ÿþPV Installation Manual - Ample Energy Services Ltd
Contents
1. Table of contents 1 Introduction 1 1 Overview 1 2 Intended use 1 3 Standards and technical directives 1 4 About this manual 2 Safety 2 1 Basic safety instructions 2 2 Working on roofs 2 3 Warnings 2 4 Responsibilities of the operator 3 Technical Description 3 1 System overview 3 2 Scope of delivery 4 Designing the module field 5 Important installation instructions 5 1 Operating conditions 5 2 Preparation 5 3 Tools 6 Installation of roof connections 6 1 Installing the standard roof hook 170 Variation when using roof hooks for heavy snow RAHA HASH WWWW WwW 00 00 00 00 N O1 O1 e O O Variation for plain tile roof covering Variation for shingle slate roof covering 6 2 Installing hanger bolts 6 3 Installing clamp on roof hooks 7 Install the system 7 1 Installation procedure 7 2 Quickstone and X Stone Installing the Quickstone Installing the X Stone 7 3 Installing the base rails Fixing the base rails Aligning the rails Inter connecting base rails Installing telescoping end pieces optional 7 4 Installing the modules Installing anti slip protection Fixing the outer modules of each row Fixing the inner modules of each row Installing further rows of modules 8 Variation for landscape installation of the modules 8 1 Installing base rails vertically 8 2 Installing cross rails 1 Introduction 1 1 Overview The Sun Grid is a robust long life mounting system for photovoltaic m2. Warning symbol pictograph Indicator word to denote the danger level Information about type and source of the danger Information about possible consequences if the danger is not observed Measures for avoiding the danger and for preventing injuries or property damages The heading of the warning notes identifies one of the following danger levels Denotes a major risk failure to observe which could lead to serious injury or death WARNING Denotes a potentially dangerous situation which may lead to moderate to serious physical injury and property damage CAUTION Denotes a potential risk which may lead to physical injury and property damage 2 4 Responsibilities of the operator Modifications to equipment may be performed only by authorized personnel The operator of the system has the following safety related responsibilities Performing recommended maintenance work Ensuring that the installation of the frame is performed only by qualified personnel with adequate skill and knowledge Ensuring that the assigned installation personnel can evaluate the work assigned and recognize possible dangers Ensuring that the installation manual is available during the installation The installation manual is part of the product Ensuring that the installation manual and particularly the safety instructions are read and understood by the authorized installation personnel prior to beginning the work Ensur
3. In that way the exact necessary length of rail can be realized After adjusting the telescoping end piece to the last module of a row fix it completely by tightening the Allen bolt on the rail side of the telescoping endpiece tightening torque 8 Nm 15 7 4 Installing the modules DANGER Working on the roof During work on the roof parts can drop down or persons may fall off Secure yourself against falling Do not remain in the danger area Wear a hard hat After completing the installation check that the system and the PV modules are securely fastened The modules are successively mounted onto the base rails It is recommended to start on one side of the module field When using telescoping end pieces start installing the modules on the rail side of each row so that the telescoping end piece can be aligned with the last module to be mounted Add anti slip protection consisting of a bolt and nut inserted into the holes on the underside of the module frame to the lowest row of modules horizontal rail installation only This keeps the modules from sliding off and thus facilitates installation The anti slip protection does not have any static function in the finished installation The modules are fixed with inter module clamps and endclamps An end clamp will hold one module an inter module clamp 2 consecutive ones When installing laminates laminate clamps need to be used instead of module cl
4. Without appropriate flashing of the roof hook the roof can leak Use a zinc metal sheet with at least 20mm around the recess in the tiles underneath the roof hook Installation Cut a recess into the tiles around the position of the roof hook 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 10 Variation for shingle slate roof covering CAUTION Damage to the building through leakage Without appropriate flashing of the roof hook the roof can leak Use a zinc metal sheet with at least 20 mm around the recess in the tiles underneath the roof hook Installation The roof hook for shingles slate is installed in the same manner as the roof hook for plain tiles However it is fixed with 3 wood screws 6x100 mm 6 2 Installing hanger bolts Installation Drill through the roof cladding at the planned location Screw the hanger bolts into the purlins Press the sealing washer onto the drill hole and fix it with the nut without further damaging the sheeting The tightening torque depends on the type of roof sheeting 1 Hanger bolt with L bracket 2 Sealing washer 3 Nut CAUTION Damage to the building through leakage Inappropriately fixed hanger bolts can cause leakage Never position hanger bolts on the low parts of the corrugated sheets CAUTION Observe minimum edge distances Ha
