Universal SunMount Installation Manual
Contents
1. SOLION INNOVATION e QUALITY e SERVICE Universal SunMount Installation Manual For use with any Crystalline PV Panels with dimensions Length X direction Any length Width Y direction 960 1060mm Thickness 34 50mm de 1 1 i l 1 1 imm A D 4 Solion Ltd South Bank Technopark 90 London Road London SE1 6LN Tel 44 0 207 815 7678 Fax 44 0 20 7928 3957 E mail query solion co uk SS INNOVATION e QUALITY e SERVICE The installer is solely responsible for e Complying with all the European and national building codes including any code which may supersede this installation manual e Ensuring that all the products purchased from Solion and other suppliers are appropriate for the particular installation and there are no issues of compatibility with the other building materials e Use only Solion s parts and authorised distributors parts as specified by the installation manual of Solion Substitution of parts may void the warranty given below e Ensure that all Solion parts and authorised distributors parts as specified by the installation manual are in good condition when they arrive to site before the installation e Ensuring that the roof is flat free from peaks troughs and crusts bigger or deeper than 5cm and the building structure can support the array under all appropriate code level loading conditions e Ensuring correct and appropriate values are used to determ2. Code 185 Green Good Fit The colour red means one modular unit only will be required to be cut by the stated length number highlighted in red in the table If the colour is green then No cutting action is required even if there is an overhang or under hang Example The PV panel length is 1680mm and 12 PV panels to be used to make up the row How many SunMount units are required and will one unit require cutting Solution The intersection of the panel length column at 1680 with the number of panel row of 12 are the numbers 25 BBB as shown in table 1 Number 25 signifies the number of the SunMount modular units required to make this row length Number BBB signifies one SunMount modular unit needs to be cut by 225mm from the LHS as in step 5 of the mechanical installation steps 23 Document Ref No 01 SNMT DC 14 002 Revision PRO1 9 O N CCO No A0030 Date 20 January 2014 INNOVATION QUALITY e SERVICE Panel Humber of Panels in Row 12 8 10 15 19 160 8 10 15 B 19 8 10 15 5 19 80 8 10 15 20 200 9 10 15 20 320 g 10 15 20 440 9 10 15 20 560 9 10 15 20 155 9 10 15 20 g 10 15 20 85 9 11 16 21 205 8 1 16 5 21 325 9 11 16 21 445 9 11 16 21 565 9 11 16 21 5S9 9 11 16 21 9 11 16 21 90 9 11 16 22 210 9 16 22 330 9 17 22 9 17 22 17 22 17 22 17 22 17 23 17 23 17 23 17 23 18 23 z bo to Ga 69 EG z mdbaiz o tn
3. 01 SNMT DC 14 002 Revision PRO1 9 Q O N CCO No A0030 INNOVATION e QUALITY e SERVICE Date 20 January 2014 4 3 4 Ballasting the SunMount Before starting the installation procedure please determine the amount of ballast required for your particular installation The Universal SunMount has an internal ballasting system The ballast is mostly applied to the outer units forming the edge of the PV array Please attach the ballast before placing the PV panels on the SunMount i e before step 15 in the mechanical installation steps of the next section The internal ballast front or back ballast consists of 2 brackets attached to the opposite side walls of the SunMount by a screw and a nut Two stainless steel cable ties are then inserted into the slots of the bracket feet and tied around the concrete slabs Please see the drawings and explanations below of how to attach the ballast to the SunMount Rear bracket location Once the array is complete and before placing the PV panels on the SunMount place the ballast brackets depending on whether you are using a back or front ballast or both on the red point locations as shown in the drawing above Document Ref No 01 SNMT DC 14 002 Revision PRO1 CCO No A0030 Date 20 January 2014 ANIOI LORN INNOVATION QUALITY e SERVICE Slot the metal bracket onto the lip RHS side wall drill a hole in the plastic wall using 6 1mm drill bit through the top ho
