HORIZONTAL INSTALLATION

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1 THERMO/SOLAR Žiar s.r.o. MANUAL FOR INSTALLATION PV SUPPORTING FRAMES HORIZONTAL INSTALLATION Technical alternation reserved A /2014

2 CONTENT ORD.NO. PAGE Mounting information 3 Mounting, flat roof A-frame S Connecting of supporting sections 9 Mounting of safety angle brackets 12 Mounting of side and centre fixtures Mounting of additional bracing strut Mounting, sloping roof - basic roof hook S Mounting, sloping roof - stainless steel roof hook S Mounting, sloping roof - aluminium straight roof hook S Mounting, sloping roof - stainless steel holder S Mounting, sloping roof - combi screw S Mounting on facade A /2014

3 Mounting information Follow the positions of the roof hooks according to this manual. In areas with heavy snow loads it is strongly recommended use roof hooks on all of the rafters. In case of heavy snow load (snow load above ZONE 4) it is recommended to use replacement of standard tiles for metal tiles or kombi-screws. Spacing the roof hooks (S3014) in this installation manual meets standards according to STN EN for the following: Wind load - dynamic pressure of gusty wind q (z) = 0,5 kn/m² - equivalent for wind speed v = 105 km/h Snow load - snow load on the ground s k = 1,5 kn/m² - snow load 1,2 kn/m² It is necessary to observe locally valid safety regulations for working at heights when working on the roof. Tools Bits for screwdriver Torx Allen key Phillips Ø5 Ø8 Ø8,5 A /2014

4 SUPPORTING FRAME FOR PV PANELS - FLAT ROOF A-FRAME, HORIZONTAL INSTALLATION Dimensional sketch A /2014

5 A-frame 2pcs A-frame 3pcs A-frame 4pcs A-frame 5pcs A-frame 6pcs A-frame 7pcs Panel s layout If the field of PV panels should be symmetrical it is necessary to keep the dimensions according to the picture below. PV PANELS QUANTITY A-FRAME QUANTITY A /2014

6 A-frame assembling Screw the floor beam, ledger and post together using M8x20. The holes for roof fixing are already set in the floor beam. One piece of A-frame is needed for one PV panel. Two pieces of A-frame are needed if only single PV panel is used. POST LEDGER FLOOR BEAM A /2014

7 Notice for mounting To protect the panels from fall over by strong winds they have to be screwed tightly to the roof structure. If this is not possible, each panel must be attached to a minimum weight of 330 kg/panel. Illustration of mounting A-frame to the concrete blocks using mechanical anchor to the concrete. A /2014

8 A /2014

9 Connecting of supporting sections Depending on quantity of PV panels, supporting sections are multi-parted. Connection of supporting sections is shown in the picture below. If possible, connect the sections the way that connecting plate is facing to the bottom. Roof direction A /2014

10 Mounting of supporting sections to the A-frames Push the carriage bolts M8x20mm into the section. It can be done from the side or through cut groove in the section. Subsequently push the supporting section with bolts into the A-frame and tighten through flange nuts. A /2014

11 Illustration of mounted supporting frame for 2 pcs of PV panels. Condition: A=B! A B A /2014

12 Illustration of PV panel Mounting of safety angle brackets Mount safety angle brackets as shown in the picture. Use M6x16 bolt, M6 flange nut and. Montovať bezpečnostné uholníky podľa zobrazenia. Použiť skrutku M6x16, prírubovú maticu M6 and large washer. A /2014

13 Mounting of PV panel to the supporting frame Mount the PV panel to the supporting frame as shown below. A /2014

14 Mounting of side fixtures Mount the side fixtures as shown in the picture. Use M8x30 carriage bolt and M8 nut with inner Allen. 83 A /2014

15 Mounting of centre fixtures Mount the centre fixtures as shown in the picture. Use M8x30 carriage bolt and M8 nut with inner Allen. A /2014

16 Picture of required fixing points for 4 pcs of PV panels A - Joint between panels B - Joint on the side of panel A B A /2014

17 Mounting of additional bracing strut It is highly recommended to use additional bracing strut in case of frame instability and increased adverse weather conditions (snow, wind). Mount the additional bracing strut as shown in the picture. Drill 8,5mm holes on the lower part of the post and attach the bracing strut to the posts. Use M8x20 bolt, M8 nut and 8,4 washer to the attachment. A /2014

18 Drill 8,5mm holes on the lower part of the post and attach the bracing strut to the posts. A /2014

19 SUPPORTING FRAME FOR PV PANELS - SLOPING ROOF BASIC ROOF HOOK, HORIZONTAL INSTALLATION Dimensional sketch A /2014

20 Hooks quantity 4pcs Hooks quantity 6pcs Hooks quantity 8pcs Hooks quantity 10pcs Hooks quantity 12pcs Hooks quantity 14pcs Panel s layout FIXING HOOKS QUANTITY RAFTERS SPACING 800 mm ROOF INCLINATION 30 PANELS QUANTITY HOOKS QUANTITY A /2014

