ASSEMBLY INSTRUCTIONS

Transcription

1 00MK-MA0140-EN00 ASSEMBLY INSTRUCTIONS Universal system with fixing screws, for sloped roof Rev.02 February 2014

2 Table of contents General instructions 2 General safety instructions 3 Universal system with fixing screws, for sloped roof 4 Regulations 5 Components required 6 Tools required 8 Assembly instructions 9 Notes 12 Table of contents 1

3 General instructions Ensure you observe the general fitting and maintenance prescriptions. If you need any clarifications, please call immediately our customer service at number The Around You fitting system is constantly evolving and may therefore be subject to changes; before starting, check the version of the assembly instructions in your possession and, if it is not up to date, send a request for an updated version to info@thesan.com. All personnel on work site must have a copy of the assembly instructions. The 12-year warranty is assured by our warranty certificate subject to compliance with assembly instructions, general instructions and general safety prescriptions provided by Thesan S.p.A. In case of non-compliance with the assembly instructions, or are not used the parts listed, the warranty is void and Thesan declines all liability. To disassemble the system, perform the assembly steps in reverse sequence. Follow the instructions of the manufacturer of PV modules and the manufacturer of inverters. Is necessary to provide routine maintenance on all parts of the plant, on a regular basis (maximum each 6 months). Visual inspections: Atmospheric events Dirt, musk and other deposits Corrosion of metal parts Stability of the structure Sealing of the roof cover Mechanical inspections: Check the tightness of nuts and, if necessary, retighten the nuts to the torque given in the assembly instructions The areas under the modules are more prone to becoming dirty, so remove all the deposits during the routine maintenance. General instructions 2

4 General safety instructions Ensure you observe the general safety fitting and maintenance prescriptions. If you need any clarifications, please call immediately our customer service at number Fitting and commissioning of the systems must be carried out exclusively by skilled personnel who, thanks to their specific training or professional experience, are able to ensure that the work is performed correctly and to high standards. The existing structures on which the system is to be fitted must be checked to ensure that the loading capacity of the building/structures is adequate. Observe all regulations and local and national building regulations, and provisions relating to the environment. Observe all regulations and national laws and local regulations regarding health and safety, accident prevention and the requirements of professional associations. In particular, it is necessary : Wear personal protective equipment: safety helmet, safety gloves, safety shoes, etc. If the system is to be fitted on an elevated surface comply with safety regulations for work at heights by using safety harnesses, falling objects signs, etc. At least two people must be on the work site during the fitting procedures, so that one person can provide first aid or call emergency services in case of accident Efficient earthing system is essential. If necessary, use the lightening protection devices. If you need to cut the mounting rails to the installation location, you must make sure to remove the burrs on the surfaces affected by the cut in order to eliminate any possible risk of injury. Also you need to make sure that the cutted rails are not curvy. The electrical installation must be carried out exclusively by skilled personnel who, thanks to their specific training or professional experience, are able to ensure that the work is performed correctly and to high standards. The wiring of the photovoltaic modules must be made to avoid the possible creation of loops. General safety instructions 3

5 Universal system with fixing screws, for sloped roof FEATURES OF THE SYSTEM Thanks to the significant reduction in the number of components, the Around You system allows a reduction of approximately 57% in the amount of time required to fit the photovoltaic panels, compared to similar mounting systems of key competitors. Robustness, practicality, and reliability over time are key characteristics of the system. Suitable for photovoltaic modules with and without frame. Around You is leader in guaranteeing, on request, a reliable and efficient after-sales service, which is at customers disposal for any requirements. The Universal system with fixing screws, for sloped roof is a not pre-assembled mounting system for photovoltaic modules. There are different types of screws with double thread, depending on how the roof substructure is made, for example with concrete, with steel beams, or wooden beams. The difference between them is the screw thread. The waterproofing of the roof coverage is ensured by special seals. In order to ensure safe and proper fitting of the system, each step described in these instructions must be carefully and accurately followed. At each step, necessary materials and equipment are listed. For any inconvenience or misunderstandings please call immediately our customer service at number Universal system with fixing screws, for sloped roof 4