4. amp to to D a Lo F F bo o D UO LQ Woo ko PRRRVRPURRRRRBRRRRR ao cm m i hbo m D m Un Gg LJ Lug Lag LJ QJ Lg LJ GJ LJ Lu LJ LJ LJ LJ Lu Lg Lu Lu Lg Lg LJ Lu Lg LJ QJ LJ Lg GJ GJ Lu Lg GJ Lu Lg RJ RJ MJ RJ BJ MJ BJ R3 RJ hp hh hh BO hj RJ RO hh RJ hm ho ho BO ho hM ho ho in jin in in ia jin in mm n in in n nm tn Cn in t n Cn in in Cn in Ln in t n in Cn 5 fF 5 FF fF fF fF FE EE FF EEE EEE SFE EE EEE F 5 EE FE F F FS FE GO QQ Da CO Ca DO a E EID ed Cin Cn Ln Ln 19 19 B 19 i 20 13 18 20 13 18 230 20 i 13 18 310 20 14 18 390 20 14 18 20 27 235 14 16 18 20 E 25 27 355 14 290 16 460 18 20 25 l 27 475 14 350 16 530 18 20 25 27 595 14 410 16 18 21 25 27 0 14 470 16 18 21 235 23 435 25 200 27 14 530 16 19 21 325 23 535 25 28 14 16 19 21 415 25 28 16 19 275 21 505 26 130 28 17 19 26 240 28 17 185 19 26 350 28 17 255 19 26 4 28 17 325 19 26 28 17 395 19 26 29 17 465 19 26 29 17 535 19 26 29 17 19 27 29 4 17 20 27 29 17 20 27 29 24 Document Ref No 01 SNMT DC 14 002 Revision PRO1 CCO No A0030 Date 20 January 2014 Panel Length 1300 1310 1320 1330 1340 1350 1360 1370 1380 1390 1400 1410 1420 1430 1440 1450 1460 1470 1480 1400 1500 1510 1520 1530 1540 1550 1560 1570 1580 1590 1600 1610 1620 1630 1640 1650 1660 1670 1690 1700
5. 1710 1720 1730 1740 1750 1760 1770 1780 1790 1810 1840 1860 1870 1900 1910 1920 1930 1940 1950 1960 1970 1920 1990 d j A dw o 21 305 22 25 3k 21 21 21 21 22 22 22 N 81818 23 23 23 23 23 23 24 24 MJ Ba RM M o RM RJ RJ M RF Bo 9111191 9 en o mmm UJ LU Ld Lu Shhh m D D b Db Db E 8 E Aee L o SSS e b D G Q 330 OO 22 F 23 23 23 23 23 23 BI F 24 R3 A MJ MJ MJ MJ MJ M 8933533 99 L3 LJ LQ LO LJ KQ L3 LJ LO La RJ RJ RO B3 RO MJ P LB B G O G W F 100 F 240 F 380 520 F 175 27 28 28 28 28 29 29 29 5 29 29 29 30 a0 30 30 30 30 31 31 i 3l 31 410 24 SEE D D b D b b b S S SS SSS SSS S S Se Db Db D Db Db Db E L3 LU LU LJ LJ LU LO LJ LJ LJ LJ Lu NIN IN ISIN K ee ele F P Q Q Q G Q D Q D G O usi 400 580 26 190 135 26 350 26 510 es 26 165 315 26 55 27 3 220 27 ha N 585 Tus an p a U Lu PSSsSsRBREGGhRkRhRaRYN eA 190 E F SAD 32 300 F F a90 a2 450 Sassi 32 5235 32 33 535 130 280 430 33 33 4 33 33 33 7 34 34 34 F 34 34 35 35 35 5 35 35 5 35 5 36 36 36 37 af 37 37 37 37 38 38 38 38 t 39 39 195 410 27 UJ Da Lg LJ D LJ LJ M3 M RM M
6. M EB F P F G Q G Q S S S 9 S G Q Q Q Q Q Q Q Q Q GQ Q GQ Q G R R P 6 O 6 6 6 Q D Q S Q b Q b Q b 5 ur S NW gt 495 42 HEBBREBBS5S58585505555555uusutuuessou uutsubbs5Bbiuut 175 SRGGGGGESERESSEES Number of Panels in Row m T e J COEM 29 125 30 590 32 220 33 110 150 530 amp amp amp s555 24X21l5s55ssohhoktkk oolb5s SOLION INNOVATION QUALITY e SERVICE SSG GGG GGG 3 a a mam a a Q Q 42 3 2 5 315 36 155 375 595 38 410 95 335 43 45 45 45 46 210 46 46 46 47 47 575 47 46 46 30 230 30 470 51 115 51 355 51 595 57 145 57 385 57 210 of 58 270 58 510 25 Document Ref No 01 SNMT DC 14 002 Revision PRO1 9 Q 9 N CCO No A0030 INNOVATION e QUALITY e SERVICE Date 20 January 2014 Table 2 Clamp and spacers number VS PV Panel Thicknesses PV Panel Thickness Clamp Size mm Number of Spacers mm 26 Document Ref No 01 SNMT DC 14 002 Revision PRO1 CCO No A0030 Date 20 January 2014 Product Specifications Compatible PV panel dimensions X direction Y direction Depth Average modular unit area Average full SunMount area 2 units interlock Average weight of full SunMount Average roof loading with PV module SunMount tilt angle Maximum certified wind speed uplift res
7. No A0030 INNOVATION e QUALITY e SERVICE Date 20 January 2014 13 The curved strip can be attached to the SunMount by first attaching the U clip to the bottom arch beneath the SunMount as shown in the circular figure below Once the U clip is engaged click fit the middle latches of the strips into the slots located at the back curve of the SunMount and finally clip the latches at the top of the SunMount as shown in the figures below Please note that the gap at the bottom of the curved strip can be used to pass PV electrical cables from one row to the next 16 Document Ref No 01 SNMT DC 14 002 Revision PRO1 9 N CCO No A0030 INNOVATION QUALITY e SERVICE Date 20 January 2014 14 For the back row