On-roof system Tau Installation manual
Contents
1. e Insert the Quickstone into the chan nel The shape of the Quickstone fits precisely into the profile of the base rail e Tighten to 8 Nm with the Allen wrench Material damage due to incorrect assembly of the Quickstones Incorrectly installed Quickstones may rip out of the profile e Install all Quickstone connections in accordance with the instructions Mounting the modules 15 Tau Installation manual mounting systems 7 2 Anti slip protection for portrait orientation Installation e The anti slip protection is only necessary for modules in the bottom row e Install one anti slip protection M 6 x 20 mm bolt with nut in each of the lower holes of the module frame e Place the first module of the bottom row so that the anti slip protection sits in the rail channel of the lowest rail Tau Installation manual 7 3 Fixing the outer modules of each row Installation Fix each outer module with two module end clamps e Insert the Quickstone of the module end clamp in the rail channel of the base rail When positioning the Allen bolt must not protrude past the underside of the Quickstone e Insert and align the module e Clamp the module under the module end clamp and tigh ten the Allen bolt torque 8 Nm 16 Mounting the modules 7 4 Fixing the inner modules of each row Installation e Use two inter module clamps bet ween the modules e Insert the Quickstone of the inte2. mounting systems 810 0052 Tau Installation manual mounting systems Tau The innovative trapezoidal solution Table of Contents 1 1 122 l3 1 4 rA Zid 23 2 4 pel 3 2 3 3 5 1 32 ae 5 4 6 1 6 2 6 3 6 4 6 5 6 6 6 7 7 1 1 2 haa 1 4 Jad 8 1 8 2 Introduction Short description Intended use Standards and guidelines About these instructions Safety Basic safety information Information regarding working on roofs Warnings Operator s responsibilities Technical description System overview Scope of delivery Technical specifications Planning the module area Important installation information Conditions of use Preparation Mounting aids and required tools Grounding the mounting system Install the system Using the EPDMs Placing and aligning the base rails Positioning of the side fixing clips Positioning of the top fixing clips Mounting the base rails Connecting the base rails Securing the base rails against excessive slipping Mounting the modules Quickstone installation Anti slip protection for portrait orientation Fixing the outer modules of each row Fixing the inner modules of each row Installing further rows of modules Distinctive features when installing the modules in landscape orientation Correct alignment of the base rails Installation of the base rails and modules Tau MA ENG 1110 OUA A WN NNN e he h e He ja o o o o oo
3. 10 10 11 12 12 14 14 15 15 16 16 17 17 18 19 20 1 Introduction 1 1 Short description The Tau flat roof system is a sturdy frame system for mounting PV modules on trapezoidal sheet metal roofs It consists of aluminum base rails and all necessary small parts to install the modules to the rails and connecting the components to each other Both portrait and lands cape mounting of the modules are possible 1 2 Intended use The on roof system Tau is to be used for the installation of PV modules only Any other use is considered improper Please follow the instructions in this manual carefully Mounting Systems is not responsible for damage that results from improper installation Be sure to follow the safety and installation guidelines closely 1 3 Standards and guidelines When planned correctly Tau fulfills the following stan dards and directives e Eurocode 9 DIN EN 1999 1 1 Design of aluminum structures e Eurocode 1 DIN 1055 Actions on structures e DIN 18807 3 Trapezoidal sheeting in building trapezoi dal steel sheeting structural analysis and design e DIN 18807 Trapezoidal sheeting in buildings Part 9 Aluminium trapezoidal sheeting and their connections application and construction In addition every installation must be in compliance with the following codes rules e VDE 0100 712 IEC 64 1736 Installation of low volta ge systems e VDE 0185 Serie IEC 81 335 Lightning prot
4. The wider flat surface of the base rail can be used as an orientation aid It must face the direction of the roof ridge The other rows of rails are mounted with the wide flat surface facing down Distinctive features when installing the modules in landscape orientation 19 Tau Installation manual mounting systems 8 2 Installation of the base rails and modules Installation e Mark the positions of the base rails e Apply the EPDMs on all necessary high beads Align use a spacing template and fasten the base rails with the fixing clips Installation of the modules For landscape mounting the Quick stone must be place in the channel from the side of the profile It is not possible to insert the Quickstone into the channel from the top 20 Distinctive features when installing the modules in landscape orientation mounting systems the base for solar power Mounting Systems GmbH Mittenwalder StraBe 9a D 15834 Rangsdorf Tel 49 0 33708 529 0 Fax 49 0 33708 529 199 info mounting systems de www mounting systems de Subject to technical alterations 2011 Mounting Systems
