Professional Solar Mounting Systems Mounting And Project Planning

Transcript

Professional solar mounting systems Mounting and project planning 2 / 12 This guide will provide you with instructions for project planning and mounting of Schletter © Solar Mounting Systems. Schletter Systems are made of high quality durable components, and offer solutions to most mounting scenarios with engineering of customized products to fit your needs. Please note that correct selection, mounting, and installation of the components affect the integrity of the photovoltaic system. The PV system should only be installed by certified experienced photovoltaic installation companies. Schletter personnel are readily available for consultation for the application and mounting of your PV system. CONTENT SYSTEM PAGE General Application Information 4 System Characteristics 5 Roof forms and Attachment Elements Tiled and pan-tiled roofs Corrugated composite roof Trapezoidal sheet metal roof Standing seam roofs (and system roofs) Roof hooks 6 Hanger bolts, FixT/FixE™ 8 Fix2000, FixT, Vario FixV™ 9 Standing seam clamps, FixPlan 10 Elevation Elements Standard support types Support fixation/Loading Support XL, Profi, Light 11 SolRack, SolTub, SolCube™ 13 Windsafe™ 14 Combined Construction Forms System Mounting Vertical continuous beam Horizontal continuous beam Without continuous beam Yield optimization for trapezoidal sheet metal roofs CompactVario™ CompactGrid™ CompactDirekt™ FixZ-7™ 15 16 Pitched roof Flat roof Facades Standard, GridNorm™ Flat roof Facades 18 21 23 Application Suggestions for Module Mounting Framed modules Unframed modules OptiBond OptiBond™ 24 25 26 Special Systems In-roof Industrial membrane roof Special dimensioning for flat roofs Carport Open area Plandach5 IsoTop™ Windsafe™ Park@Sol™ Open area FS / PVMax3™ 26 27 Accessories Anti-theft device Cable duct Lightning and over voltage protection SecuFix™ / SecuFix2™ 28 Important hints Safety and liability 17 29 3 / 30 12 General Application Information • • • • • Efficient, simple mounting saves time and costs 10 year warranty provides customer confidence and reliability Modular design solves mounting issues with custom configurations for individual products Useful calculation tools and support programs save time during the planning process to create a customized racking system and initial offer Complete documentation and statical dimensioning charts allow optimum and cost-efficient plant planning In addition to this mounting instruction guide, please ask your local sales representative for more information on the following tools in order to obtain further mounting and project planning assistance. System calculations program-aided load calculations drawings and charts give important direction on dimensioning and individual statical verifications. In addition to the mounting instruction, the examples given in the system calculations have to be diligently considered. System Overview brochure offering various system combinations and possible solutions including: The Klick™ system, cross beam connector system, universal roof fastening elements, elevation elements for flat roofs, system mounting, facade fixation, module mounting, special systems, accessories and lighting, over voltage and cabling. Component Overview covering the available components in a pictorial arrangement of attachments, clamps, rails, systems, accessories, and hardware. An auto-calculator using Microsoft® Excel® program which facilitates the PV system rack configurations, dimensioning including price calculation and piece list creation. Schematic pictorials provide mounting information. Product sheets and application suggestions contain further system specific information, mounting examples, and new developments. On the internet all current information is always available for download. Visit www.schletter.ca for more information. Load determination / superimposed load calculation for simple project planning, allows customers access to locationspecific load determinations and load calculation software. Certifications and Associations (NAED, ASES): We meet highest quality standards of solar racking systems, and are continually working to improve our product application development and standards. We partner and interface with solar industry installers across the Americas. See also general summaries and mounting issues as described in: • • • • • 44 // 12 30 Laminate mounting Module mounting Facade mounting Flat roof mounting Grounding PV plants and lightning protection System Characteristics In the development of the mounting system it is important to consider system safety, durability, and mounting times. Further factors are the universal compatibility and utilization of standard components such as bolts, nuts, other hardware. Such components are demonstrated below. The Klick™ System The fastening points for the module clamps can be chosen at any location by means of square nuts into the aluminium duct of the rail. Using an M8 quality steel nut to be clicked in at any spot of the rail, sparing the tedious pullingthrough of the nuts over the entire rail length. Cross Beam System The standard cross beam (purlin rail) is the interface between roof fastening device and module attachment, as well as cross beam to cross beam in a cross beam grid system. Upwards, in direction of the module square nuts (Klick System), serve as variable fastening locations. Downwards, towards the roof, the rail is attached to a roof hook with the KlickTop system. (Note, the direction of the KlickTop on the Roof Hook will face the opposite direction. The rail will hang down.) The Roof Hook arrives with the Klick Assembly loosely tightened. The bolt is tightened from the top when the rail is set in place. The KlickTop component can also be used to mount cross rails running perpendicular to each other. There is a slight variation in the KlickTop hardware when used in the cross rail application. Universal Fastening Elements for most any roof including: • Ashpalt shingle • Tired roof • Trapezoidal sheet metal roof • Corrugated roof • Sandwich roof • Standing seam roof Schletter uses only high grade durable materials including certified aluminium , quality steel, and rubber form parts made of vulcanized UV resistant materials. We offer fastening fixtures that are universally applicable to pitched roofs, slanted roofs, and elevations. Engineering and the design staff will assist you in finding the best fastening element for your application. 5 / 30 12 Fastening Systems for Various Roof Types Tiled and Shingle Roofs With grooved tiled roofs or ashalt roofs, standard roof hooks are available. For special tiled forms special roof hooks are available (please also take a look at the component overview). Tools: Angle grinder with a small diamond grinding wheel, ratchet wrench with 13 mm socket wrench and a drill with 6 mm pilot bit. If using impact driver, use caution not to over tighten. A bit of grease with brush for wood screws is also recommended.  Determination of the position of the rail The rails should be positioned 1/4 of the module height away from the lower and upper module edge (see module manufacturer’s documentation for more information). The position of the support rails for module rows above of each other must be aligned to the tile rows. Rails must be installed parallel to tile configuration (perpendicular to rafters).  