On-roof system Alpha Installation manual
Contents
1. mounting systems 810 0002 Alpha Installation manual mounting systems Alpha A stroke of genius Content 1 Introduction 1 1 Overview 1 2 Intended use i Standards and technical directives 1 4 About this manual 2 Safety 2 1 Basic safety instructions 2 2 Working on roofs 2 3 Warnings 2 4 Responsibilities of the operator 3 Technical Description 3 1 System overview 3 2 Scope of delivery 4 Designing the module field 5 Important installation instructions 5 1 Operating conditions 5 2 Preparation 5 3 Tool 5 4 Grounding of the Mounting System 6 Installation of roof connections 6 1 Installing the standard roof hook 170 Variation when using roof hooks for heavy snow Variation for plain tile roof covering Variation for shingle slate roof covering 6 2 Installing hanger bolts 6 3 Installing clamp on roof hooks 7 Install the system 7 1 Installation procedure ta Quickstone and X Stone Installing the Quickstone Installing the X Stone 13 Installing the base rails Fixing the base rails Aligning the rails Inter connecting base rails Installing telescoping end pieces optional 7 4 Installing the modules Installing anti slip protection Fixing the outer modules of each row Fixing the inner modules of each row Installing further rows of modules 8 Variation for landscape installation of the modules 8 1 Installing base rails vertically 8 2 Installing cross rails Alpha MA ENG 1201 NNN NA ul Ul WNNN N PrP PP oOo wo2. part of the product e Ensuring that the installation manual and particularly the safety instructions are read and understood by the authorized installation personnel prior to beginning the work Ensuring that work site safety regulations and requirements are observed e Ensuring that suitable lifting devices are used for the installation Safety 3 Alpha Installation manual Do A gt mounting systems 3 Technical Description 3 1 System overview e Type of roof Type of module All components of the system are listed below The version e Number of modules and quantities of the parts can vary depending on e Site specifics OS MEE LEE ME a 4 IERE LETE p S A E LMM A SUAT ia haf ema E Alpha Installation manual S S LY A SSS i er m Lift 4 4 _ a 7 PF ae 4 f x Lf MITT 7 ff a y lt r V aa f i Base rail Joiner piece Inter module clamp Roof hook Module end clamp Qa A FSW Telescoping end piece optional D Technical Description A y S lt Ne gt Q h O QA A 3 2 Scope of delivery All system parts and requisite small parts which are required for instal lation are included in the delivery The precise scope of supply will depend on the size and number of PV modules which you specify when ordering o o Roof hook 170 Roof hook for heavy snow Roof hook for p
3. tion of the roof If necessary take out the fixing bolt and use the Spax wood screw to fix the roof hook to the lath Ce oeoooooooooooooooooooooooo oooooooooooooooooooooooooooooo onoo oooooo oooo oH o Installation Position the roof hook above the low part of the tile and clamp it onto the roof lath e Adjust the spacer bolt so that the roof hook does not touch the small side of the tile min 2mm distance e Tighten the fixing bolt by hand so that the roof hook can a Spax wood screw optional d Roof lath no longer move under wind suction conditions b Spacer bolt e Clamp on roof hook with If necessary use an angle grinder or hammer to cut a c Fixing bolt L bracket recess in the tile that covers the roof hook so that the tile lies flat on the surface 10 Installation of roof connections 7 Install the system Installing the Quickstone 7 1 Installation procedure The following pages list the individual steps for installing the Alpha in the correct sequence Each column representsa complete sequence of actions The sequence of actions consists of an illustration the corresponding steps and additional information and safety instructions 7 2 Quickstone and X Stone During the installation of Alpha Quickstones are used The Quickstone is a special nut used to connect several parts of the Alpha The only tool needed for installation is a 6 mm Allen key Alpha Installation manual The Quickstone
4. can be used on both channels a Element to be fixed e g module clamp of the base rail b Allen bolt For a cross installation of two layers of base rails c Quickstone XStones are used These consist of an aluminium block d Base rail with two pre assembled Quickstones Material damage through faulty AN installation Incorrectly installed Quickstone CAUTION connections can rip out of the profile e Install all Quickstone connections as described below Installation If necessary adjust the bolt so that it does not protrude the Quickstone Fit the Quickstone from above into the profile channel so that it wedges underneath the protruding rail hooks When fitted correctly the Quickstone machtches the form of the profile exactly Tighten the bolt with a torque of 8 Nm Install the system 11 Alpha Installation manual mounting systems Installing the X Stone a Horizontal base rail b X Stone with 2 Quickstones c Vertical base rail When installing on uneven roof surfaces the use of a special X stone version is recommended Please ask your Sales contact for further information 12 Install the system Installation e Install both Quickstones as described above e Make sure the upper rail lays flat on the lower one e Completely tighten both Quickstones only when you have put the rails in their final position 7 3 Installing the base rails LL GILLI T TTT TTA WTTTS hf a Jo