5. cm screws Individual rails must be equipped with two dril ling screws each e Ensure that the use of the module clamps or splices is not impeded by the drilling screws 14 Install the system 7 Mounting the modules The modules are successively installed onto the base rails It is recommended to start on one side of the module field The modules in the bottom row can be equipped with anti slip protection Inter module clamps and modu le end clamps are used to fasten the modules The module end clamps are used to hold one module The inter mo dule clamps are positioned between two modules 7 1 Quickstone installation Quickstones are used for the assembly of the modules A Quickstone is a special profiled nut that is used to fasten the module clamp in the base rail For the installation you only need an Allen wrench 6 mm You can insert Quickstones into the rail channel of the base rail from the top CAUTION DANGER Danger to life from falling and falling parts Falling from the roof or being struck by falling parts may result in critical injuries e Protect yourself against falling e Do not remain in the danger zone e Wear a hard hat After the assembly is complete check to make sure that the frame system and the modules are secure Installation e Loosen the Allen bolt before the ins tallation without removing it com pletely The bolt must not protrude past the bottom of the Quickstone
6. on the side or top with the supplied 6x25 mm drilling screws with gaskets Do not over tighten the screws The torque setting of the cordless screwdriver is dependent on the thickness and the material of the trapezoidal sheet metal Positioning of the 6x25 mm drilling screws with a gasket 12 Install the system CAUTION Building damage through leakage Incorrectly installed fixing clips and drilling screws can cause leaks e Be sure each clip is evenly aligned on the high bead e Make sure that the seal or EPDM rests cleanly between the high bead and the fixing clips Mounted side fixing clips Ce o Tau Installation manual CAUTION Material damage due to incorrect assembly Incorrectly installed drilling screws may rip out e Do not over tighten the drilling screws eoceeececee cece ec ec eee eee eee eee eee eee eee eee eee eee eee eee eee eee eee eee eee eee eee eee eo Mounted top fixing clips CAUTION Damage to the building and the PV system through incorrect frame installation Incorrect spacing of the fixing clips can cause dama ge to the building and the PV system e When fastening the base rails with the fixing clips select the spacing corresponding to the project specific design tool configuration e Comply with the different configurations for the spacing of the clips that are to be placed at the edge and in the field area of the roof Install the system 13 Tau Insta
7. 3 Technical specifications Application areas Pitched roof on roof Roof covering Trapezoidal sheet metal 1 Min sheet thickness 0 63 mm 2 Min bead height Free 3 Roof pitch Up to 20 4 Height of building Up to 20 m PV module Framed Module alignment Portrait landscape Size of the module field Free Position of the module field Free Possible height leveling Up to5 mm Distance between rail fixation Depending on the load situation automatic verification by the design software Furocode 1 DIN 1055 Actions on structures Tau Installation manual peanidarde Eurocode 9 Design of aluminum structures Profiles Extruded aluminum profiles EN AW 6063 T66 Rail fixation Aluminum EN AW 5754 Small parts Stainless steel V2A Color Aluminum cold pressed 1 Not suitable for sandwich roofs 2 After contacting Mounting Systems and a verification of the codes thinner sheet metal thicknesses may be possible 3 In case of a very low bead height below 20 mm a special clip can be screwed on top of the trapezoidal sheet instead of the standard side fixing clip which is fixed to the sheet laterally 4 Depending on the location building selected fixing devices and the module type other values may vary With the Tau design tool you can calculate the permissible maximum values for any system quickly and easily 5 Because of the expected thermal expansion due to temperature differences and the resulting stress on the rails we rec