Choice and arrangement of roof hooks Roof hooks are arranged vertically according to the intended cross beam positions and N-S directions. Adjustable roof hooks are available for height adjustment in case of uneven roofs. If the substructure does not give any suitable attachment locations for support rails, often a cross rail system is recommended. For more information, see section on GridNorm later in this document.  Attachment of roof hooks The covering tile is lifted and set aside. The bar of the roof hook aligns over a rafter and lies in the hollow respectively in the flat area of the pan tile. A distance of 3 – 5 mm / 0.12 – 0.2 inches must be maintained between roof hook and tile. Therefore, at the bottom plate of the roof hook an according distance piece has to be applied (plywood or metal distance pieces item nr. 400 893-2 o. 5 mm / 0.08 o. 0.2 inches which are available as accessories). The roof hook is fixed to the rafter with at least 2 lag bolts, 8 mm / 0.31 inches, about two thirds of the entire screw length must be pre-drilled. Make sure that at least 70 mm / 2.76 inches of the lag bolts have a grip in the rafter. Reference design documentation for further information on bolt depth. Screw lengths of 80 mm / 3.15 inches for non-decked roofs and screw lengths of 120 mm / 4.72 inches for decked roofs have been well-proven. Only use bolts allowed by system specification.  Replace covering tile Often, there are uneven surfaces on the underside of tires. In such cases, a grinder may be necessary (use an angle grinder with a small diamond grinding wheel) so that the tiles can be placed neatly over the roof hooks. 66 // 12 30 Calculation Notes Bearing profiles The maximum span widths of the bearing profiles for the respective wind and snow loads can be calculated using a Schletter Excel calculator program and verified by engineering. On pitched roofs, the span widths of the profiles is not the limiting factor in most cases (Example: Profi Solo 05 span 1.6 m / 63 inches in case of normal snow loads). With standard applications, the profiles should not cantilever for more than 0.4 m / 15.75 inches at the sides. Roof hooks Use the Roof Hook Calculator to determine the dimensioning of the roof hooks is sufficient. This is doubly important where high wind and snow loads are a factor. It is generally recommended to use a roof hook on every rafter in order to distribute the load more evenly over the roof. In case of high snow loads, sheet metal substitute tiles are generally recommendable, because due to the individual statical dimensioning, it might happen that the roof hooks put pressure on the tiles. The required number of roof hooks per square foot of module area can be found using Schletter‘s Excel calculation program, or by contacting our engineering department. The required information on local wind and snow loads are provided by out “load determination” service, which is available on the internet. When dimensioning the number of required roof hooks, if necessary a higher number of required roof hooks has to be considered for the edge and corner areas of the roof. In the edge areas, one roof hook onto each of the first two rafters is generally recommended in order to compensate the higher stresses caused by wind loads. Weather Protection When roof hooks are applied on sloping and flat roofs, The installer of the photovoltaic plant can be held responsible for weather protection due to the installation. Therefore tile producers only guarantee a limited water protection. The Tile Roofing Institute, sets standards that roofing installers need to follow, as well as PV installers, providing that certified roofing methods and codes are followed. Schletter provides flashing and installation guidelines that comply with the Tile Roofing Institute Installation Guides. Schletter recommends the use of caulk or silicone sealant where the roof membrane is penetrated, such as with a screw or bolt, and to apply self sealing adhesive membrane product or an EPDM gasket at roof attachments with washers. 7 / 30 12 Corrugated and Trapezoidal Sheet Metal Roofs For corrugated or trapezoidal sheet metal roofs use the fastening sets consisting of a special hanger bolt with EPDM sealing and a mounting plate. Usually, a fastening set with a hanger bolt M12 x 300 mm/11.8 inches, M12 x 200 mm/7.9 inches is recommended. For special types of attachments with reduced horizontal distances, M10 x 200 mm / 7.9 inches is available. Tools, drill diameter: Hanger bolts M10: combination wrench with wrench size 15, power screwdriver with 7 mm / 0.28 inch insert. Wood is pre-drilled with a diameter of 7 mm / 0.28 inches, the roof is pre-drilled with a diameter of 15 mm / 0.59 inches. Hanger bolts M12, combination wrench with wrench size 18, power screwdriver with insert 9 mm / 0.35 inches. Wood is predrilled with a diameter of 8.5 mm / 0.31, the roof is pre-drilled with a diameter of 16 mm / 0.63 inches.  The fastening of mounting sets The roof cladding is drilled through at the appropriate locations, making sure that such locations are not performed in the water-bearing valleys of the sheet metal, but rather on the top areas of the plate profile. By pre-drilling, the fastener drilling penetrates the rafter or the purlin. The hanger bolt should be completely screwed into the wood. Screw in the hanger bolt in such a manner that only the metric thread stands out of the roof cladding, and if possible a bit of the shaft as a seating for sealing. Greasing the screw makes the screwing easier.  Creation and check of the sealing For sealing, the rubber gasket is pushed down as far as possible and slightly pressed onto the roof cladding with the flange nut.  Alignment of mounting plates In case of cross rails, an upwards arrangement of the plates is recommended, in case of vertical rails the plates should be arranged according to the symmetrical load distribution and screwed with flange nuts. See section on System Mounting to continue. The number of fixation spots per square meter of module area has to be dimensioned according to the calculations of the local wind and snow loads. Due to the position of the roof cladding, a fixation to the vertical rafters is not possible in many cases. If a screwing to the cross purlins or to the cross battens is intended, usually a vertical rail position is required. In this case it should be checked, if the modules can be fixed vertically onto two vertical rails, thus the optimum rail combination regarding statics with the minimum of required rails is possible. Fastening Elements—FixE™ Universal fastening system for corrugated roofs  Mounting instruction and additional suggestions for FixE (available for wood and steel) 88 // 12 30 Trapezoidal Sheet Metal Roofs A solution for trapezoidal and overlapping roofs: In some cases fastening to the substructure (for example with hanger bolts see previous section) is generally preferable due to the unknown statical characteristics of the sheet metal roof. For cases, in which this is not possible (for example self-supporting trapezoidal sheet metal roofs or sheet metal roofs made of sandwich elements), Fix2000™ (here a mounting example with KlickTop™), provides an unquestionably simple and swift fastening solution.  