of the array only a shutter can be slotted into the curved strip before click fitting it into the SunMount as shown into the figures below h w km E N T w 15 Place the PV panels on the SunMount as shown in the figures below ZU 17 Document Ref No 01 SNMT DC 14 002 Revision PRO SOLION CCO No A0030 INNOVATION e QUALITY e SERVICE Date 20 January 2014 16 The S shape fixing clamp fits 4 different PV panel thicknesses sizes they are 35 40 45 amp 50mm A spacer as shown in the figure below can be used to fit different PV panel thicknesses in between these sizes quoted above Please table 2 for the use of number of clamp and spacer vs PV panel thic
8. flanges using the three latches as shown in the figure below 10 Document Ref No 01 SNMT DC 14 002 Revision PRO1 9 O N CCO No A0030 INNOVATION e QUALITY e SERVICE Date 20 January 2014 4 Repeat steps 2 amp 3 to interlock the required number of units which make up the row length as determined in step 1 and as shown in the figure below 5 If the PV panels length over or under hang as determined from step 1 then table 1 will show the required length to be cut for one modular unit only The guide lines on the SunMount will aid the cutting operation to be simple and accurate as shown in the figure below Please note that if a cut unit is required it should NOT BE INSTALLED AS THE LAST UNIT IN THE ROW See figure in step 8 Use the guide to cut along the required length 11 Document Ref No 01 SNMT DC 14 002 Revision PRO1 S O N CCO No A0030 INNOVATION QUALITY e SERVICE Date 20 January 2014 6 Place the cut unit on the wall of the RHS SunMount as shown below 7 Screw the cut units in three places to adjacent RHS unit using the M6 x 11 6 mm flat head screw Please use a low torque setting to drill the screws in as shown in the figure below Please make sure to use low torque setting on the drill to stop once the screw is fully engage into the material 12 Document Ref No 01 SNMT DC 14 002 Revision PRO1 gt 9 O N CCO No A0030 INNOVATION QUALITY e
9. 002 Revision PRO1 gt S 5 L G N CCO No A0030 INNOVATION e QUALITY e SERVICE Date 20 January 2014 SunMount and array dimensions 1565mm Full unit size Modular unit size 245mm 1 676mm 893mm Length of PV panels in landscape 93mm 1630mm 1630mm 1630mm 22 Document Ref No 01 SNMT DC 14 002 SOLION CCO No A0030 Revision PRO1 INNOVATION QUALITY e SERVICE Date 20 January 2014 Table 1 The PV panel length selector Select the PV panel size to be used from Table 1 to establish how many modular units are required to make a row length The table will also establish if the total length of the number of the PV panels used will match exactly or over under hang e match exactly the length of the row in which case NO cutting action will be required e Over hang or under hang the row length in which case one modular unit only will be required to be cut to adjust the length The figure below explains the different parameters seen in table 1 Number of Panels in Row Panel Length po n mm uU I a 2 oe Tn 7170 Number of Universal Ze DS x SunM t Unit 140 univioun nits 51 1310 1320 1330 1340 220 240 260 280 300 320 340 360 Length of PV Panel in mm 225 215 205 195 185 580 590 Amount of Overhang in mm 40 Negative Numbers Indicate 600 s Kos TENURE Eu P b p p p b p b Underhang Colour 300 Red Requires Cut
10. SERVICE Date 20 January 2014 8 Place the last unit on the LHS side of the row as in step 2 and interlock as in step 3 The row length now has the exact length of the PV panels length 9 To form a second row overlap the back flange of each unit on the front nose of the last row screw them together with M6 x 16 mm screws use a low torque setting to avoid rotation after the screw being drilled into the boss as shown in the figures below and repeat steps 2 to 8 as before to complete the second row Please make sure to use low torque setting on the drill to stop once the screw is fully engage into the material 13 Document Ref No 01 SNMT DC 14 002 Revision PRO1 CCO No A0030 Date 20 January 2014 SOLION INNOVATION QUALITY e SERVICE 10 In the special case when the modular unit is cut into two equal halves if the LHS cut unit is less than half the width of a unit then the remaining RHS can be trimmed and used in the next row as in the two figures below 14 Document Ref No 01 SNMT DC 14 002 Revision PRO SOLION CCO No A0030 INNOVATION e QUALITY e SERVICE Date 20 January 2014 11 Repeat steps 2 10 until the array shape is complete as shown in the figure below 12 Attach the cover strip to cover the gap between the adjacent SunMount modular units as shown in the figure below m M pt o MES M y M m 15 Document Ref No 01 SNMT DC 14 002 Revision PRO1 9 O N CCO