8. ance or repair later on otherwise all guarantees will be void Safety 3 Tau Installation manual mounting systems 3 Technical description 3 1 System overview All system components are listed below The design of the individual system components may vary They are dependent on e roof type e module type e number of modules and e onsite conditions Base rail Side fixing clip Top fixing clip Inter module clamp Module end clamp EPDM gt Q 9 amp 4 Technical description Please note This illustration shows the portrait orientation of the PV modules 40 cm pieces of Tau base rail are used for lands cape orientation In addition the system overview shows the possibility of fastening the Tau rails on the side and on the top on the high beads of the corrugation 3 2 Scope of delivery Following the descriptions of all Tau components that may be included in delivery are listed The exact delivery contents and the quantities of the individual system components are based on your order a a F amp F Tau rail Tau side fixing clip with Alu Fixband seal Tau top fixing clip Drilling screw with gasket 6x25 mm Tau splice preassembled for framed modules EPDM 80 mm for top fixing or 40 mm for side fixing Box Module end clamp Z Module end clamp Inter module clamp Weeb grounding clip Technical description 5 Tau Installation manual mounting systems 3
9. ce connection between the modules and base rails Unless otherwise specified by the module manufacturer the modules for Tau can be connected conductively to the rails in the following way e Slide a Weeb clip onto the still uninstalled module clamp only inter module clamps Tau Installation manual e Mount the module clamps as usual but make sure the Weeb clip is correctly inserted at the same time The correctly inserted clip sits between the base rail and the module frame The 4 noses protrude into the rail channel 6 Install the system Material damage by stepping on frame AN components The following pages contain all the operations for instal ling the Tau in the correct order Fixing clips are used for CAUTION Stepping on the roof fixations or base the assembly of the base rails They can be fixed either to rails may damage the underlying mate the side of the high bead or on the high bead itself rial e g the trapezoidal sheet metal To avoid damaging the underlying material do not stand on or put any weight on the frame components Co cooooooooooooooooooooooooooooooooooooo ooooooooooooooooooooo ooo oooooooooHo o eoereece eee eee eee eee eee eee eee ee eee eee ee eee eee eee eee eee eee eee ere eee ee eee eee sree eee eee eee eee ese ee eee eee eee eee ese eee eee eee ee eee ereeere eee ee eee eee eee eee eee eee ese eeeeee A Danger to life from falling and falling parts DANGER Falling from the roof or bein
10. de fixing clips always make Fasten the first side fixing clip on the high bead sure that the clips are seated correctly in the as described above channel e The second trapezoidal side fixation can only be fastened opposite on the same side of the high bead e To do this pull the sealing off the clip and stick it on the opposite side A piece of EPDM can also be used e Then position the second clip on the same side of the high bead as the first Install the system 11 mounting systems 6 4 Positioning of the top fixing clips Installation e Place a top fixing clip onto the EPDM and attach to the base rail as shown in the picture e Place the opposite top fixing clip Take into account that longer 80x20x1 mm EPDM pieces must be used Positioning of the top fixing clips for bead heights lt 20 mm CAUTION Tau Installation manual Material damage due to incorrect assembly Incorrectly assembled fixing clips may rip out e When fastening the top fixing clip always make sure that the clip is seated correctly on the base rail and on the EPDM strip Correct fit of the top fixing clip Ce ooo ooooooooooooooo ooooloH o 6 5 Mounting the base rails Do not fix all base rails at once but instead alternate between installation steps 6 5 and 6 6 Fix the first rail then connect the second rail to the first before fixing the second rail to the roof and so on Installation e Fasten the fixing clips
11. ection 1 4 About these instructions Subject The purpose of this manual is to provide instructions for the installation of the on roof system Tau The illustrations in this manual show the installation for framed modules in portrait orientation The installation in landscape orientation is dealt separately in section 8 Users This manual is written specifically for qualified installers who have undergone instructions by the operator and have basic mechanical and trade skills Orientation aids The following aids will improve the readers understanding when using this manual Footers The chapter heading and page number are shown in the footers Tau Installation manual Symbols Gi Useful Tips Simplifies handling procedures and contributes Shows detail and additional information for handling procedures to the success of the installation Introduction 1 Tau Installation manual mounting systems 2 Safety 2 1 Basic safety information The following basic safety information and warnings are an important part of this manual and needed for safe handling of this product e Ensure that the product meets local code requirements prior to mounting and installation e Ensure the building meets the increased local require ments resulting from the PV unit prior to mounting and installation e Comply with the relevant safety regulations e Wear a hard hat protective gloves and safety shoes e A