5. numbers from the illustrations are depicted in a text box as 1 2 etc Pictographs Identifies background and additional information for processes Tips and tricks Facilitate installation 2 Safety 2 1 Basic safety instructions The following basic safety instructions and the warning notes are an essential part of this manual and are of fundamental importance for handling the product Regardless of the certified structural analysis it must be ensured prior to every installation that the product meets the static requirements on site according to the local jurisdiction having authority for such installation 2 2 Working on roofs When working on roofs note the following instructions Pay attention to accident prevention regulations for working on roofs If appropriate use a barrier to protect against falling parts In line with accident prevention regulations work on roofs should be carried out using safety harnesses for individuals or safety scaffolding Observe the relevant local safety regulations Before stepping on to the roof check the load bearing capability of all parts which are under stress Use fall protection Use protective equipment to guard against falling even when carrying out short jobs Do not carry materials on to the roof via ladders but rather use suitable lifting gear 2 3 Warnings The warning notes used in this manual identify safety related information They consist of
6. screws with a diameter gt 6mm Depending on the type of roof covering different roof connections must be used The type of roof connection included in your delivery depends on your order 6 1 Installing the standard roof hook 170 3x wood screw 6 x 80 mm Rafter Standard roof hook 170 Wood plates to shim roof hooks if necessary CAUTION Material damage through faulty installation The roof hook must not press against the tiles to avoid damaging the tiles If necessary Shim roof hook with wooden plates so that the roof hook does not touch the underlying tile If necessary use an angle grinder or hammer to cut a recess in the tile that covers the roof hook so that the tile lies flat on the surface 1 2 3 4 Installation Remove the roof tiles at the marked positions or if possible simply push them up Position the roof hooks above the low parts of the tiles Fix the roof hooks to the rafter using three 6 x 80 mm wood screws Variation when using roof hooks for heavy snow The roof hook for heavy snow is installed in the same manner as the standard roof hook However it is fixed with 2 hex head screws 8x80 mm and 2 washers Variation for plain tile roof covering 1 2x wood screw 6 x 80 mm 2 Roof hook for plain tiles 3 Sheet of titanium zinc 4 Wood plates to shim roof hooks if necessary CAUTION Damage to the building through leakage
7. X stone version is recommended Please ask your Sales contact for further information 7 3 Installing the base rails DANGER Working on the roof During work on the roof parts can drop down or persons may fall off Secure yourself against falling Do not remain in the danger area Wear a hard hat After completing the installation check that the system and the PV modules are securely fastened CAUTION Damage to tiles through stepping on roof hooks Do not use fitted roof hooks as a ladder as this extreme point load could damage the tile below Base rails Depending on the number of modules in one row the base rails can be of one or of several pieces The length of the base rail corresponds with the width of the module field The parts of base rail are inter connected with joiner pieces Telescoping end piece The Telescoping end piece enables you to adjust the overall length of the base rails to the millimeter without the need for on site cutting Joiner piece 1 Base rail 2 Telescoping end piece 3 13 Fixing the base rails 1 Roof connection 2 Quickstone 3 Base rail Installation The installation is shown with the base rail 13 58 If your set of rails consists of rails of different lengths then always begin with the shortest piece Install the rails for each row of modules loosely on the roof hooks using an M 8x25 mm Allen bolt washer retaining washer and Quickstone e
8. a landscape orientation of the modules is desired or vice versa 8 1 Installing base rails vertically 1 Roof connection with L bracket 2 Base rail Installation If necessary turn the L bracket on the roof connection by 90 Fit the Quickstone into the channel of the base rail and fix it 19 8 2 Installing cross rails 1 Horizontal base rail 2 X Stone with 2 Quickstones 3 Vertical base rail Installation Insert one X Stone into the side channel of the upper rail Align the rails Insert the X Stones into the top channel of the lower rail Make sure the upper rail lays flat on the lower one Fix both Quickstones to the base rails tightening torque 8 Nm