11. any other materials not provided by Solion This Guarantee does not cover damage to the Product that occurs during its shipment storage and installation or from force majeure acts including natural disasters like storm hurricane flood or fire earthquake or criminal acts If within the Guarantee Period the Product shall be proven in Solion sole discretion to be defective then Solion shall repair or replace the defective Product or any part thereof at Solion option Any such repair or replacement does not cause the beginning of new guarantee terms nor shall the Guarantee Period of this Limited Guarantee be extended Solion aggregate liability under this Limited Guarantee shall not exceed the original Purchase Price of the Product Buyer shall bear all costs of shipment or transportation related to the repair or replacement of the defective product Such repair or replacement shall be Buyer s sole remedy under this Limited Guarantee and shall fulfil all of Solion obligations with respect to this Limited Guarantee Document Ref No 01 SNMT DC 14 002 Revision PRO1 9 O N CCO No A0030 INNOVATION e QUALITY e SERVICE Date 20 January 2014 Content Page 1 Required tools for installation 3 2 Universal SunMount features 4 3 Important Notes before starting the mechanical Installation 5 3 1 Edge distance between PV array and roof edges 5 3 2 List of compatible sealants with roof materials 6 3 3 Applying primer barrier layer to th
12. e edges of the PV array 6 8 3 4 Ballasting the SunMount 8 9 4 Mechanical installation steps 10 21 5 SunMount and array dimensions 22 6 Table 1 The PV panel length selector 23 25 7 Table 2 Clamp size and number of spacer vs PV panel thicknesses 26 8 Product specification summary 27 Document Ref No 01 SNMT DC 14 002 Revision PRO1 9 Q 9 N CCO No A0030 INNOVATION e QUALITY e SERVICE Date 20 January 2014 Pozi Drive 2 Drill beo Wi Right angle grinder fitted with a diamond cutting disk or any other Gloves for handling SunMount which saw blade or rotary saw blade cutter could develop sharp corners to cut SunMount module to the right 1 Required tools for installation Please use low torque settings to drill the thread forming screws into the plastic Avoid using high torque setting as this will rotate the screw after it has been drilled into the boss This Will damage the plastic and it will leave the screw with a very poor grip into the SunMount Document Ref No 01 SNMT DC 14 002 Revision PRO1 gt 9 O N CCO No A0030 INNOVATION e QUALITY e SERVICE Date 20 January 2014 2 The Universal SunMount USM features The Universal SunMount fits most of the PV panel sizes sold in the market today It can fit any PV panel length as long as the width of the PV panel is in between 960 1060mm An S shape clamp with a spacer has been designed with different heights to accommodate PV pane
13. he figure below PV array distance from all roof edges 2 x H 10 H 5 PV array distance from all corners 2 x H 4 H 2 H is the height of the building including a parapet wall In case of parapet wall on the roof the edge distance is taken between the PV array and the inner wall of the parapet Please note that in the drawing below the distance between roof edges and line of the white area is the minimum recommended distance between PV array and roof edges amp corners The bigger the distances between the array and roof edges corners the lower the wind loading forces Document Ref No 01 SNMT DC 14 002 Revision PRO1 9 9 N CCO No A0030 INNOVATION e QUALITY SERVICE Date 20 January 2014 3 2 List of compatible sealants with roof materials The