Fix2000 application • The screws must not spin free of grip during the mounting process (use a  Review datasheet for depth-stop). measurements on Fix2000 • Screwable from 0.5 mm / 19.7 mil in the case of steel sheet metal and screwable from 0.8 mm / 31.5 mil in the case of aluminium sheet metal roofs • The roof must have sufficient load bearing reserves to support the additional load of the photovoltaic installation • The fastening of the trapezoidal sheet metal must be able to absorb the additional wind suction forces (a roof-parallel PV power plant does not increase the uplift forces) • In case of overlapping elements, a sufficient adhesive force between the layers must be applied  See section on System Mounting to continue. Calculations The Fix2000 fastening elements must be able to transfer the exact load forces to ensure reliable system calculations. For Fix2000 calculations attention to the wind load is more relevant than the snow load. The snow load upon the power plant is transferred into the roof by all the ribs of the sheet metal; due to a slight elastic deformation, the ribs between the clamps are also loaded. The cross rails should be arranged vertically to the ribs. It is essential transfer for the wind load to transfer and that the trapezoidal sheet metal is sufficiently attached to the substructure. Only if this has occurred can the mounting of the Fix2000 take place. By using an adequate amount of Fix2000 elements will the adhesive force of the clamps to the sheet metal according to the calculations take place. Individual verifications for the load transfer into the sheet metal are required. Usually, a horizontal distance of 1.2 – 1.4 m / 47 – 55 inches between the clamps is sufficient for this to occur; more clamps should be placed at the edges. Elevation on Fix2000 is only recommendable when the adhesive force of the sheet metal can definitively be verified.  Please see the application suggestions for Fix2000 for additional product information. For Trapezoidal (U-Shaped) Sheet Metal • • FixT™: Universal fastening system for trapezoidal (u-shaped) sheet metal roofs. VarioFixV™: Standard stock item that works with all u-shaped sheet metal roofs, cutting installation time.  See addition product data sheets for each system. 9 / 30 12 Standing Seam Roof, Sheet Metal Roofs The fastening takes place by means of special standing seam clamps, onto which the cross rail profile is screwed. Various designs are available for different types of roof systems. An alternative to the standard clamps is the FixPlan™ for direct screwing into the substructure. 400503 Stehfalz 400510 KalZip, Bemo 400520 Zambelli Series 465 400522-A 400524 Zambelli Baur.500 Fischer KlipTec 400879-12 Alternative.: FixPlan  See mounting instruction for FixPlan Tools: Ring wrench 13 plus insert 13, torque wrench, if necessary power screwdriver with torque setting Alternative: FixPlan, tools as need for corrugated roof kit mounting (see above)  Positioning of standing seam clamps. The clamps are arranged vertically according to the required cross rail positions. In case of horizontal applications the following has to be considered: One clamp should be positioned on each standing seam. The cross beam should not bear more than a maximum of 0.4 m / 15.75 inches to the left and right.  Fastening of standing seam clamps The clamp is put on the seam and loosely tightened. The alignment is completed when the cross rails are fastened. The clamp must be shifted onto the seam as far as possible.  See section on System Mounting for more information. Please Note: Torque for the clamp screws of the standing seam clamp should be 15 Nm; Rule of thumb: Fasten tightly with a short ratchet. When fastening the PV power plant onto sheet metal roofs, the roof cladding must be able to absorb the wind load. Careful review should be performed by the installer on the installation site to ensure the roof has proper support. ATTENTION: With system roofs (for example Kalzip), the standing seams must not be altered in shape when the clamps are tightened to make sure that the roof sheetings are not blocked in case of thermal expansions. 10 10 // 12 30 Elevation Systems for Flat Roofs Standard Support Designs Flat roof supports are used if the installations can be screwed directly onto the roof decking or onto concrete weights placed upon the roof. Using screw sizes M10 and M12, there are special washers available which offer more flexibility. • • • The Light Support Series offers light weight and cost-efficient designs for modules from ca. 0.8 m – 1.6 m / 31.5 - 63 inches. Light 10/13/15 The Profi Series is intended for applications where high snow loads are expected. Example include: Module heights: Profi 15: ca. 1.3 m -1.7 m / 51.2 - 67 inches; Profi 22: up to ca. 2.2 m / 86.6 inches XL Flat Roof Support is especially designed for large modules or two rowed mounting of modules, up to 3.6 m or 141.7 inches Special sizes are available upon request. Find detailed information regarding the optimal support design in the calculation charts. The pre-assembled supports are unfolded and screwed by means of socket head screws M8 and self-locking nuts M8. For the connection to the fixation element, usually long holes (13 mm / 0.51 inches) with adapter plates 10 mm are available are available, according to the individual design. Bottom beam hole distances Light U07 1 m item no. 430911 LightU07 1.3 m item no. 430912 Light U07 1.5 m item no. 430913 Profi U07 1.5 m item no. 430941 A 21.14 +/- 0.315 25 37 37 B 29.8 33,66 +/- 0,315 +/- 0.315 +/- 0,315 +/- 0.315 45.67 +/- 0.315 +/- 0.315 45.67 +/- 0.315 Note: Diagonal struts resp. tensile struts have to be checked individually? No – if the support is tightly attached; for example with concrete or FixT Yes – if the row is not horizontal; for example east/ west roof, elevation to the south 11 / 30 12 Special Support Designs The modularity of the Schletter system allows for multiple combinations with different fastening and loading possibilities. The following highlights some of the systems offered. SolTub™ • • • • Loading with gravel or concrete blocks Good load distribution on the roof Different tray widths available All-metal construction If necessary, a roof surface protection mat could be required depending on roof surface.  See data sheet on SolTub for more information Windsafe™ • • • • Considerable reduction of the required load calculations Wider span widths of the rails bearing the modules are possible Decreases the required load capability of the roof structure With lower superimposed loads, the system prevents overturning and/or up-lift in high wind situations The Windsafe system is designed modularly. Because of the system‘s unique wind deflector, verification of structural safety is possible and allows for lower loads than conventional systems. In case of metal sheets for standard suppoer systems, the mounting is completed with three sheet metal screws carried with 3 sheet metal screws per strut. One is screwed in the upper quarter of the sheet metal height one screw each in the two lower quarters of the sheet metal height.  