HORIZONTAL INSTALLATION

THERMO/SOLAR Žiar s.r.o. MANUAL FOR INSTALLATION PV SUPPORTING FRAMES HORIZONTAL INSTALLATION Technical alternation reserved A1410 1 12/2014

CONTENT ORD.NO. PAGE Mounting information 3 Mounting, flat roof A-frame S7348 4-18 Connecting of supporting sections 9 Mounting of safety angle brackets 12 Mounting of side and centre fixtures 14-16 Mounting of additional bracing strut 17-18 Mounting, sloping roof - basic roof hook S3014 19-31 Mounting, sloping roof - stainless steel roof hook S3758 32-35 Mounting, sloping roof - aluminium straight roof hook S3895 36-40 Mounting, sloping roof - stainless steel holder S3011 41-42 Mounting, sloping roof - combi screw S3244 43-48 Mounting on facade 49-51 A1410 2 12/2014

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 1991-1-1 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 10 13 6 18 Bits for screwdriver Torx Allen key Phillips Ø5 Ø8 Ø8,5 A1410 3 12/2014

SUPPORTING FRAME FOR PV PANELS - FLAT ROOF A-FRAME, HORIZONTAL INSTALLATION Dimensional sketch A1410 4 12/2014

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 1 2 3 4 5 6 7 8 A-FRAME QUANTITY 2 3 4 5 6 7 8 9 A1410 5 12/2014

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 A1410 6 12/2014

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. A1410 7 12/2014

A1410 8 12/2014

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 A1410 9 12/2014

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. A1410 10 12/2014

Illustration of mounted supporting frame for 2 pcs of PV panels. Condition: A=B! A B A1410 11 12/2014

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. A1410 12 12/2014

Mounting of PV panel to the supporting frame Mount the PV panel to the supporting frame as shown below. A1410 13 12/2014

Mounting of side fixtures Mount the side fixtures as shown in the picture. Use M8x30 carriage bolt and M8 nut with inner Allen. 83 A1410 14 12/2014

Mounting of centre fixtures Mount the centre fixtures as shown in the picture. Use M8x30 carriage bolt and M8 nut with inner Allen. A1410 15 12/2014

Picture of required fixing points for 4 pcs of PV panels A - Joint between panels B - Joint on the side of panel A B A1410 16 12/2014

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. A1410 17 12/2014

Drill 8,5mm holes on the lower part of the post and attach the bracing strut to the posts. A1410 18 12/2014

SUPPORTING FRAME FOR PV PANELS - SLOPING ROOF BASIC ROOF HOOK, HORIZONTAL INSTALLATION Dimensional sketch A1410 19 12/2014

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 1 2 3 4 5 6 7 8 HOOKS QUANTITY 4 6 8 10 12 14 16 18 A1410 20 12/2014

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. A1410 23 12/2014

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 A1410 24 12/2014

Remove the lock from relevant roof tile in the area where to hook is going to be set. A1410 25 12/2014

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 A1410 26 12/2014

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. A1410 27 12/2014

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. A1410 28 12/2014

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. A1410 29 12/2014

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. A1410 30 12/2014

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 12-18. A1410 31 12/2014

SUPPORTING FRAME FOR PV PANELS - SLOPING ROOF STAINLESS STEEL HOOK, HORIZONTAL INSTALLATION Dimensional sketch A1410 32 12/2014

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 1 2 3 4 5 6 7 8 HOOKS QUANTITY 4 6 8 10 12 14 16 18 A1410 33 12/2014

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! A1410 34 12/2014

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 12-18. Spacing according to scheme on page 33 ca.1450 680 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! A1410 35 12/2014

SUPPORTING FRAME FOR PV PANELS - SLOPING ROOF ALUMINIUM STRAIGHT ROOF HOOK, HORIZONTAL INSTALLATION Dimensional sketch A1410 36 12/2014

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 20-22. 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 A1410 37 12/2014

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. A1410 38 12/2014

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. A1410 39 12/2014

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! A1410 40 12/2014

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 1 2 3 4 5 6 7 8 HOLDERS QUANTITY 4 6 8 10 12 14 16 18 A1410 41 12/2014

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! A1410 42 12/2014

SUPPORTING FRAME FOR PV PANELS - SLOPING ROOF COMBI SCREW, HORIZONTAL INSTALLATION A1410 43 12/2014

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 1 2 3 4 5 6 7 8 SCREWS QUANTITY 4 6 8 10 12 14 16 18 A1410 44 12/2014

FIXING SCREWS QUANTITY RAFTERS SPACING 900 mm Screws quantity 4pcs PANELS QUANTITY 1 2 3 4 5 6 7 8 Screws quantity 8pcs SCREWS QUANTITY 4 8 12 16 20 22 26 30 Screws quantity 12pcs Screws quantity 16pcs Screws quantity 20pcs Screws quantity 22pcs FIXING SCREWS QUANTITY RAFTERS SPACING 1000 mm Screws quantity 4pcs PANELS QUANTITY 1 2 3 4 5 6 7 8 Screws quantity 8pcs SCREWS QUANTITY 4 8 10 14 18 20 24 28 Screws quantity 10pcs Screws quantity 14pcs Screws quantity 18pcs Screws quantity 20pcs A1410 45 12/2014

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 A1410 46 12/2014

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. A1410 47 12/2014

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! A1410 48 12/2014

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! A1410 49 12/2014

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. A1410 50 12/2014

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! A1410 51 12/2014

Technical alternation reserved A1410 52 12/2014