sealant is to be applied under the flat flanges of the SunMount for the edge units of the PV array only Apply a sealant bead of no less than 6mm wide The sealant integrity should be checked every 10 years in time with usual roof maintenance For Bitumen roofs with chipped stones the sealant integrity should be checked every three years Some of the sealants will have primer component to apply before applying the sealant and some have not please check the sealants list which suitable for different roofing materials Bitumen Asphalt PVC EPDM Metal material Roofs Dow Corning 758 Sealant You can buy this sealant directly from Solion Ltd Please apply Pr
14. imer 84 before applying the sealant to the roof in case of Bitumen and Asphalt roofing materials Sarnafill membrane roof SarnaPlast 2235 Obtained directly from Sika UK or Sika roof contractor Bauder membrane Roof Bauder Sealant one part low modular sealant and Bauder Sealant Primer Both obtained directly from Bauder UK or Bauder roof contractor 3 3 Applying primer barrier layer to the edges of the PV array Please Note This procedure is to be followed only in the case that the roofing material requires a primer barrier before the application of the sealant 1 Make sure that the roof surface is clean and free from dirt and water 2 Mark the outer edge boundaries of the PV array configuration by drawing a line with a marker pen One of the easiest and quickest ways is by placing the SunMounts to make the outer edge boundaries of the array 3 Apply the primer to the surface with a wide paint brush over the marked boundary line make sure that the primer covers 50 60mm on each side of the line 4 Leave the primer to dry for an hour before applying the sealant Meanwhile you can place and interlock the SunMounts in the chosen configuration X j ee m 1 2 Document Ref No 01 SNMT DC 14 002 Revision PRO1 9 9 N CCO No A0030 INNOVATION e QUALITY e SERVICE Date 20 January 2014 3 3 Document Ref No
15. ine the design loads used for the specific installation Parameters such as wind speed static loading snow loading exposure and topographic factors should be confirmed with the local building official or a licensed professional engineer Solion s Limited Product Guarantee Solion will guarantee the buyer at the original installation site that any of the Universal SunMount components purchased from Solion shall be free from structural defects in material and performance as referenced in the Solion installation manual for a period of 20 years This guarantee applies from the date when the installation of the Product at the Site is complete Buyer may transfer this guarantee to subsequent owners or if the Buyer is a contractor to the property owner In this guarantee the term Buyer refers to the original buyer and any subsequent transferee of which Solion has advance notice and a proof of purchase is required This Limited Guarantee shall be void if 1 Installation of the Product is not performed in accordance with Solion installation manual instructions 2 If the Product has been modified repaired or reworked in a manner not previously authorized by Solion in writing 3 The Product is installed in an environment for which it was not designed each as determined by Solion sole discretion This Limited Guarantee covers only the Product and not PV modules electrical components and or wiring used in connection with the Product or
16. istance SunMount Material Product life guarantee Transport PV cable connection Aesthetics Interlocking method Overlapping SOLION INNOVATION e QUALITY e SERVICE Any PV panel length 960 1060 mm 34 50mm 1 497 m 2 80 m 9 53 kg 10 kg m 10 for best ratio of power generation to surface area exploitation for European climate 110 mph Recycled Polypropylene UV stabilised 20 years 50 USM units minimum 6 25kW per double size pallet Easy cabling connection disconnection can be carried out from the top and placed in recesses with covering strips Flush modules give an integrated appearance Left to right interlock by latches and with of front to back 27