5. hook Ce ee a 2xwood screw 6 x 80 mm b Roof hook for plain tiles Sheet of titanium zinc A Q Wood plates to shim roof hooks if necessary Installation e Cut a recess into the tiles around the position of the roof hook e Cut titanium zinc metal sheets to fit and install them under the roof hooks Fix the roof hooks to the rafter using two 6 x 80 mm wood screws Installation of roof connections 9 Alpha Installation manual mounting systems 6 2 Installing hanger bolts A Damage to the building through leakage AN Inappropriately fixed hanger bolts can cause leakage CAUTION e Never position hanger bolts on the low parts of the corrugated sheets Observe minimum edge distances Hanger bolts fixed too close to the edges of purlins can rip out CAUTION e Observe a minimum distance of 5xd to the edge of the purlin when installing hanger bolts e Predrill holes when using bolts with a diameter gt 6mm gt a Hanger bolt with L bracket Installation b Sealing washer c Nut Drill through the roof cladding at the planned location e Screw the hanger bolts into the purlins e Press the sealing washer onto the drill hole and fix it with the nut without further damaging the sheeting The tight ening torque depends on the type of roof sheeting 6 3 Installing clamp on roof hooks f Damage to the isolation With some roof constructions the CAUTION fixing bolt can damage the isola
6. lifting pads e Power drill as necessary 5 4 Grounding of the Mounting System The potential equalization between the individual system components must follow the respective country specific regulation A possibility of grounding the Alpha mounting system is shown in the following The cable gauges as well as the general grounding concept are not included in this manual 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 base rails Insert and tighten a cable clamp in the side channel of the base rail in every rail line tightening torque 8 Nm e Strip the insulation from the grounding cable at the appropriate place Insert the bared section in the cable clamp and fasten it in place by tightening the top screw Alpha Installation manual Low resistance connection between modules and base rails Unless specified otherwise by the module manufacturer the modules for Alpha can be connected conductively to the base rails as follows e Slide a Weeb Clip onto the still uninstalled module clamp only inter module clamps e Mount the module clamps as usual but make sure the Weeb Clip is simultaneously correctly inserted The correctly inserted clip sits between the base rail and the module frame The 4 noses protrude into the rail channel Important install
7. the lower one e Fix both Quickstones to the base rails tightening torque 8 Nm a Horizontal base rail b X Stone with 2 Quickstones c Vertical base rail 18 Variation for landscape installation of the modules 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 com www mounting systems com Subject to technical alterations 2011 Mounting Systems
8. wo o 10 10 11 11 11 11 12 12 14 14 14 15 15 16 16 16 17 18 18 18 1 Introduction 1 1 Overview The Alpha is a robust long life mounting system for pho tovoltaic modules on pitched roofs It comprises alumini um rails roof connections and all necessary small parts to ensure a Safe installation The proven Quickstone profile nut makes installation quick and easy With Alpha modules can be mounted in both landscape and portrait orientation 1 2 Intended use The mounting system Alpha is to be used for the roof mounting of photovoltaic modules only Mounting Systems is not liable for damages resulting from failing to comply with the installation instructions particularly the safety instructions as well as misuse of the product 1 3 Standards and technical directives When planned correctly Alpha fulfills the following standards and technical directives e Eurocode 9 DIN EN 1999 Design of aluminium structures e Eurocode 1 DIN 1055 Actions on structures In addition the following must be observed for every installation e VDE 0100 712 IEC 64 1736 Installation of low voltage systems e VDE 0185 Serie IEC 81 335 Lightning protection 1 4 About this manual Subject This manual details the installation and assembly of the Alpha photovoltaic mounting system User group The manual is intended for qualified personnel with a basic knowledge of mechanics hand tools and mechanical skills S
9. ation instructions 7 Alpha Installation manual mounting systems 6 Installation of roof connections Depending on the type of roof covering different roof connections must be used The type of roof connection included in your delivery depends on your order A l Working on the roof WARNING During work on the roof parts can drop down or persons may fall off e Secure yourself against falling e Do not remain in the danger area e Wear a hard hat After completing the installation check thatthe system and the PV modules are securely fastened Damage to tiles through stepping Observe minimum edge distances on roof hooks Screws fixed too close to the edges of CAUTION Do not use fitted roof hooks as a ladder CAUTION rafters can rip out as this extreme point load could dam e Do not fix any screws closer than age the tile below 30mm to the edge of rafters e Predrill holes when using screws with a diameter gt 6mm Ce ooo oooooooo ooo ooooooooo 7 ooooooooooooooooooooooooooooooooooooooooo ooo ooooooo ooo ooo oooooo ooo ooo oooooo o Material damage through AN faulty installation The roof hook must not press against CAUTION the tiles to avoid damaging the tiles If necessary e Shim roof hook with wooden plates so that the roof hook does not touch the underlying tile If necessary use an angle grinder or hammer to cut a recess in the tile that covers the roof hook so that the tile lies flat on the su