21 Hooks quantity 4pcs Hooks quantity 8pcs Hooks quantity 12pcs Hooks quantity 16pcs Hooks quantity 20pcs Hooks quantity 22pcs Panel s layout FIXING HOOKS QUANTITY RAFTERS SPACING 900 mm ROOF INCLINATION 30 PANELS QUANTITY HOOKS QUANTITY A /2014

22 Hooks quantity 4pcs Hooks quantity 8pcs Hooks quantity 10pcs Hooks quantity 14pcs Hooks quantity 18pcs Hooks quantity 20pcs Panel s layout FIXING HOOKS QUANTITY RAFTERS SPACING 1000 mm ROOF INCLINATION 30 PANELS QUANTITY HOOKS QUANTITY A /2014

23 It is necessary to keep the hooks spacing because of static strength of whole construction. Keeping the hooks spacing and following assembly instructions ensures the tile protection against breaking. It prevents to get water through the roof casing into the roof itself. A /2014

24 Mounting preparation Discover the location of rafters beneath the roof tiles. Pull or take roof tiles out placed above the rafters. RAFTERS SPACING 680 to 845 mm A /2014

25 Remove the lock from relevant roof tile in the area where to hook is going to be set. A /2014

26 Strengthen the correctly-placed hook as shown in the picture. Use wood screw with min. of length 80 mm. Use wood screws with ordering no. F1486 (F1488). If the hooks are being underlaid, it is necessary to use wood screws with min. of length 120 mm, ordering no. F1487 (F1489). Pre-drill hole with ø5 drill to 2/3 of the total screw length. Grease the screws with solid lubricant before the mounting. When installing the hook, rule of minimum space between hook and roof tile needs to be kept. It is necessary to keep the distance of 5 mm. See picture below. 5 mm A /2014

27 Using of underlay beneath the hook If the space between roof tile and hook is smaller than 5 mm, the underlay needs to be used! See picture below. A /2014

28 If the certain hook cannot be fixed correctly to the rafter, it is necessary to take measures according to following picture! Rafter is located between the roof tiles. It is necessary to mount additional support because of impossibility to fix the hook reliably. A /2014

29 Mounting of additional support. Choose dimension of support according to the rafter size. Minimum length of the support is 600 mm. Use the screws with appropriate length or screwed joint for fixing the support. A /2014

30 RAFTERS 680 to 845 mm SPACING After mounting of hooks, the supporting sections can be mounted. Strengthen the supporting sections according to the picture. Use M8x20 carriage bolts and M8 flange nuts. Push the bolts into the sections from the side or through cut groove in the section. A /2014

31 Check the diagonals! Condition A=B! B A For mounting of PV panels follow the instructions in section Mounting of PV panel to the supporting frame, pages A /2014

32 SUPPORTING FRAME FOR PV PANELS - SLOPING ROOF STAINLESS STEEL HOOK, HORIZONTAL INSTALLATION Dimensional sketch A /2014

33 Hooks quantity 4pcs Hooks quantity 6pcs Hooks quantity 8pcs Hooks quantity 10pcs Hooks quantity 12pcs Hooks quantity 14pcs Panel s layout If the field of PV panels should be symmetrical it is necessary to keep the dimensions according to the picture below. PANELS QUANTITY HOOKS QUANTITY A /2014

34 Mounting preparation Pull the roof tiles out depending on hooks position Check the existing battens for stability. The battens must not show any signs of deteriorations. Rotten battens needs to be replaced. If the battens to be used are smaller then 50 x 30 mm give them additional strength by fixing additional wood screws (ø5 x 60 mm not sup- Place the roof hooks in the correct position using 2 wood screws (ø5x30 - F1406). Fix the sliding blade under the lower roof batten and bolt together using screws. The sliding blade holds the hook in its correct position. In case of roof tiles with high thickness: Bend the blade of the tile, in order to fit under the batten and not just under the roof tile. If necessary, grind the roof tiles so that the hook has full contact to the tile! A /2014

35 Mounting of supporting frames For mounting of supporting frames (supporting sections) to the stainless steel hooks follow the instructions for the basic roof hook. See page 30, below. For mounting of PV panels follow the instructions in section Mounting of PV panel to the supporting frame, pages Spacing according to scheme on page 33 ca to 845 mm Stainless steel hook is height adjustable. This can be used if the unevenness situated on the roof needs to be compensated. For mounting of supporing section and PV panels follow the instructions on pages 31 and 32! A /2014

36 SUPPORTING FRAME FOR PV PANELS - SLOPING ROOF ALUMINIUM STRAIGHT ROOF HOOK, HORIZONTAL INSTALLATION Dimensional sketch A /2014

37 Panel s layout The straight roof hook can be fixed as follows: into the rafter It is necessary to keep the hooks spacing according to the basic roof hook S3014, see pages Use the wood screws ø8x120. Depending on type of roof tile, grind the roof tiles so that the hook has full contact to the tile! (When fixing to the rafter, it is necessary to underlay the hook. See picture below. The underlay of hook is quite demanding for precision and therefore we recommend to use different fixing elements. into the shingle roof, tin roof, or into the different underlay It is necessary to keep the hooks spacing according to the hook S3758, see page 33. Illustration of underlaying of hook when fixing to the rafter A /2014