9. ach 2 to 3 turns of the screw are adequate for loose installation Completely tighten the Quickstones only when you have put the rails in their final position Aligning the rails 1 Base rail 2 String or spirit level Installation Align all rails using a piece of string or a spirit level Tightly fix all Quickstone connections on the rails tightening torque 8 Nm Li J The oblong holes in the roof hooks or L brackets allow for a height adjustment of the rails to level out the PV installation on uneven roofs 14 Inter connecting base rails 1 Base rail 2 Joiner piece Installation Slide the joiner pieces halfway onto the rear side of the base rails Fix the according Allen bolt to the base rail tightening torque 8 Nm Slide the next rail segment into the Joiner piece Leave a 1cm gap as an extension joint Fix the second Allen bolt to the base rail tightening torque 8 Nm The connected rails should not be longer than 12 meters Installing telescoping end pieces optional 1 Base rail 2 Telescoping end piece 3 Loose rail section on the telescoping end piece 4 Roof connection Installation Mount a telescoping end piece at the end of every row of base rails If necessary fix the loose rail section of the telescoping end piece to a roof connection The telescoping end piece should not be firmly fixed until the last module of the row is positioned
10. amps The installation process is identical The laminates are set between the rubber lips of the laminate clamps 16 Installing anti slip protection Fixing the outer modules of each row Fixing the inner modules of each row 1 Module frame underside 2 Anti slip protection 3 Base rail Installation The anti slip protection is only necessary on the lowermost row of modules Fit two bolts M6 x 20 and nuts into the lower holes of each module 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 1 Module end clamp with Quickstone 2 Module 3 Base rail Installation Slide the Quickstone into the rail channel Align the module and push the module end clamp firmly against the side of the module Tighten the Allen bolt and Quickstone tightening torque 8Nm Li J When installing laminates laminate clamps need to be used instead of module clamps The installation process is identical The laminates are set between the rubber lips of the laminate Clamps 17 1 Inter module clamp with Quickstone 2 Module 3 Base rail Installation Slide the Quickstone into the rail channel Push the Inter module clamp firmly against the already fixed module Push the next module against the other side of the module end clamp Tighten the Allen bolt and Quickstone tightening torque 8 Nm When installing lam
11. ckstone and X Stone During the installation of SolarConstruct Quickstones are used The Quickstone is a special nut used to connect several parts of the Sun Grid The only tool needed for installation is a 6 mm Allen key The Quickstone can be used on both channels of the base rail For a cross installation of two layers of base rails XStones are used These consist of an aluminium block with two pre assembled Quickstones Installing the Quickstone Installing the X Stone 1 Element to be fixed e g module clamp 2 Allen bolt 3 Quickstone 4 Base rail Material damage through faulty installation Incorrectly installed Quickstone connections can rip out of the profile Install all Quickstone connections as described below Installation If necessary adjust the bolt so that it does not protrude the Quickstone Fit the Quickstone from above into the profile channel so that it wedges underneath the protruding rail hooks When fitted correctly the Quickstone matches the form of the profile exactly Tighten the bolt with a torque of 8 Nm 12 1 Horizontal base rail 2 X Stone with 2 Quickstones 3 Vertical base rail Installation Install both Quickstones as described above Make sure the upper rail lays flat on the lower one Completely tighten both Quickstones only when you have put the rails in their final position When installing on uneven roof surfaces the use of a special
12. inates laminate clamps need to be used instead of module clamps The installation process is identical The laminates are set between the rubber lips of the laminate clamps Installing further rows of modules Installation Set the modules of the next row above the lowest row of modules For optical reasons a gap can be left between module rows Use a spare inter module clamp as a gauge for the space between module rows In this way the horizontal and vertical gaps between modules will be identical Fix the modules to the base rails using inter module clamps and module end clamps as described above for the first row of modules 18 8 Variation for landscape installation of the modules DANGER Working on the roof During work on the roof parts can drop down or persons may fall off Secure yourself against falling Do not remain in the danger area Wear a hard hat After completing the installation check that the system and the PV modules are securely fastened When installing the modules in landscape orientation the rails need to run vertically For most types of roof connections you just turn the preassembled L bracket by 90 For roof connections without L brackets cross rail installation can be used X stones are used to interconnect two perpendicular layers of rails Cross rail installation is used when The roof construction demands a horizontal installation of the base rails while
13. ing that work site safety regulations and requirements are observed Ensuring that suitable 3 Technical Description 3 1 System overview All components of the system are listed below The version and quantities of the parts can vary depending on Type of roof Type of module Number of modules Site specifics 1 Base rail 2 Joiner piece 3 Inter module clamp 4 Roof hook 5 Module end clamp 6 Telescoping end piece optional 3 2 Scope of delivery All system parts and requisite small parts which are required for installation are included in the delivery The precise scope of supply will depend on the size and number of PV modules which you specify when ordering 1 Roof hook 170 2 Roof hook for heavy snow 3 Roof hook for plain tiles 4 Roof hook for Slate Shingles 5 Clamp on roof hook 6 Hanger bolt 7 Base rail 13 58 19 63 and 25 65 8 Base rail 7 49 9 Joiner pieces 13 58 19 63 and 25 65 10 Joiner piece 7 49 11 Telescoping end pieces 13 58 19 63 and 25 65 12 Telescoping end piece 7 49 13 Inter module clamp 14 Module end clamp for frame heights 24 5 mm to 51 mm 15 Module end clamp for frame heights 35 43 46 50 mm 16 Inter laminate clamp for laminates 6 to 8 mm thick 17 Laminate end clamp for laminates 6 to 8 mm thick 4 Designing the module field Below the distances between roof connections for a portrait installation are specified C