10. bove for the previous row of modules Install the system 17 mounting systems 8 Variation for landscape installation of the modules When installing the modules in landscape orientation the Working on the roof l l rails need to run vertically During work on the roof parts can l l DANGER drop down or persons may fall off For most types of roof connections you just turn the preas o Secure yourself against falling sembled L bracket by 90 e Do not remain in the danger area For roof connections without L brackets cross rail e Wear a hard hat After completing the installation installation can be used X stones are used to interconnect check that the system and the n two perpendicular layers of rails Cross rail installation modules are securely fastened 1s used when e The roof construction demands a horizontal installation of LET MARC R TIS RSET An See eae EAL ERNE AAMT EE CR REA E ee ee eee the base rails while a landscape orientation of the modules is desired or vice versa Alpha Installation manual Installation If necessary turn the L bracket on the roof connection by 90 Fit the Quickstone into the channel of the base rail and fix it Roof connection with L bracket Y b Base rail Installation Insert one X Stone into the side channel of the upper rail Align the rails Insert the X Stones into the top channel of the lower rail e Make sure the upper rail lays flat on
11. carry materials on to the roof via ladders but rather use suitable lifting gear 2 Safety 2 3 Warnings The warning notes used in this manual identify safety related information hey consist of e Warning symbol pictograph Indicator word to denote the danger level Information about possible consequences if the danger is not observed e Measures for avoiding the danger and for preventing injuries or property damages The heading of the warning notes identifies one of the following danger levels DANGER Denotes a major risk failure to observe which could lead to seri ous injury or death Denotes a potentially danger ous situation which may lead to moderate to serious physical gt WARNING fake injury and property damage Denotes a potential risk which may lead to physical injury and CAUTION property damage Ce i o 2 4 Responsibilities of the operator Modifications to Mounting Systems equipment may be performed only by authorized personnel The operator of the system has the following safety related responsibilities Performing recommended maintenance work Ensuring that the installation of the frame is performed only by qualified personnel with adequate skill and knowledge Ensuring that the assigned installation personnel can evaluate the work assigned and recognize possible dangers Ensuring that the installation manual is available during the installation The installation manual is
12. ignposts The following will assist you in finding your way around in this manual Footers The footers display the chapter heading and the page number Pictographs Identifies background and additional information for processes Tips and tricks Facilitate installation Introduction l Alpha Installation manual Alpha Installation manual mounting systems 2 Safety 2 1 Basic safety instructions The following basic safety instructions and the warning notes are an essential part of this manual and are of fun damental importance for handling the product Regardless of the certified structural analysis it must be ensured prior to every installation that the product meets the static requirements on site according to the local jurisdiction having authority for such installation 2 2 Working on roofs When working on roofs note the following instructions e Pay attention to accident prevention regulations for working on roofs If appropriate use a barrier to protect against falling parts In line with accident prevention regulations work on roofs should be carried out using safety harnesses for individuals or safety scaffolding e Observe the relevant local safety regulations Before stepping on to the roof check the load bearing capability of all parts which are under stress e Use fall protection e Use protective equipment to guard against falling even when carrying out short jobs Do not