See data sheet on Windsafe for more information AluLight™ • • • Standard stock item, reduces product cost to produce using high volume manufacturing Reduces pounds per square foot of roof loading Works with most PV modules Adding to a history of proven system designs, the AluLight features quick and easy installation for flat roof installations. Like all Schletter products, the Alulight works with most photovoltaic modules while completely enclosing in rows at a fixed 12 degree angle. Proper roof fasteners and concrete slabs incorporated into the system ensure the AluLight trough sits securely and inline making it ideal for exacting high-wind conditions where load weight is a concern.  See data sheet on AluLight for more information 12 12 // 12 30 Combined Construction Forms The benefit of using compact module support construction is the enhanced integration The basic idea of compact support construction forms is the optimum integration of the roof construction in the statical arrangement of the module elevation respectively an optimized even load distribution into the roof structure (usually by continuous beams). Therefore, the continuous beams are installed vertically to the roof construction (CompactVario, CompactGrid). If it is possible to screw the supports directly to the roof structure (CompactDirect), the span of the module beam must be aligned to the distances of the roof structure when carrying out the statical planning. CompactVario™ Schletter‘s CompactVario is a very flexible module elevation system for both flat and pitched roofs, ideally suited of for bridging wide purlin distances. A complete series of double groove profiles DN0-DN2,5 are available as distribution rails in north-south direction, offering the most economic solution.  See mounting instructions for CompactVario This construction is designed requiring no drilling at the installation site. A wide range of fastening elements for different roof systems is available. Please also consider:  Product sheet FixT™ (trapezoidal/u-shaped and overlapping roofs)  Product sheet FixE™ (corrugated sheet metal)  First define the positions of the continuous rails, then mount according to the fastening element instructions (FixT, FixE, Fix2000 etc.) When mounting cross rails, the lower groove of the rail comes with standard screws with square screw heads sized M10 x 25 mm / 0.98 inches. Insert the screws into the corresponding holes in the fastening elements. Screw them with flange nuts M10.  Click in the square nuts M10 into the upper groove and attach the fittings using hexagon head screws M10 x 20 mm / 0.79 inches. Measurement X with support series 07: Light 1.0 m = 811 mm / 31.93 inches Light 1.3 m = 965 mm / 38.0 inches Light 1.5 m = 1360 mm / 53.54 inches Profi 1.5 m = 1360 mm / 53.54 inches  Unfold the supports and assemble them using socket wrench and M8 screws with self-locking M8 nuts. The next step is to screw the cross rails onto the supports using standard square head screws M10 x 25 mm / 0.98 inches and M10 flange nuts.  See section on module mounting for more information. 13 / 30 12 CompactGrid™ The CompactGrid continuous rail system offers an excellent solution for mounting elevated PV power plants where the roof structure is inclined to the east.The application of our well-proven double-grooved mounting rails make it possible to optimize the support distances and to transfer the loads evenly and safely into the roof cladding or substructure. The installation of diagonal strut kits prevents any potential twisting of the module rows.In combination with the fastening elements, Schletter offers individual solutions to meet our customers needs.  See CompactGrid mounting instructions for more details. As with the CompactVario™, connecting CompactGrid to the substructure is performed using our industry proven FixT™ connectors. The distances of the continuous beams must be altered to coorespond with fastening element holes as closely as possible. In certain circumstances the support has to be adapted to the fastening system distance by drilling an additional hole (10 mm). The support attachment is done by clicking in the square nuts into the upper groove of the rail and screwing them with hexagon screws M10 x 20 mm / 0.79 inches, using the required insertion plates (see below). Potential twisting of the module rows is prevented by the installation of diagonal strut kits. CompactDirect™ With some elevated systems, the distances of the module rows are directly determined by the shade distances. In such cases, a load distribution beam is required for an unimpeded arrangement of the module rows while fitting the most modules on the PV power plant. Roofs that are aligned in east-west direction with purlins in north-west direction often allow direct mounting of the supports. In these cases the flat roof supports are directly attached to the roof (i.e. rafters) using hanger bolts or the FixT/FixE fastening systems. Regardless, the connection point must be as close as possible to the assemblage points of the supports. All standard support systems from Schletter are suitable for this method. Contact your local representative for more information. 14 14 // 12 30 FixZ-7™ When attaching modules to u-shaped (trapezoidal) sheet metal roofs, the FixZ-7 offers the maximum power yield by slightly elevating the modules in order to capture the most solar energy.  See the FixZ-7 for more detailed information. The system is ideally designed for module heights from about 1.3 – 1.7 m / 51.2 – 67 inches and setting angles from 5 – 7 degrees. For technical reasons, FixZ-7 is only suitable for framed modules in portrait (vertical) mounting positions. The setting angle depends on the position of the clam locations, positioned at a range from 1/4 to 1/5 of the module height (also reference module manufacturer´s informations). Because of load calculation parameters, mounting on other fastening elements than the Fix2000™ KlickTop™ (Kalzip clamps, roof hooks, etc.), is only possible with an additional bottom layer of rails (cross rail combination): Moreover, only the KlickTop-attachment can be used for the fastening to the system rails. Please review the mounting suggestions for the Fix2000, referencing the distances to the roof edges which must be adhered to—which are 1.5 m / 59.1 inches at the sides and 1.2 m / 47.2 inches at both the northern and the southern roof edge. With the FixZ-7 design, the module frame itself is integrated into the support system. The special FixZ-7 profiles are designed for a module inclination of 5° –  7° (in relation to the roof surface). Therefore, the mounting positions of both the front beam and the back beam have to be determined according to the module height. While mounting the modules, it is very important not to twist the frames, with is why mounting with the FixZ-7 is only possible with framed modeules. Distance to module height Rows to shade destance 15 / 30 12 System Mounting After the fastening elements are mounted, the next step is to apply the cross beams and rails. Pitched Roof Mounting: Cross beam mounting With classic pitched roof fastening, two rows of roof hooks and respective roof fastening elements are attached to the supporting roof substructure. The cross beam profile is mounted onto these profiles. Two cross beam profiles bear one module row, which is aligned and fastened to the cross beams by means of end and middle clamps. Usually, the modules are mounted vertically (portrait). IMPORTANT! Due to thermal expansion, ensure that the rows are no over long. Long, continuous rows should be subdivided. Schletter‘s auto-calculator provides suggestions on thermal expansion. On tiled roofs a maximum length of about 20 m / 787 inches, on sheet metal roofs without the possibility of thermal equalization a maximum length of about 10 m / 394 inches is common. If plug-in connectors are installed in profiles with cable ducts, drainage drillings should be made in the cable ducts. Note: Within a module combination, connection of rail/beam profiles is only to be carried out with fixed screw connections. Tools: Combination 15 mm wrench with and 6 mm / 0.24 inches. 