14. lamp on roof hooks roof hooks and hanger bolts need to be installed in specific distances depending on the distance of rafters and the statical 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 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 The configuration must be in accordance with the local conditions and with DIN 1055 parts 4 and 5 Eurocode 9 DIN V ENV 5 Important installation instructions 5 1 Operating conditions The various components of the on roof system Sun Grid can withstand different maximum charges Therefore the exact components for a project need to be checked as to their comp
15. liance with the local standards and regulations for each project This can easily be done for example by way of the Sun Grid calculation tool 5 2 Preparation It is recommended to familiarize yourself with the conditions on site before ordering Sun Grid especially regarding The roof construction including isolation Dimensions and quality of roof laths and rafters Type shape and material of the roof covering 5 3 Tools The following tools are required for the installation 6 mm Allen key Cordless drill Open end spanner 13 Torx 30 AW 30 Bit Angle grinder with stone disk Cord Spirit level rule If necessary timber to shim the roof hooks Hoisting gear Vacuum lifting pads Power drill as necessary 6 Installation of roof connections WARNING Working on the roof During work on the roof parts can drop down or persons may fall off Secure yourself against falling Do not remain in the danger area Wear a hard hat After completing the installation check that the system and the PV modules are securely fastened CAUTION Damage to tiles through stepping on roof hooks Do not use fitted roof hooks as a ladder as this extreme point load could damage the tile below A CAUTION Observe minimum edge distances Screws fixed too close to the edges of rafters can rip out Do not fix any screws closer than 30mm to the edge of rafters Predrill holes when using
16. nger bolts fixed too close to the edges of purlins can rip out Observe a minimum distance of 5xd to the edge of the purlin when installing hanger bolts Predrill holes when using bolts with a diameter gt 6mm 11 6 3 Installing clamp on roof hooks 1 Spax wood screw optional 2 Spacer bolt 3 Fixing bolt 4 Roof lath 5 Clamp on roof hook with L bracket CAUTION Damage to the isolation With some roof constructions the fixing bolt can damage the isolation of the roof If necessary take out the fixing bolt and use the Spax wood screw to fix the roof hook to the lath Installation Position the roof hook above the low part of the tile and clamp it onto the roof lath Adjust the spacer bolt so that the roof hook does not touch the small side of the tile min 2mm distance Tighten the fixing bolt by hand so that the roof hook can no longer move under wind suction conditions If necessary use an angle grinder or hammer to cut a recess in the tile that covers the roof hook so that the tile lies flat on the surface 7 Install the system 7 1 Installation procedure The following pages list the individual steps for installing the Sun Grid in the correct sequence The pages feature three columns Each column represents a complete sequence of actions The sequence of actions consists of an illustration the corresponding steps and additional information and safety instructions 7 2 Qui
17. odules on pitched roofs It comprises aluminium rails roof connections and all necessary small parts to ensure a safe installation The proven Quickstone profile nut makes installation quick and easy With Sun Grid modules can be mounted in both landscape and portrait orientation 1 2 Intended use The mounting system Sun Grid is to be used for the roof mounting of photovoltaic modules only SOLFEX is not liable for damages resulting from failing to comply with the installation instructions particularly the safety instructions as well as misuse of the product 1 3 Standards and technical directives When planned correctly Sun Grid fulfills the following standards and technical directives Eurocode 9 DIN V ENV 1999 Design of aluminium structures DIN 1055 Actions on structures Part 100 Basis of design safety concept and design rules 1 4 About this manual Subject This manual details the installation and assembly of the Sun Grid photovoltaic mounting system User group The manual is intended for qualified personnel with a basic knowledge of mechanics hand tools and mechanical skills Signposts The following will assist you in finding your way around in this manual Headers The headers display the heading of the current chapter Footers The footers display the product name the name of the document and the page number Text markups Labels in the text are printed in bold brand and company names in italics item
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