13. iner piece b Base rail c Telescoping end piece Base rails Depending on the number of modules in one row the base rails can be of one or of several pieces The length of the base rail corresponds with the width of the module field The parts of base rail are inter connect ed with joiner pieces Telescoping end piece The Telescoping end piece enables you to adjust the overall length of the base rails to the millimeter with out the need for on site cutting EL ff ey Lf AEE ha ha ha hah LiL LL ine amp Boars Bsa Bis Alpha Installation manual Working on the roof During work on the roof parts can DANGER drop down or persons may fall off e Secure yourself against falling e Do not remain in the danger area e Wear a hard hat After completing the installation check that the system and the PV modules are securely fastened A Damage to tiles through stepping on roof hooks CAUTION Do not use fitted roof hooks as a ladder as this extreme point load could damage the tile below CM ooo ooo oooooo ooo ooo oooooo ooo ooo oooooooo o Install the system 13 mounting systems Fixing the base rails Aligning the rails c Base rail i 5 z 2 amp T D a Roof connection a Base rail PS b Quickstone b String or spirit level Q lt Installation Installation The installation is shown with the base rail 13 58 Align all rails using a piece of str
14. ing or a spirit level If your set of rails consists of rails of different lengths e Tightly fix all Quickstone connections on the rails then always begin with the shortest piece tightening torque 8 Nm Install the rails for each row of modules loosely on the roof hooks using an M 8x25 mm Allen bolt washer oo eee cecneceseecneeeeeeeeseeceeeeeeecesseseeenseeeeseeeneeeeneees retaining washer and Quickstone each 2 to 3 turns of the G The oblong holes in the roof hooks or L brackets allow for a height adjust ment of the rails to level out the PV installation on uneven roofs Ce o screw are adequate for loose installation e Completely tighten the Quickstones only when you have put the rails in their final position INFO Inter connecting base rails Installation e Slide the joiner pieces halfway onto the rear side of the base rails Fix the according Allen bolt to the base rail tightening torque 8 Nm Slide the next rail segment into the Joiner piece e Leave a 1cm gap as an extension joint Fix the second Allen bolt to the base rail tightening torque 8 Nm The connected i rails should not be longer than a Base rail INFO 12 meters b Joiner piece 14 Install the system Installing telescoping end pieces optional Base rail Telescoping end piece Loose rail section on the telescoping end piece a 9 Ogg Roof connection 7 4 Installing the modules Installation e Mount a te
15. lain tiles Roof hook for Slate Shingles Clamp on roof hook Hanger bolt Base rail 13 58 19 63 and 25 65 Base rail 7 49 Joiner pieces 13 58 19 63 and 25 65 Joiner piece 7 49 Telescoping end pieces 13 58 19 63 and 25 65 Telescoping end piece 7 49 Alpha Installation manual Inter module clamp Module end clamp for frame heights Module end clamp for frame heights Inter laminate clamp for laminates 6 to 8 mm thick Laminate end clamp for laminates 6 to 8 mm thick Weeb Clip Cable clamp for grounding Technical Description 5 Alpha Installation manual mounting systems 4 Designing the module field Below the distances between roof connections for a portrait installation are specified Clamp on roof hooks roof hooks and hanger bolts need to be installed in specific distances depending on the distance of rafters and the statical conditions When positioning the modules please take into consideration e That the values above are guidelines e That dimensions of tiles or other roof covering and the position of the rafters define the precise actual horizontal distance between roof connections e That the distance between roof laths defines the precise actual vertical distance between roof connections The configuration must be in accordance with the local conditions and with Eurocode 1 DIN 1055 parts 4 and 5 Eurocode 9 DIN V ENV Height of the module field mod
16. les on the rail side of each row so that the telescoping end piece can be aligned with the last module to be mounted Install the system 15 Alpha Installation manual mounting systems Add anti slip protection consisting of a bolt and nut inserted into the holes on the underside of the module frame to the lowest row of modules horizontal rail instal lation only This keeps the modules from sliding off and thus facilitates installation The anti slip protection does not have any static function in the finished installation The modules are fixed with inter module clamps and endclamps An end clamp will hold one module an inter module clamp 2 consecutive ones Installing anti slip protection lips of the laminate clamps 16 Install the system Ce cocoon ooo cooo ooo ooo oo oo o When installing laminates laminate clamps need to be used instead of module clamps The installation process is identical The laminates are set between the rubber lips of the laminate clamps Ce i Installation e The anti slip protection is only necessary on the e lower most row of modules Fit two bolts M6 x 20 and nuts into the lower holes of each module e Place the first module of the bottom row so that the anti slip protection sits in the rail channel of the lowest row of rails Module frame underside Ss amp Anti slip protection c Base rail Installation Slide the Quickstone into