16 16 // 12 30  Screw and align the cross beams on the fixation spots Insert the screws (usually M10 x 25 mm / 0.98 inches hexagon head respective square head) into the groove of the cross beam rails and arrange them at approximate distances. Then insert the first piece of the cross beam (starting with the first screw) in the attachment row (roof hooks, corrugated roof fasteners, standing seam clamps). The best way to do it is to secure the first screw with a nut at the roof attachment, then lift the rail slightly diagonal inserting screw by screw and secure them each with a nut—DO NOT TIGHTEN at this point. If necessary, extend the cross beam rail with a connector plate. How to even out different heights on roofs. a) for tiled and pan tiled roofs: Use height adjustable hooks or use underlayments with fasteners such as an M10. b) for corrugated or trapezoidal (u-shaped) sheet metal roofs: Adjust the mounting plate at the hanger bolt by adjusting the fastening nuts. c) for standing seam roofs: if necessary, use underlayments and appropriate screws such as M10‘s. Next, the lowest rail should be aligned straight. After fastening the lower row of rails, the other rails are attached, ensuring that the rails at the sides are aligned to the roof covering. Important: Make sure that the side rails are aligned at a 90˚ angle. If this does not occur, the rails in the complete module field cannot be aligned in one direction! To achieve the right angle, use the means of number triples. For example; 60, 80 cm / 23.6, 31.5 inches result in a diagonal of 100 cm / 39.4 inches) After aligning all cross beam rails screw down all connection screws tightly! Use only special nuts with locking teeth! If the installation is supposed to be integrated in the lightning protection of the building, pay regard to the hint in the last paragraph!  All screws of the substructure have to be fastened tightly resp, checked  Continue module mounting suggestions on page 22. Tip: If the wiring is to be installed within the cable duct, water accumulations have to b e avoided. This can be done by a suitable alignment or also by drilling individual holes at the lowest spots of the cable duct. When plugs are installed in the cable duct, this has to be especially considered! 17 / 30 12 GridNorm™ with KlickTop for Cross Rail Mounting • • • • Can be assembled with cost-efficient standard rails Flexible mounting options Can be combined with all Schletter system components Works with cross-rail connector KlickTop™ for reduced mounting times Tip: The cross rail mounting (regardless of the mounting system) should be used when the substructure does not offer fastening locations for cross rails. The intention of cross rail mounting is not to reduce the number of required roof hooks for certain module arrangements. The number of required roof hooks per square meter is determined by the structural requirements and is NOT influenced by the mounting systems that are applied. In typical applications, Schletter recommends the use of standard mounting systems, which offer quick and efficient attachment of the cross rails to the substructures. When this isn‘t an option, the GridNorm cross rail system is ideal for instances where the substructure has poor fastening locations or the position of the cross rails must have improved alignment to the module rows. Examples of such applications are the module mountings on all trapezoidal (u-shaped) sheet metal roofs with only horizontal battens or the horizontal (landscape) mounting of modules on pantiled roofs with unfavourable row partition. Suggestions for using GridNorm: 18 18 // 12 30 • Arrangement: Usually, the bottom profiles are arranged vertically from the eaves to the ridge and fixed onto the fixation spots (roof hooks, corrugated roof kits, etc.). Then the cross beam profiles are arranged onto the vertically mounted profiles in suitable distances to the module. The cross rail connector KlickTop is comfortably screwed from above with a socket head screw. • Profile distances and span widths: The allowable distances of the profiles and support spots can be looked up in the system statics. It has to be considered that also the minimum number of fixation spots per square meter must be maintained! • Calculation and compilation: Similar to the typical standard system, GridNorm can be compiled using the Schletter Excel auto-calculator. Contact us for more information. • Conventional cross rail mounting: In addition to GridNorm mounting, the VA plate may also be used as a cross rail connector. See Component Overview brochure for more information. Flat Roof Mounting General Suggestions With flat roof elevations, usually a module row of vertically arranged modules is fixed onto a pair of cross beams. The pair of cross beams is mounted onto a row of supports. Most supports are available in different settings: For example in Germany 25–30 degrees gain the optimum annual utilization ratio for grid-connected plants, in case of island locations, 45 degrees can optimize the yield in the winter half year, 20 degrees can be used as an additional elevation on slightly inclined flat roofs. The cross beam profiles are attached onto the support elements. Usually, two cross beam profiles bear one module row, which is aligned and fixed to the cross beams by means of end clamps and middle clamps. Special alignments of modules are also possible. Different kinds of supports allow the adaption to different conditions. Tip: As a tool for the determining row distances, an automatic shade calculator is available at www.schletter.us. • The calculations for all supports must be done while considering the boundary conditions (building height, snow/wind load zone, module height, etc.). The allowable support distances can be found in the system specifications. • Verification that the roof can safely bear additional loads of the mounting system, PV panels, and potential snow loading MUST BE performed. This is ultimately the responsibiilty of the installer. • Wind load must be considered with all systems, though it is even more important where elevated forces can occure at the attachment locations. When supports are combined with fastening elements (for example supports on hanger bolts, clamps, etc.), the verification of structural safety has to be carried out within in the framework of a type calculations, because such cases usually cannot be listed in the system schematics. Moreover, a statical verification of the construction conditions on the installation site must be completed. • In case of fastening by superimposed loads, the required loads can be looked up in the system statics.Here it has to be considered by all means that the roof substructure must be able to bear both the additional load of the PV plant and the required loadings! • The statistical calculations for the supports usually refer to vertical loads and not individual lateral and tilt stabilities. For example, it has to be determined individually in each case, if the support combinations require stabilization by means of additional diagonal struts, or the like. • With tight roof claddings, often only a fastening by loading without perforation of the roof cladding is possible. In these cases, special care should be taken to ensure no stone or gravel remain under the loadings, potentially damaging the roof cladding (a mat for the protection of the roof cladding is recommendaed). 