PITCHED ROOF STRUCTURES

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1 PITCHED ROOF STRUCTURES for framed and frameless photovoltaic modules Needed tools and materials: cordless screwdriver 10mm and 13mm spanners 5mm Allen key bolts, screws and tools for fixing the system to the roof Please note that our mounting instructions reflect the state of technology and our experience on how to install our systems on site. Due to the fact that each roof has individual characteristics, we highly recommend to commission a professional assessment before beginning the installation. In particular it is necessary to take into account structural load requirements. During the installation of the system always comply with health and safety standards and legislation. 1

2 PITCHED ROOF STRUCTURE Fastening to the roof The S:FLEX roof hook is recommended for most profiled tile roofs. The assembly sequence is explained below. Hanger bolts can be used for corrugated panels or trapezoidal sheets. With pitched roofs, this is possible up to a maximum pitch of 20. Drill holes in the roofing on the planned site and screw the hanger bolt in the rafter/purlin. The EPDM gasket must be pressed firmly against the roofing material by the nut. Fasten the hanger bolt to the supplied angle brackets. If it is not possible to penetrate the roof, the bolts can be fastened direclty to existing trapezoidal and/or corrugated sheets with an angle for plate assembly. The angle for plate assembly can be used on pitched roofs with a maximum pitch of 20. Before attaching rails, the plate must be adequately fastened to the substructure, and its maximum load capacity checked. For further information, refer to the angle plate assembly instructions. The Trapezoid Sheet Metal Rail can be used with piched roofs up to a maximum pitch of 43. Rivets or sheet metal screws are used to attach the Bracket for Plate Assembly and the Trapezoid Sheet Metal Rail to the roof. 2

3 Framed PV modules/pantile roofing 01 Position the roof hooks according to the design. Consult the project-specific assembly drawings. Remove the roof tiles from the marked positions or just slide them up, as necessary. When positioning the roof hooks, they must not be pressed against the roof tile. The roof hooks can be lined with wood. Mount the roof hooks on the rafters with three wood screws each as per DIN 1052 (e.g. 6 x 80mm or 6 x 100 wood screws). 02 If necessary, a grinder can be used to notch the roof tile where the roof hooks are installed. The roof hooks must not prop up the roof tile above them. In the case of interlocking tiles, the lower tile must also to be notched. 03 For each row of modules, install the mounting rails on the roof hooks using the M8x20 hammer-head bolts, the M8 serrated lock washer and M8 hexagon nut. Check for correct alignment of the hammer-head bolts in the mounting rail slot (torque: Nm). 04 To install several mounting rails in a row, slide the splice halfway onto the assembled mounting rail. Then, slide the next mounting rail onto the splice. Apply pressure while sliding the mounting rails together. The connection is complete. There is no need to fix the splice in place with bolts or screws. 3

4 Framed PV modules/pantile roofing 05 max. 600 mm Optional: To best adapt the length of the mounting rails to the module dimensions, use the pre-assembled telescopic shaft. Slide the shaft onto the mounting rail and fasten it to the roof hooks. Adjust the length (max. 600mm). Now, slide the locking clip onto the mounting rail and tighten the screw (torque: 12-15Nm). 06 Before they are mounted, the modules are equipped with anti-slip protection. This is done by attaching M6 x 20 screws (with the shank downward) with M6 nuts in the lower mounting holes of the module. When mounting large modules (e.g. ASE250), M8 x 20 screws are used. 07 Now, slide the first module onto the mounting rail until the screws on the lower side of the module frame hit the mounting rail. Slide the end clamp onto the vertical mounting rails. Slide the first module into the end clamp. Then, adjust the end clamp to the module frame height. Fasten the end clamp by turning the screw counterclockwise (torque: 9-10Nm). 08 click! Now, click the mid clamp onto the mounting rail and slide it onto the module. Ensure that the mid clamp clicks onto both sides of the mounting rail. 4

5 Framed PV modules/pantile roofing 09 Now, slide the next module under the mid clamp, adjust it to the module frame height and tighten the screws (torque: Nm). 10 Once all modules are mounted, an end clamp is also attached to the end of the mounting rail. 5

6 Interlocking crossbar 11 Assembly sequence of the horizontal mounting rail (substructure) as described under Items Mount the vertical mounting rails onto the horizontal mounting rails for each row of modules using the cross adapter clamps (torque: 9-10 Nm). Please use the correct number of cross adapters for the mounting rails. Number of clamps per intersection point: ST/AK 7/47 = 1 cross adapter ST/AK 13/60 = 2 cross adapters To set up several mounting rails in a row, follow the procedure described under item Slide the end clamp onto the vertical mounting rails. Afterwards, push a locking clip on for each one and fasten it (torque: Nm). Slide the first module into the end clamp. Then, adjust the end clamp to the module frame height. Fasten the end clamp by turning the screw counterclockwise (torque: 9-10Nm). 14 Additional modules are mounted as described under Item

7 Frameless PV modules/pantile roofing 01 Set up cross adapter clamps as described under Item Attach and fasten a locking clip on the lower end of the mounting rail (torque: 12-15Nm). Then, place the laminate end clamp into the slot of the mounting rail with the hammer-head bolt, and slide it into the locking clip. The module should not rest on the mounting rail. Therefore, fasten the laminate mid clamps before fastening the module. Check for correct alignment of the hammer-head bolts in the mounting rail slot! 03 Now, slide the module into the laminate end clamp and tighten the hammer-head bolt (torque: 9-10 Nm). Then slide the laminate mid clamp onto the module and tighten the hammer-head bolt (torque: 9-10 Nm). 04 Once all modules are mounted, a laminate end clamp is fastened at the end of the mounting rail. Check for correct alignment of the hammer-head bolts in the mounting rail slot! 7

8 Assembly sequence roof hook Plain roofing 01 Berlin plain tile North German plain tile South German plain tile 15,5 x 38,0 cm 15,5 x 36,0 cm 18,0 x 38,0 cm LA distance on the pitch 14,5-16,5 cm Position the roof hooks according to the design. Consult the project-specific assembly drawings. 02 Remove the roof tiles from the marked positions and exchange the tile underneath the roof hook with a sheet metal tile. Glue the foam wedge into the sheet metal tile. Mount the roof hooks on the rafters with three wood screws each as per DIN 1052 (e.g. 6 x 80mm or 6 x 100 wood screws). The roof hooks must not apply pressure to the sheet metal tile. Then the angle brackets supplied with delivery are fastened to the roof hooks (torque: 9-10 Nm). 03 When all roof hooks are installed please set up mounting system as described under Items The mounting structure is installed according to the assembly instructions for pitched roofs. 8