12. g struck by falling parts may result in critical injuries Protect yourself against falling e Do not remain in the danger zone e Wear a hard hat After the assembly is complete check to make sure that the frame system and the modules are secure Important installation information Install the system 9 Tau Installation manual mounting systems 6 1 Using the EPDMs Installation Define the position of the base rails on the trapezoidal sheet metal taking into account the allowable clamping area of the used PV mo dules e Use the chalk line to mark the positi on of the EPDM on each high bead e Stick an EPDM strip onto each high Positioning the EPDMs with the help of a chalk line bead on which the base rails rests EPDM 40x20x1 mm is used for as i l cambline the paseo wane cide Material damage due to incorrect assembly fixations EPDM 80x20x1 mm is used AN i orineton enone CAUTION Resting the base rails on the trapezoidal sheet metal wit hout EPDM can lead to damaging the roofing material e Stick an EPDM strip onto every high bead that comes into Make sure that the base rails do not contact with the base rails rest on calottes It might be necessary to adapt the positions of the base _ _ a anNEN USNSNSENNUHNDSTONANESU USENENNSTETOUNIU SS SISTETO UTE USL SDNT ODS EUS ESTO a nO SS a a STO EO aa OTe a aaa a aaa EaETA rails 6 2 Placing and aligning the base rails Positioning the ba
13. llation manual mounting systems 6 6 Connecting the base rails A splice is provided for connecting individual rail series They can also be used for grounding individual base rails together Installation e Put the splice into the Quickstone channel from the top e Make sure it is seated correctly in the channel Tighten the first M 8 Allen screw torque 8 Nm with the Allen wrench Profiled rail connection with Tau splice for framed PV modules e Tighten the second M 8 Allen screw torque 8 Nm with the Allen wrench The connected series of rails should not exceed 12 min length From that point on an expansion joint approx 5 cm must be used Do not install any modules over an expan sion joint 6 7 Securing the base rails against excessive slipping Installation The base rails should be secured in their position The Two 6x25 mm drilling screws identical to the screws for fixing clips allow the base rail an expansion possibility fastening the trapezoidal fixations are used to secure the as e g arise from high temperature differences To secure base rails their position and still allow an expansion of the base rails they have to be secured with two drilling screws e Screw the drilling screws into the side of the base rail to from the side Rows of rails that are connected with the the right and left of the trapezoidal fixation at a distance Tau splice only have to be secured once with two drilling of approx 2
14. ls in the vertical in accordance with the clamping points defined by the module manufacturer approx the quarter points of the modules 1 2 x module height Spacing of the fixations according to the specific design plan depending on the trapezoidal sheet metal and the structural analysis Spacing between the modules 17 19mm Planning the module area 7 Tau Installation manual mounting systems 5 Important installation information 5 1 Conditions of use The on roof system Tau with its different rail and roof mounting variations is designed for different maximum loads in accordance with Eurocode 1 Actions on structu res The suitability of the material must be checked for each system with the help of the Tau design tool CAUTION danae 5 2 Preparation Mounting Systems recommends that you familiarize your self with the local conditions prior to ordering Tau Pay special attention to the following the roof configuration e g corrugation bead spacing and bead height e the thickness as well as the material of the trapezoidal sheet metal e the quality and the condition of the trapezoidal sheet metal e the adequate fixation of the trapezoidal sheet metal to the substructure Material damage due to inadequate fastening Inadequate fastening of the trapezoidal sheet metal roof to the substructure can lead to material e Check to see whether the fastening of the trapezoidal sheet metal to the substruct