19 / 30 12 Mounting Tools: Extended socket wrench 15 mm / 0.59 inches  Mount the supports and arrange them on the roof area The sidewise distance of the supports must be determined according to the boundary conditions (building height, snow load, wind load, module height). In normal cases 1.6 to 1.8 m / 63 to 70.9 inches are typical. The sidewise bearing-out of the profile should be 0.4 to 0.5 m / 15.75 to 19.7 inches at most.  Only in the case of mounting on concrete material: Screw the supports individually onto the elements  Arrange the supports in a row  Fasten the cross rails loosely onto the supports Insert the screws into the groove of the cross rail profile and arrange them roughly in spacing according to the support distances. Loosely fasten the first cross rail profile (starting with the first screw) in the first support. Then arrange all supports one by one in a row. Connect the cross beam with a connector plate to the lower side. After aligning all cross beam rails to the supports, tightly screws completely. Only use self locking nuts. If the installation is supposed to be integrated into the lightning protection of the building, please review the last section in this document.  Bring the rack in the right position, if necessary  All screws of the substructure have to be screwed tightly respectively checked (M8: 5 resp. 15Nm; M10: 40Nm)  Cross beam mounting The next step is to screw the cross beam onto the supports using standard resp. square head screws M10 x 25 mm / 0.98 inches and flange nuts M10.  See Module Mounting 20 20 // 12 30 Awning and Façade Attachment Façade fastening represents a special case of module mounting where the mounting is usually attached to vertical walls. For power plants in visible areas, the fastening elements can also be delivered with a specially processed surface (for example anodized or powdercoated). Please note: anodized or coated elements are only conductive to a limited extent (capacity charge, lightning protection).  See general mounting suggestions on page 22  Draft a sketch of the plant configuration and determine the desired positions of the facade supports. The cross beams should not bear out for more than 0.4 m / 15.75 inches at the left and at the right. The maximum support distance is determined by statistical dimensioning charts. • Mount bottom beams • Module rail and hook into the strut, secure with screw 15 – 75°  Check the position of the cross beams according to the module height. The cross beams should be positioned in a distance about 1/4 – 1/5 of the module height from the upper respectively lower edge of the module. The position of the connector boxes has to be considered! It has to be checked, if the drilling at the supports are suitable for the modules used. If not, please make an inquiry for façade supports with according special measurements  Check the substructure and choose a suitable fixation system. Make sure that both the substructure and fasteners can support the loads (especially in case of both wind and snow loads). Heavy-duty anchors or adhesive anchors are recommended. If necessary, the fastening locations must be integrated into the power plant statistical calculations.  Levelling and mounting of the supports of a row. In order to align the supports, the two most outtermost elements are attached in the same height (horizontal alignment by means of a level or laser measuring). Stretch a cord between the external supports from the top corner to the bottom corner and align the inner supports to the cord (if necessary, use underlayments).  Screw the cross beam onto the facade supports and align. Insert the screws (usually M10 x 25 mm / 0.98 inches) in the groove of the cross beam rail and arrange at approximate distances. Then insert the first part of the cross beam (starting with the first screw) into the outmost rail. The best way to do that is to secure the first screw at the support with a nut, lifting the support slightly, and then insert the screws one by one securing with nuts—do not tighten yet. If the walls are uneven, corrections can be made by using underlayments at the fastening side of the façade support or by using underlayments between the support and the cross beam (if necessary use longer screws). Extensions of the cross beams are possible by means of cross beam connectors, aligning the lower rail until straight. After fastening the lower rail, attach the upper rail. The alignment at the sides must be exact and at right angles. After aligning the cross beam rails, screw all connection screws completely and securely. Only use special nuts with locking teeth. If the power plant is designed with the lightning protection of the building, review additional information on page 22 of this manual.  Tighten all screws completely.  Continue with Module Mounting section. 21 / 30 12 Module Mounting Suggestions Framed Modules  Preparation of the mounting of the modules Cabling to the module rows must be prepared. Keep in mind the necessary steps for lightning protection (page 22) as the cabling is prepared. For module cabling, at the end of string cables, suitable plugs/sockets for the individual module types must be mounted. Connect the first module as specified by the manufacturer followed by the other modules. Click in the square nuts into the upper groove of the cross beam rail in approximate distances by means of the click-in component (item nr. 430024). Loosely place the first two end clamps at the end of the cross beam rail. Then apply the first module and fit them loosely with the end clamps (the end clamps should be positioned 2 mm or more away from the edges of the cross beams). Now align the first module to the cross beam (use a cord, auxiliary device available as an accessory).  Mounting of the module rows After aligning the first modules, one middle clamp per cross beam rail is loosely fixed to the according cross beam. Then the next module is loosely clamped, shifted under the module clamp and fastened. The next middle clamp is attached accordingly. The cables can be placed in the cable duct of the rail, securing them to the cross beam by means of UV resistant cable straps.  Tighten all module attachment screws and check each one a second time.  End cap: If desired, the cross beam rails can be finished with an end cap (for Solo™ and Profi™). 22 22 // 12 30 Frameless Modules The Schletter laminate module clamping system is specifically designed to accommodate the requirements of frameless (laminate) modules. Consisting of a two-part clamp suitable for clamping laminates from 3 – 14 mm / 0.12 –  0.55 inches in thickness. Each middle clamp has a corresponding end clamp. The clamps are designed in such a manner that the module only has direct contact to rubber on all sides, including the front side. The result is a frameless module with no direct clamping to metal parts.  