17. knesses Please use ow torque settings to drill the thread forming screws into the plastic Avoid using high torque setting as this will rotate the screw after it has been drilled into the boss 1 Li Uil uidi I l X S Tab Spacer 18 Document Ref No 01 SNMT DC 14 002 Revision PRO1 9 Q L Q N CCO No A0030 Date 20 January 2014 INNOVATION e QUALITY e SERVICE 18 Repeat step 17 until all the PV panels are installed and fixed on the SunMount array as shown in the figure below 19 Document Ref No 01 SNMT DC 14 002 Revision PRO1 9 9 N CCO No A0030 INNOVATION e QUALITY e SERVICE Date 20 January 2014 19 For the LHS amp RHS edge SunMount units of the array only attach the side cover strip and the cable hole strip only for unused cables holes as in the two figures below Use the M6 x 11 6 mm screws to attach the cover strips 20 Document Ref No 01 SNMT DC 14 002 Revision PRO1 9 Q L Q N CCO No A0030 INNOVATION e QUALITY SERVICE Date 20 January 2014 20 For the back row of the array only place the back flanges over the back of the SunMount and screw it down to the SunMount using the M6 x 11 6mm screws as in the figure below Please note the back flange can be cut to the required length to fit a cut modular unit and then screwed as mentioned above This complete the instruction for the Mechanical Part of the Installation 21 Document Ref No 01 SNMT DC 14
18. le of metal bracket and use the 6mm screw with the nut to fix the bracket to the side wall as shown in the figure above POMS Fix the LHS brackets as above YW Place two stainless steel cable ties through the slots of the RHS bracket s feet and then into the slots of the LHS bracket Place the concrete slabs over the cable ties use either 450 x 450 x 50mm or 500 x 500 x 50mm concrete slab dimensions Finally tie the cable tie NOT too tightly over the concert slabs please do not cut off the access cable tie once tightened You can use a maximum of 2 concrete slabs of 50mm thick for the back ballast and 1 concrete slab of 50mm thick for the front ballast per 1 USM Document Ref No 01 SNMT DC 14 002 Revision PRO1 gt 9 O N CCO No A0030 INNOVATION e QUALITY e SERVICE Date 20 January 2014 4 Mechanical installation steps 1 From table 1 select your PV panel size to establish how many modular units are required to make a row length The table will also establish whether the total length of the PV panels used will e match exactly the length of the SunMount row in which case NO cutting action will be required e Over hang or under hang the row length in which case one modular unit will be required to be cut to adjust the length see step 5 page 11 Starting from right to left place first one modular unit and then another unit to its left as shown in figure below 3 Interlock the two units along its
19. ls thicknesses of 34 50mm Please refer to table 2 page 26 for Clamps spacer VS PV panel thickness The Universal SunMount is a unique design comprising a modular unit where one SunMount is made out of two interlocked modular units Extra single modular units can be added as required to suit the length of the number of PV panel used in one row Figure 1 shows the Universal SunMount modular unit and its most important features Arch cover click fits to Electrical cable 1 fill the gap between 2 exit from row to modular units row Shutter can be slotted into the arch cover before click fitting to the array t S clamp 1 of 4 available in various sizes to fix a PV panel to SunMount t Back flange fixed to modular unit by screwing it to the back of the SunMount in the last row of array Bosses to screw clamps into SunMount formed by interlocking 2 modular units Modular unit Document Ref No 01 SNMT DC 14 002 Revision PRO1 9 9 N CCO No A0030 INNOVATION e QUALITY e SERVICE Date 20 January 2014 3 Important Notes before starting the mechanical Installation 3 1 Edge distance between PV array and roof edges As you plan the PV installation on a roof always leave a gap between the PV array and all roof edges and its corners in accordance with the Euro code 1 part 1 4 General Actions Wind action and the UK National Annex of the Euro code 1 as in the two equations and t
Download Pdf Manuals
Related Search