6 Regulations The installation of the system have to be performed in accordance to the following regulations, or similar standards which are being used in the region of installation. The quality level of the standards need to be equal or higher as the standards which are mentioned. BGV A1 BGV A3 BGV C22 DIN EN DIN VDE 0185 DIN VDE 0100 part 410 DIN VDE 0100 part 712 DIN VDE 0105 DIN VDE 0298 DIN DIN DIN 4102 DIN DIN VDS 2023 Eurocode 1 Eurocode 1 Eurocode 3 Eurocode 9 Accident prevention regulations General rules Power system and equipment Construction work Lighting protection Lighting protection Components Grounding Electrical installations of buildings Operation of electrical installation Application of cables and cords in power installations Roofing work Scaffolding work Fire behavior of building materials and building components Electrical installations in residential buildings Waterproofing of roofs Electrical installations in structural works with mainly flammable materials Wind loads Snow loads Design of steel structures Design of aluminum structures Regulations 5

7 Components Required RAILS Universal Aluminium. Alternatives available: SO-AYP01L (3,1 m) SO-AYP01L (4,1 m) SO-AYP01L6A (6,2 m) Screw with double thread. Depending on the type of roof, refer to general catalogue. FASTENERS Allen head screw, M8, stainless steel. (DIN993) Alternatives available: (M8x25mm) (M8x30mm) (M8x35mm) Nut with safety fit, M8, stainless steel. (DIN6923) CLAMP SETS Aluminium clamp sets for glass-glass modules. Aluminium clamp sets for modules with standard frame. Depending on the type of module, refer to general catalogue. Depending on the type of module, refer to general catalogue. Components Required 6

8 Aluminium clamps for modules with standard frame. Depending on the type of module, refer to general catalogue. CLAMPS Nut with safety fit, M8, stainless steel. (DIN6923) Alternatives available: SOST-V209-00TH (M8X30mm) SOST-V206-00TH (M8X36mm) SOST-V210-00TH (M8X42mm) Protective Neoprene tape Width 120 mm, thickness 5 mm, roll 20 m OPTIONAL Other accessories available on request. Consult the general catalogue. For the possible use of alternative components contact Thesan S.p.a. technical department at info@thesan.com Components required 7

9 Tools Required Wireless screwdriver. Torque wrench. Mark line cord. Metric tape measure. Tools Required 8

10 Assembly instructions Step 1 Preliminary checks a. Check the design measurements on the roof on which the system is to be fitted. b. The system is designed for assembly of all types of modules, with or without frame. c. Provide a minimum distance of the rails from the edge of the roof of 500 mm. Step 2 Pre-drilling the metal sheet/fiber cement sheet and the steel supporting structure a. Check that the supporting structure is intact and adequate before making the holes. b. Check the position of the supporting structure joists and mark the position for the pre-drilled holes on the roof sheet. c. Pre-drill the hole both in the roof sheet and in the supporting structure. The two hole diameters are identical, refer to the table below. d. T he support points of the mounting rail on the fixing screw plate must be at the same height to ensure the mounting rails are aligned. e. The number of fixing screws and the relative application distance will be determined by Thesan Technical Dept. (or Thesan configuration software) depending on the specific project to be carried out. In case of different assembly solutions the warranty is void. Step 3 Pre-drilling the metal sheet/fiber cement sheet and the wood supporting structure a. Check that the supporting structure is intact and adequate before making the holes. b. Check the position of the supporting structure joists and mark the position for the pre-drilled holes on the roof sheet. c. Pre-drill the hole both in the roof sheet and in the supporting structure. The hole diameter in the metal sheet/ fiber cement must always be larger than the diameter of the fixing screw. Consult the table below. d. The support points of the mounting rail on the fixing screw plate must be at the same height to ensure the mounting rails are aligned. e. The number of fixing screws and the related application distance will be determined by Thesan Technical Dept. (or Thesan configuration software) depending on the specific project to be carried out. In case of different assembly solutions the warranty is void. Assembly instructions 9