15. o rail segments width of the module minus 20 mm 2mm inside width 2 Distance between the middle rail segments width of the module minus 23 mm 2mm inside width 3 Distance between the top two rail segments width of the module minus 28 mm 2mm inside width 4 Height of the module field Number of modules in the vertical x module width 19 mm 31mm Width of the module field number of modules in the horizontal x module height Module height Module width The values for points 1 3 each refer to the inside width between the rails see picture above Base rails that are 40 cm long are used for installing the modules in landscape orientation You must be especially careful to maintain the correct spacing between the base rails Accuracy is a must Mounting Systems recommend using a spacing template to maintain the correct spacing Precise rail alignment must be maintained Take into account that the rail row near to the roof ridge is mounted always turned by 180 INFO 18 Distinctive features when installing the modules in landscape orientation 8 1 Correct alignment of the base rails Correct alignment of the rail segments is mandatory Align the base rails as follows Tau Installation manual During the alignment the wider flat surface of the base rail with the nose can be used as an orientation aid Uppermost rail Bottommost rail Middle rails Position the top row of base rails as shown in figure 1
16. ommend a maximum length of 12 m per module row eoerecee ec eee eee eee eee eee ee eee eo eee eee eee eee eee eee eee eee ee eee eee eee eee eee eee eee eee ee eee eee eee eee eee eee eee eee eee eee eee ee eee ere e eee eee ee eeee eee eee eee eee eee e eee eee 6 Technical description 4 Planning the module area The following gives the spacing of the roof fixations for installing modules in portrait orientation The spacing for landscape orientation can be found in section 8 The fixing clips must be mounted at specific distances depending on the material thickness of the trapezoidal sheet metal the spacing of the high bead of the corrugation consideration of the edge area and the further general conditions a tool is used for the design Taking the above mentioned points into consideration the trapezoidal fixation must be placed so that they are as close as possible to the module clamps When positioning please note that e the given dimensions are guidelines e the dimensions of the trapezoidal sheet metal and the high bead of the corrugation define the true horizontal Spacing Design in accordance with the local conditions to Eurocode 1 DIN 1055 Eurocode 9 DIN EN 1999 1 1 is required Tau Installation manual 1 Height of the module field Number of modules in the vertical x module height Width of the module field Number of modules in the horizontal x module width 19 mm 31 mm Spacing of the base rai
17. r module clamp into the rail channel of the base rail and slide it onto the mounted module Align the second module to the mo dule clamp and tighten the Allen bolt tightening torque 8 Nm Tau Installation manual 7 5 Installing further rows of modules Installation Align the modules of the top row with the bottom row being sure to keep the space between them even e Fasten the modules with the mo dule end clamps and inter module clamps identical to the first row see section 7 3 and 7 4 TOOL You may use a inter module clamp for example as a spacing gauge You will obtain identical spacing horizontally and vertically using this technique Mounting the modules 17 Tau Installation manual mounting systems 8 Distinctive features when ins talling the modules in landscape orientation The spacing is determined by the dimensions of the modules to be installed Ensure compliance with the clamping points stipulated by the manufacturer The spacing of the base rails is deter mined as follows DANGER Danger to life from falling and falling parts Falling from the roof or being struck by falling parts may result in critical injuries e Protect yourself against falling e Do not remain in the danger zone e Wear a hard hat After the assembly is comple te check to make sure that the frame system and the modules are secure 1 Distance between the bottom tw
18. se rails onto the roof to interpret and define the possible cuts The connected series of rails should not exceed a length of 12 m The required total rail length is determined by the width of the module area see point 4 Make sure that the maximum cantilever of 17 5 cm is not exceeded if necessa ry cut rails or use splices The spacing of the rails to each other is defined by the size of the PV module see section 4 Base rails with a length of 40 cm are used for landscape mounting see section 8 Installation e Place the base rails on the applied EPDMs e Using a level align the base rails to each other Aligning and placing the base rails 10 Install the system 6 3 Positioning of the side fixing clips Installation e Insert the side fixing clips in the side channel e Press the clips against the side of the high bead and make sure that they rests uniformly and are hooked into the side channel of the base rail correctly e The side fixing clips are fastened opposite from each other on the high bead Tau Installation manual Positioning of the side fixing clips for bead heights gt 20 mm The following points must be considered when CAUTION installing the side fixing clips at the verge of the roof Material damage due to incorrect assembly e Because of the verge it is not possible to place Incorrectly assembled fixing clips may rip out the fixing clips set off to one side e When fastening the si
