 4.2.3A: Multi Adaptor fixing rail to fastener Fig 4.2.3B: Rail attachment to fasteners

WE SUPPORT SOLAR

P a g e 16 | 23

4.3 Module Mounting
4.3.1 Position Modules I. Position end clamps on rail approximately 20mm from end of rail, do not tighten [Fig 4.3.1A].

II. Position first module and secure using prepositioned end clamps, do not tighten [Fig 4.3.1B].

Fig 4.3.1A: Positioning end clamp

III. Attach middle clamps to rail on the exposed side of the first module [Fig 4.3.1C].

Fig 4.3.1B Postioning first module

IV. Place second module next to first module and secure using middle clamp, do not tighten [Fig 4.3.1D].
V. Repeat until end of row.

Fig 4.3.1C Postioning middle clamps Fig 4.3.1D Postioning second module

WE SUPPORT SOLAR

P a g e 17 | 23

4.3.2 Secure Modules
I. Verify that the module clamp is fully engaged on the rail and 1.5 mm maximum middle clamp to module offset is aligned with the module frame [Fig 4.3.2A].
II. Secure all clamps [middle and end] to recommended torque settings [15Nm].
When mounting modules, please observe the clamping points specified by the module manufacturers.

Fig 4.3.2A: Securing middle clamp and PV modules

III. Please observe 30mm gap between module rows for better heat dissipation [Fig 4.3.2B].

Fig 4.3.2B: Gap between PV Module rows

WE SUPPORT SOLAR

P a g e 18 | 23

4.4 Accessories 4.4.1 Micro/Optimiser Kit Proline
The optimiser kits enable mounting of optimisers and microinverters on top of the Proline Rails.
I. Loosely connect the bolts and washer to the mounting holes of the micro- inverter.
II. Slide in or simply insert the hammerhead nut from above. III. Secure the bolt using recommended torque settings
[14Nm].
4.4.2 Earthing Lug
The earthing lug can be used as a potential equalization within the mounting racks.
I. The lug can be positioned by top entry or sliding in top of the rail [V-channel] using the hammerhead nuts.
II. Place the earthing wires inside the lug chamber. III. Secure the bolt using recommended torque settings
[14Nm]. IV. Clamp distance to the edge: 8-10 mm. V. Connection (single/multi- wired): 4-50 mm2.

WE SUPPORT SOLAR

P a g e 19 | 23

4.4.3 Rail Cable Clip The Proklip-Multi 10 allows quick rail cable clip installation without the use of any nuts and bolts. · Position the clip (A) of the rail cable clip underneath the bottom (rectangular) channel (B) of the Proline rails. · Insert cable clip by pushing firmly into the channel, until it snaps in, as shown in Fig 4.4.3A. · The cables are then run through the retainer and the clip can be closed by pressing it in.
Fig 4.4.3A: Rail cable clip attached to Proline rail

WE SUPPORT SOLAR

P a g e 20 | 23

4.5 Torque Specifications and Tolerances
The various bolt sizes of the mounting system and their recommended torques in the mounting system is listed in Table 6.5:

Bolt Size

Recommended Torques

Torx Bolt for RapidPro Module Clamps

15 N-M

M6 and 1/4″ Bolt

6 N-M

M8 and 5/16″ Bolt

14 N-M

M10 and 3/8″ Bolt

30 N-M

M12 and 1/2″ Bolt

50 N-M

M16 and 5/8″ Bolt

121 N-M

M20 and 3/4″ Bolt

244 N-M

Note: Recommended speed for installation of self-drilling 1/4″ diameter is 1200-1800 RPMS

Table 4.5: Size of bolt and recommended torques

For project specific system design, please refer to project specific drawings for recommended torque for each size of bolt used in the system and allowable tolerances. In the event of deviation from approved drawings, contact Schletter Australia immediately.

WE SUPPORT SOLAR

P a g e 21 | 23

4.6 Maintenance
In general, once correctly assembled, the roof-top systems should operate reliably with minimal maintenance. However, Schletter Australia recommends yearly inspection of system should be conducted to maintain optimal performance. This ensures the system’s long-term durability and reliability.

The following best practises and inspection guidelines are advised for roof- top mounting systems:

I. Prior to installation, it is advisable to store products free from contamination by contact with items that may contain rust, dirt and chemicals. If contamination occurs, affected products have to be cleaned using appropriate methods such as using galvanised zinc spray on affected areas.

II. Clean any visible contamination from soil, and other particles. Further guidelines on this can be found in:

Standards Standards Association of Australia Galvanizers Association of Australia (GAA) Galvanizers Association of New Zealand (GANZ)

Material Aluminium Steel Steel

Country Australia Australia New Zealand

III. Visually inspect for signs of damage, wear, corrosion, or movement. Replace any affected components immediately.

Aluminium components may undergo surface oxidation, forming a thin and hard film of Aluminium oxide which looks like powdery white or dull grey finish. This is standard ageing process for Aluminium and is beneficial for long-term durability of the product. The oxide layer acts as a barrier against atmospheric corrosion.

IV. Check torque values of fastening bolts in the structure as per recommended torques in section 6.5. The following inspection process can be followed:

a) At least 2% of bolted connections must be checked using a calibrated torque wrench. The torque wrench must have a display or be a click type torque wrench.
b) Torque wrench should be set at 50% of intended tightening torque. Check is successful if the bolt cannot be loosened.
c) If more than 10% of checked bolted connections are loose, a re-check has to be done. The re-check should be increased to 10% of all bolted connections.
d) If more than 10% of connections are still loose, all bolted connections much be checked. e) Tighten all non-conforming bolts to specified torques as per section 6.5.
V. Check for loose wiring.

The maintenance guidelines above apply only to the components of the mounting structure that are manufactured from Schletter. For external components, maintenance should be carried out respective to the relevant manufacturer’s guidelines.

WE SUPPORT SOLAR

P a g e 22 | 23

SCHLETTER SOLAR GMBH UNIT 4, 27 WILLIAMSON ROAD 2565 INGLEBURN AUSTRALIA P: (02) 9426 7800
WWW.SCHLETTER-GROUP.COM
WE SUPPORT SOLAR We reserve the right to changes, including technical modification.

P a g e 23 | 23

References

• High-Quality Solar Mounting Systems | Schletter Group
• High-Quality Solar Mounting Systems | Schletter Group
• High-Quality Solar Mounting Systems | Schletter Group

Read User Manual Online (PDF format)

Read User Manual Online (PDF format)  >>

Download This Manual (PDF format)

Download this manual  >>