11 Table of reference hole diameters Pre-drilling Diameter in mm, corrugated sheet metal and supporting structure Supporting Structure thickness in mm Supporting Material Steel Timber Material thickness in mm 1,5...< 5,0 5,0...< 7,5 7,5...< Pre-drilling Diameter in mm for corrugated sheet metal + supporting structure Solar panel fixing screw for steel Ø 8 mm Solar panel fixing screw for Timber Ø 8 mm 6,8 mm 7 mm 7,2 mm 7,4 mm 5,5 mm 5,5 mm Pre-drilling Diameter in mm for fibre cement sheets Solar panel fixing screw for Timber Ø 8 mm In corrugated sheet 11 mm 11 mm In timber supporting structure 5,5 mm 5,5 mm Step 4 Positioning the Universal mounting rail Upper side Lower side a. Fasten the Universal mounting rail to the plate of the fixing screws using allen head screw M8 and nut with safety fit. The allen head screw must be inserted into the bottom of the Universal rail. b. Tighten the nut with safety fit with a tightening torque of 35 Nm. c. If necessary, use the external joint connectors to join two or more profiles in line. When using the external joint connectors, observe precautions to avoid thermal expansion. To avoid any problem of thermal expansion it is recommended not to exceed the overall lenght of 24,8 m, or 4 profiles size 6,2 m aligned with each other. Beyond such length leave a minimum distance of 4 cm from the next profile. d. Insert plastic protective plugs in the ends of the Universal mounting rails. Assembly instructions 10

12 Step 5 Positioning and fixing the photovoltaic modules c. Position the photovoltaic module and fully tighten the nut with safety fit to a torque of 14Nm. d. Ensure the correct position of the clamp compared to the frame of PV module. The vertical walls of the clamp must adhere perfectly to the frame of the module : End clamp for PV module with frame Module Rail Pre-assembled end clamp for PV module with frame Module Rail Note : Follow the instructions of the manufacturer of the PV modules. a. If pre-assembled clamp sets are used, insert the hammer head screw into the specific opening in the upper side of the mounting rail, press the clamp gently to turn the screw of 90 clockwise. Make sure that hammer head screw is in an orthogonal position respect to the rail, and that the spring of the clamp makes completely adhere the hammer head screw to the rail. If the clamps you are using are not preassembled, insert the hammer head screw in the specific opening in the upper side of the mounting rail, turn the screw of 90 clockwise, position the clamp and partially tighten the nut with safety fit. Upper side Lower side b. If the PV module is mounted landscape, the long side of the clamp must be in longitudinal position respect the mounting rail, if instead the PV module is mounted portrait, the long side of the clamp must be in orthogonal position respect the mounting rail. e. The cable lock and the cable lock with rings should be used to clipping the PV module wires, and they may be clipped everywhere on the bottom side of the Universal rail. The PV module wires must be placed in the zones illustrated below. The cables of the PV modules can be placed in the following zones, using the clip for cables. Please note that the electrical installation must be carried out exclusively by skilled personnel who, thanks to their specific training or professional experience, are able to ensure that the work is performed correctly and to high standards. Upper side Bottom side Positioning area for PV module wires Cable lock Cable lock with rings Step 6 Earthing system a. E essenziale prevedere un efficiente sistema di messa a terra b. Fissare con una vite il cavo elettrico di messa a terra in un punto qualsiasi del profilo in alluminio. Assembly instructions 11

13 Notes Notes 12

14 SOLUZIONI CHE INNOVANO. ENERGIE CHE SI RINNOVANO. INNOVATING SOLUTIONS. RENEWING ENERGY. Thesan S.p.A. - Via Torino Chiusa di San Michele (TO) Italy - tel info@thesan.com 13