19. second person must be present during the entire ins tallation to provide assistance in the case of accident e Keep a copy of this installation manual in the immedia te vicinity of the system 2 2 Information regarding working on roofs When working on roofs Always follow accident prevention regulations and if necessary install guards to protect against falling com ponents e Accident prevention regulations require a safety harness or protective scaffolding be used e Observe valid local safety regulations e Test and verify the load bearing capacity of all relevant components prior to walking on the roof e Use fall protection equipment e Use protective equipment even for simple and quick tasks e Always use appropriate lifting equipment Never carry material up the ladder 2 Safety 2 3 Warnings The warnings listed in this manual indicate safety relevant information They include e Warning symbols e Key words to indicate the risk level Information about the type and source of the risk Information about possible consequences if the danger is ignored e Measures for avoiding risk and preventing injuries or property damage The key words in the warnings always indicate one of the following risk levels Indicates a severe and unusual risk that if ignored could lead to DANGER serious injury or death Indicates a potentially hazardous situation that could lead to seri WARNING ous or modera
20. te bodily injury and property damage Indicates a potential hazard that could lead to property damage CAUTION 2 4 Operator s responsibilities The system operator must fulfill the following safety rela ted obligations e Ensure that only persons with basic mechanical and trade skills are installing this system e Ensure that responsible persons are able to recognize and assess all possible dangers involved in the work assigned to them e Ensure that the responsible persons are familiar with all system components e Ensure that the installation manual is readily availab le during the assembly This installation manual is an integral part of this product e Ensure that a project related design layout exists Tau Installation manual e Ensure that the installation manual and especially the warnings are read and understood by the responsible persons prior to assembly e Ensure that the permissible conditions of use see sec tion 3 3 have been upheld Mounting Systems will not be responsible for damage which results from a violati on of these conditions e Ensure that the roof construction has the required load bearing capacity e Ensure that the durability of the mounted connections and the roof attachments are guaranteed e Ensure that appropriate lifting equipment is used during installation e Ensure that Mounting Systems components are used both for the initial installation and for eventual main ten
21. ure is adequate Ce ooo ooooo ooo o ooon oooooooo o 5 3 Mounting aids and required tools You will need the following tools to mount the frame system 6 mm Allen key e Cordless screwdriver e Attachment for cordless screwdriver hexagonal 8 mm bit Angle grinder with metal disk e Chalk line e Spirit level e Folding rule measuring tape Lifting device e g attachable work platform shoulder straps e Suction cup tool e Spacing template if applicable for landscape installation 8 Important installation information Ce i ooo oooooooooooooolo 5 4 Grounding the mounting system The potential equalization between the individual system components must follow the respective country specific regulation A possibility of grounding the Tau system is shown in the following pictures The cable gauges as well as the general grounding concept are not included in this guide and must be calculated and or created by the installer in accordance with the applicable standards and guidelines Professional grounding methods other than the ones given here are also possible Grounding of the individual rail rows e Fasten a cable lug by means of a drilling screw to each row of rails It can be fastened to the side channel of the base rails When positioning the cable lug make sure that it does not adversely affect the use of the tra pezoidal fixations splices or module clamps e Connect the individual rows of rails Low resistan
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