38 Illustration of alternative underlaying of hook when fixing to the rafter. Use mininum of 4 screws when fixing the hook to the shingle roof, tin roof or into the different underlay. Use screws ø6, length according to the underlay. A /2014

39 Mount the angle bracket S3843 to the straight roof hook. The angle bracket is needed for fixing of supporting section. Put the angle bracket to the hook and screw with socked head screw M6x16. A /2014

40 Mounting of supporting section to the hook Push the carriage bolts M8x20mm into the section. This can be done from the side or through cut groove in the section. Subsequently put the supporting section with bolts on the angle bracket and tighten through flange nuts. For mounting of supporing section and PV panels follow the instructions on page 31! A /2014

41 SUPPORTING FRAME FOR PV PANELS - SLOPING ROOF STAINLESS STEEL HOLDER, HORIZONTAL INSTALLATION Trapezodial and sandwich sheets: When mounting on tin roofs, it is necessary to prefer mounting on the inner construction of roof, i.e. to use kombi screws (threaded bars). If this is not possible, we recommend to use stainless steel holder. The trapezodial sheets has to be sufficiently fixed to the roof construction! Panel s layout Holders quantity 4pcs Holders quantity 6pcs Holders quantity 8pcs Holders quantity 10pcs Holders quantity 12pcs Holders quantity 14pcs PANELS QUANTITY HOLDERS QUANTITY A /2014

42 Fixing of hook Use only bolts packaged with the holder Bolts cannot be slipping during the mounting Roof must be able to bear addtional load of PV panels For mounting of supporing section and PV panels follow the instructions on pages 30 and 31! A /2014

43 SUPPORTING FRAME FOR PV PANELS - SLOPING ROOF COMBI SCREW, HORIZONTAL INSTALLATION A /2014

44 Hooks quantity 4pcs Hooks quantity 6pcs Hooks quantity 8pcs Hooks quantity 10pcs Hooks quantity 12pcs Hooks quantity 14pcs Panel s layout FIXING SCREWS QUANTITY RAFTERS SPACING 800 mm PANELS QUANTITY SCREWS QUANTITY A /2014

45 FIXING SCREWS QUANTITY RAFTERS SPACING 900 mm Screws quantity 4pcs PANELS QUANTITY Screws quantity 8pcs SCREWS QUANTITY Screws quantity 12pcs Screws quantity 16pcs Screws quantity 20pcs Screws quantity 22pcs FIXING SCREWS QUANTITY RAFTERS SPACING 1000 mm Screws quantity 4pcs PANELS QUANTITY Screws quantity 8pcs SCREWS QUANTITY Screws quantity 10pcs Screws quantity 14pcs Screws quantity 18pcs Screws quantity 20pcs A /2014

46 Mounting preparation Discover the location of rafters beneath the roof tiles. Pull or take roof tiles out placed above the rafters. RAFTERS SPACING 680 to 845 mm A /2014

47 Drill a holes with ø25mm core drill through the tiles with a high quality masonry bit. Do not apply too much pressure to the drill as this may cause the tile to break, do not penetrate beyond the tile. After the holes have been drilled in the tiles use an 8mm wood bit to drill through the rafters. NOTE: The angle from the rafter to the drill must be 90! Screw the combi screw into the predrilled holes in the rafters. In order to avoid potential leaks, the boreholes can be filled with roof sealant before the combi screw gets screwed in possition. A /2014

48 Mount the angle bracket S3843 to the combi screw. The angle bracket is needed for fixing of supporting section. Fix the angle bracket to the combi screw. See picture below. Mount the supporting section to the combi screw as shown below. Push the carriage bolts M8x20mm into the section. This can be done from the side or through cut groove in the section. Subsequently put the supporting section with bolts on the angle bracket and tighten through flange nuts. For mounting of supporing section and PV panels follow the instructions on page 31! A /2014

49 SUPPORTING FRAME FOR PV PANELS MOUNTING ON FACADE, HORIZONTAL INSTALLATION When mounting on facade, follow the instructions for mounting A-frame on the flat roof (page 4). Mounting of supporting frame with 30 angle Mounting of A-frame on the facade The same A-frame is used as when mounting on flat roof. Fixing points can be seen on the post. Choose fixing points in a distance of 100 mm from the edge of the post. Holes need to be drilled manually using drill and bit with proper diameter. Use proper type of fixing elements according to material of the facade. If threaded bars are used, we recommend to use threaded bar with diameter ø12mm. Fixing points Life danger caused by falling panel as a result of improper use! A /2014

50 Mounting of supporting frame with 60 angle (supporting frame on flat roof rotated by 90 ) If the supporting frame is not stable enough, we recommend to use additional bracing struts. See picture below. A /2014

51 Mounting on facade (parallel with facade) For mounting on facade follow the instructions for combi screws (see page 43). According to the material of facade, combi screws can be changed for different fixing elements. The result can be straight mounting on the wall (facade). Life danger caused by falling panel as a result of improper use! A /2014

52 Technical alternation reserved A /2014

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