17. lescoping end piece at the end of every row of base rails If necessary fix the loose rail section of the telescoping end piece to a roof connection The telescoping end piece should not be firmly fixed until the last module of the row is positioned In that way the exact necessary length of rail can be realized After adjusting the telescoping end piece to the last module of a row fix it completely by tightening the Allen bolt on the rail side of the telescoping endpiece tightening torque 8 Nm Alpha Installation manual eoeecee rece e cere eee eee eee eee eee eres eee eee eee eee ee eee eee eee eee eee reese eee eee eee eee reer ese ee eee eee eres eee eee eee eee ee eee eee eee rere ee reese seer ee eee reer ee ereee eee eeeee Working on the roof A N During work on the roof parts can drop down or persons may fall off e Secure yourself against falling DANGER Do not remain in the danger area e Wear a hard hat After completing the installation check that the system and the PV modules are securely fastened eoerecece eee eee eee eee eee eee eee eee eee eee ee eee eee eee eee eee eee eee eee eee eee eee eee eee eee eee eee eee ee eee eee eee eee eere eee eee eee eee e ere eee ee eee eee eee eee eee ee eee ee eeeereeee The modules are successively mounted onto the base rails It is recommend ed to start on one side of the module field When using telescoping end pieces start installing the modu
18. rface a 3x wood screw 6 x 80 mm b Rafter Standard roof hook 170 Wood plates to shim roof hooks if necessary A Q 8 Installation of roof connections eecececerec cere cee eee reece eee eee eee eee eee eee eee eee eee eee ee eee eee eee eee eee eee eee eee Installation e Remove the roof tiles at the marked positions or AN if possible simply push them up CAUTION e Position the roof hooks above the low parts of the tiles Fix the roof hooks to the rafter using three 6 x 80 mm wood screws Damage to the building through leakage Without appropriate flashing of the roof hook the roof can leak e Use a zinc metal sheet with at least 20 mm around the recess in the tiles underneath the roof hook Variation when using roof hooks for heavy snow Variation for shingle slate roof covering c The roof hook for heavy snow is installed in the same Installation E amer WY manner as the standard roof hook However it is fixed with 2 hex head screws 8x80 mm and 2 washers e The roof hook for shingles slate is installed in the same f o lt manner as the roof hook for plain tiles However it is fixed with 3 wood screws 6x100 mm Variation for plain tile roof covering CAUTION Damage to the building through leakage Without appropriate flashing of the roof hook the roof can leak e Use a zinc metal sheet with at least 20 mm around the recess in the tiles underneath the roof
19. the rail channel Align the module and push the module end clamp firmly against the side of the module Tighten the Allen bolt and Quickstone tightening torque 8Nm a Module end clamp with Quickstone b Module c Base rail When installing laminates laminate clamps need to be used instead of module clamps The installation process is identical The laminates are set between the rubber Fixing the inner modules of each row Installation e Slide the Quickstone into the rail channel e Push the Inter module clamp firmly against the already fixed module e Push the next module against the other side of the module end clamp e Tighten the Allen bolt and Quickstone tightening torque 8 Nm a Inter module clamp with Quickstone b Module c Base rail When installing laminates laminate i clamps need to be used instead of module clamps The installation process is identical The laminates are set between the rubber lips of the laminate clamps Ce ooo oooooooooooooo Alpha Installation manual Installation e Set the modules of the next row above the lowest row of modules For optical reasons a gap can be left between module rows Use a spare inter module clamp as a gauge for the space between module rows In this way the horizontal and TOOL vertical gaps between modules will be identical coco ee Fix the modules to the base rails using inter module clamps and module end clamps as described a
20. ule height x number of modules vertically Width of the module field number of modules horizontally x width of the module 19 mm 31 mm Distance between roof connections vertically according to the clamping points pre defined by the module producer Quarter points of the modules about 1 2 of module height Distance between roof connections horizontally Depending on the distance between rafters and on the static requirements Distance between modules 17 mm 6 Designing the module field 5 Important installation instructions 5 1 Operating conditions The various components of the on roof system Alpha can withstand different maximum charges Therefore the exact components for a project need to be checked as to their compliance with the local standards and regulations for each project This can easily be done for example by way of the Alpha calculation tool 5 2 Preparation It is recommended to familiarize yourself with the condi tions on site before ordering Alpha especially regarding e The roof construction including isolation e Dimensions and quality of roof laths and rafters e Type shape and material of the roof covering 5 3 Tools The following tools are required for the installation gt 6 mm Allen key e Cordless drill Open end spanner 13 e Torx 30 AW 30 Bit Angle grinder with stone disk e Cord e Spirit level e Rule e Hoisting gear If necessary timber to shim the roof hooks e Vacuum
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