Laminate mounting general suggestions  Product sheet LaminatEco™  Product sheet LaminatGS™ Mounting of the clamps: Mounting end clamps and middle clamps is done in the same manner as the mounting of normal clamps for framed modules. See previous page. Mounting of safety hooks: With pitched roofs, frameless modules can be tightened, however it is recommended to use a safety hook. With each of the lower module clamps, the safety hook is applied resulting in the assurity of the module not sliding from position. The safety hook is shifted under the module clamp and attached by means of the clamp screw after the respective module is aligned. In case of two-part middle clamps, it is important not to over tighten the module clamps. For frameless modules with very narrow edges, use caution to avoid covering too much of the module with the clamp. For such narrow edge modules, it is recommended to use distance strips when mounting. Logically such strips increase the distance between modules, resulting in the need for longer rails. If using the Schletter auto-calculator, take this added distance into consideration. As the distances between the modules become bigger due to the distance strips, it has to be made sure that longer rails are ordered and installed. The results of the auto-calculator have to be corrected in such cases the results of the auto-calculator have to be corrected. With larger laminates or in case of cross mountings, the laminate must have additional support in the middle, between the clamps using support rubber or underlying sheet metal (available upon requet). Cross mounting with LaminatEco Shim for LaminatEco to heighten the support area 23 / 30 12 OptiBond™ • • • Statically optimized for big module surfaces Minimum assembly time Anti-theft device The pressure to reduce cost is a constant pressure for most when considering the installation of solar power plants. Because of this, preferential technology continues to lean towards thin film modules. The result are modules that have large surfaces with double glass construction. With this size increase, suitable fastening systems must be applied in order to maintain product integrity. For Schletter, one way to accomplish a secure hold on thin-film modules is with OptiBond. Developed by Schletter GmBH and several module producers, in order to connect such modules quickly and efficiently. OptiBond works in conjection with an adhesive (not sold by Schletter) that is placed on the OptiBond plate, which inturn is adhered to the back of the module.  Review OptiBond datasheet for more information. Special Systems In-roof System: Plandach5 • • • • Optimum water tightness Flexible and modular, applicable for all module types and sizes Increases power yields with incorporated airing Enhances costmetics of PV system Conventional roof sheeting is laid on roofing sheets (e.g. wood material plate V100 G or massive boarding plus fire prevention mats) or onto a correspondingly pressure-stable on-roof insulation. From this point, vertical rails are screwed to the boards, while using self sealing screws. Appropriate clamps are used, which can be hooked in and screwed at any desired location on the rail. The Plandach5 system is suitable for roof inclinations of approximately 20 degrees. The system is suitable for roof inclinations of approximately 20 degrees. A cross rubber is required for unframed modules, but not for framed modules.  Plandach5 mounting and project planning  Product sheet Plandach 5 24 24 // 12 30 IsoTop™ — Industrial Roof • • • Support widths of up to 10 m / 394 inches are possible Direct load transfer into the supporting structure of the building We will assist you in the planning of the project Usually the constructions are optimized in such a manner that only a few fastening points in big distances are necessary. These penetration points can be welded by the roofer reliably and inexpensively; thereby the liabilities are clearly separated.  Product sheet IsoTop Special Project Plannings for Flat Roofs • • • • Considerable reduction of the required load calculations Wider span widths of the rails bearing the modules are possible Decreases the required load capability of the roof structure With lower superimposed loads, the system prevents overturning and/ or up-lift in high wind situations The Windsafe system is designed modularly. Because of the system‘s unique wind deflector, verification of structural safety is possible and allows for lower loads than conventional systems.  See data sheet on Windsafe for more information AluLight™ • • • Standard stock item, reduces product cost to produce using high volume manufacturing Reduces pounds per square foot of roof loading Works with most PV modules Adding to a history of proven system designs, the AluLight features quick and easy installation for flat roof installations. Like all Schletter products, the Alulight works with most photovoltaic modules while completely enclosing in rows at a fixed 12 degree angle. Proper roof fasteners and concrete slabs incorporated into the system ensure the AluLight trough sits securely and in-line making it ideal for exacting high-wind conditions where load weight is a concern.  See data sheet on AluLight for more information Park@Sol Park@Sol™ Parking areas with solar car ports offer a welcome completion for the extensive use of photovoltaic utilization of photovoltaic electricity generation, especially as the roof areas on car ports are granted the maximum compensation according to the electricity feeding law! System FS  See brochure on Park@Sol Open Area The open area FS System is individually planned for the respective installation site. Besides the pile-driving technology of the FS system, PvMax3 is available as a system for concrete foundations.  See additional datasheets and mounting instructions for FS/PvMax3 PvMax3 25 / 30 12 Accessories Anti-theft Device Schletter SecuFix™ is simple in an unparalleled manner and can be added toa system at any time. Re-opened only with electric tools—with a substantial amount of time. SecuFix consists of an ordinary socket head screws, a stainless steel ball at an exact diamete for the specified system. After implementing the power plant and no other connections or changes will occur, all SecuFix screws are secured by simply hammering in the SecuFix metal ball. SecuFix will work in any PV plant design. Hammer in the metal ball Screw cannot be unscrewed with normal tools! Due to the very narrow middle clamp, loosening using pliers is not possible. Reopening (e.g. in case of damaged modules): Cut a groove and loosen the screw with a big screw driver SecuFix2 is the logical extension of the SecuFix system. An additional „protection of the flanks“ results in a further considerable improvement of theft-proofness. SecuFix2 has to be regarded as an addition to the securing of the module clamp connections and of course can be combined with other concepts (plant surveillance, etc.) in an advantageous manner. Important hint: We explicitly point out that all mechanical safety measures generally only are a delay and not a prevention of theft and therefore have to be combined with other precautions. Cable Laying In addition to the bearing beam Profi 05, cable duct, clips, and cable duct extensions are offered. Additional options can be found in the Components Overview brochure. Lightning Protection and Potential Equalization For the integration of anodized module frame for th potential equalization the following components can be used: • Middle clamp with earthing pin (series 430) replacing standard middle clamp • Earthing shim (item #430036) in combination with standard middle clamps The lightning protection (item #430035) can be used for the internal potential equalization in the rack (for example vertical connection of all cross beams with aluminium wire 8 mm / 0.31 inches). A connection to an existing lightning protection system (according to lightning protection concept) is possible with this clamp. 26 26 // 12 30 Important Safety and Liability Information Electric Installation Suggestions on electric installation are generally not the subject of this guide. However, the general suggestions listed below should to be considered: • • • • Installation and connections may only be carried out by certified electronic experts Relevant regulations and suggestions on safety must be considered When water is present, electronic stallations should not occur High direct voltages arise at the series of connections of modules, which can be life threatening in case of direct contact. Working on the Roof When performing any type of work on a roof, including flat roofs, the relevant accident prevention regulations must be considered. The Accident Prevention & Insurance Association can give valuable information on the prescribed safety measures. Starting from a working height of 3 m / 118 inches, the use of fall arresting installations is mandatory. If such installations are not possible, safety harnesses must be used that are fixed as prescribed. All tools should be secured accordingly, if necessary, the danger area on the ground has to be secured by closing off. Exclusion of Liability This instruction gives reasonable suggestions on mounting the fastening system by Schletter Inc (limited company). • • • • • • In addition to these suggestions, the expert company that carries out the installation has to consider the relevant regulations and the generally accepted rules of technology. The suggestions on dimensioning given in this instruction are only suggestions gained from practical experience; but the suggestions on dimensioning from the individual system calcultions are mandatory. The installing company is responsible for the dimensioning of the plants. Schletter Inc. provides the according suggestions in the system calculations. The Schletter company is not liable for suggestions on dimensioning given in commercial offers, as not all technical determining factors (snow load zone, building height, wind loads, etc.) can be aligned. We will be glad to assist you in your detailed planning. The installing company is responsible for the mechanical durability of the installed interface connections at the building surface, and especially for water tightness. The components produced by Schletter are designed according to the loads that are to be expected.T The Schletter company is not liable if the installed components are handled in an inappropriate manner. Schletter Inc. grants a voluntary 10 year product warranty on all racking systems if the following conditions are fulfilled: Correct handling, dimensioning according to the statical framework requirements (unless there is a separate agreement), normal conditions regarding environment and surrounding. This applies for the environmental conditions that have to be considered according to DIN 1055. For example: • The product durability that is to be expected is considerably higher than the durability of the photovoltaic modules. • As statical dimensioning for all power plants, under consideration of all possible environmental conditions is not possible. Such considerations are carried out according to the regulations of the valid norms, we generally recommend an insurance against natural hazards. 27 / 30 12 Additional Mounting Information Lightning and Overvoltage Lightning and overvoltage protection are generally not the subject of this guide. In such matters, we recommend the guide of an outside professionals who are experts in such matters. The following general suggestions may assist in planning.  Earthing and lightning protection for PV plants Discussions with the end-user (customer) should occur as to whether measure should be taken towards lightning protection (arresters, conductions, etc.) and/ or measures of inward lightning protection. Special caution is required when plants are installed on roofs that already have an external lightning protection. In these cases the customer must be informed. Generally the PV plant should be installed with a sufficient separation distance to existing lightning protection systems. In this case, the potential equalization of the PV rack must be implemented independently from the lightning protection system — also in case of sheet metal roofs. If the separation distances cannot be maintained due to the construction conditions, the rack can alternatively be connected to the lightning protection system according to the lightning protection standard. This must be done at several locations (for example using lightning protection clamp item #430035). In this case it has to be considered that all components of the interior lightning protection have to be lightning-proof. Literature: Guides on lightning on lightning protection, as well as suggestions on the complete dimensioning of PV plants can be found in the planning file Photovoltaic Plants published by the DGS. Cable laying In regards to the protection of the plant from close lightning strikes, the cable laying is of primary importance. Damage to the plant (for example the destruction of the inverters by overvoltage) is often caused by induction voltage in the module wiring. A lightning strike close to a PV plant has a very high current flow. This current flow (respectively its temporal change di/dt) induces an induction voltage into the looped circuit that is formed by the module wiring installed on the roof. Looped circuites should be avoided as much as possible when planning the racking system, string partition, and cable laying. After running through the modules that are connected in series, the module wiring should be led back in the same module string and re-enters the roof at the exit spot. For the return path along the module rows, the cable duct at the cross beam rail can be used. 28 28 // 12 30 poor better 29 / 30 12 Schletter GmbH Headquarters Gewerbegebiet an der B15 Alustraße 1 83527 Kirchdorf / Haag in OB Germany How to contact us Sven Kuenzel Vice President, Sales & Marketing Direct: +1 520 289 - 8731 Fax: +1 520 289 - 8696 Cell: +1 520 820 - 8487 [email protected] Edward Grover Strategic Alliance Manager Direct: +1 520 289 - 8741 Fax: +1 520 289 - 8696 Cell: +1 520 873 - 8601 [email protected] 30 30 // 12 30 Schletter, Inc. 3761 E Farnum Place Tucson, AZ 85706 USA Direct: +1 520 289 - 8700 Fax: +1 520 289 - 8695 [email protected] www.schletter.us For a comprehensive and competent consultation during the planning of your plant, and for questions concerning logistics and order processing, members of our team are available Monday thru Friday, from 7:00 am to 5 pm (MST). © Schletter Inc., 2010, I400111US, V2 Martin Hausner President / CEO Direct: +1 520 289 - 8811 Fax: +1 520 289 - 8699 Cell: +1 520 820 - 7458 [email protected]