INSTALLATION INSTRUCTIONS TRI-ROOF. energy for a better world
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1 energy for a better world INSTALLATION INSTRUCTIONS TRI-ROOF The flexible roof integration system Compatible for framed module types* Simple exchange of modules Replaces existing roofing Special profiles for maximum impermeability Closed module surface for aesthetically attractive PV systems Certificated for wind and snow loads Tested for statics *from the TRITEC range
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3 Table of Contents The Basics System 4 Notes 4 Load effect 4 Statics 5 Roof condition 5 TRI-DESIGN Dimensioning Software 5 Installation: Introduction Tools 6 Installation procedure 6 Installation Measuring the module field 7 Laying of the Perform 7 Installation of the vertical UP-I profiles 8 Fixation of the bottom edge plates to the first row of SafeClicks 9 Insertion of the horizontal retainers TR-H and TS profiles 10 Installation of the slats for the top connection plates 11 Installation of the lateral end plates and roof ridge plates 11 Laying of cables and insertion of modules 14 Annex: Use of the TS bending tool 16
4 4_The Basics THE BASICS System The TRI-ROOF Mounting System is a flexible roof integration system, allowing almost any photovoltaic system to be integrated into existing roofs or roofs to be constructed simply, safely and aesthetically attractively. The system is compatible with all framed module types from the TRITEC range. The installed system replaces the existing roofing. The later replacement of system modules poses no problem. The special profiles of the system enable maximum impermeability, and the closed module surface meets even the greatest demands for aesthetically attractive PV systems. Störfix Notes For the installation of the TRI-ROOF system only products from the range of the TRI-ROOF mounting system must be used. Using third-party components can affect the system s stability and result in significant damage. The system must only be installed by trained and competent personnel. We do not accept liability for damages caused by the use of third-party components or incorrect installation. In order to prevent damages due to condensation water drain, ice from forming,and storm rains a sub-roof provided on site is required for every TRI-ROOF system. These installation instructions describe the correct installation of the TRI-ROOF roof integration system. However, in some situations we recommend to consult an expert on special roof features (e.g. a roofer or carpenter). Required screw torques: SafeClick 20 Nm M10 threaded joints truss head, hammer head and hexagonal screws: 30 Nm M8 threaded joints: 20 Nm Load effect In addition to their own weight, the system components and sub-structures experience mainly wind forces and snow loads. Therefore, each system must be calculated and designed considering its requirements and external influences as well as DIN 1055* (Effects on supporting structures). The exposure to wind loads is mainly dependent on the wind zone (according to DIN *), the building s height, the shape and inclination of the roof and the system s position. Weight loads caused by snow depend on the snow zone (according to DIN *), the shape and inclination of the roof and the system s position. The wind and snow load zones, on which the system s design is based, can be determined for any location. * European standard: EN
5 The Basics_5 Statics In all cases, the statics of the roof must be checked by authorised experts. In particular, it must be examined whether the roof can bear the additional load created by the solar system. Since the load acceptance and the load effect of photovoltaic systems are affected by many factors, the statics must be calculated for every individual roof. Roof condition The current condition of the roof must be such that renovation will not be necessary for at least 20 years. When in doubt, we recommend to have the roof checked by an expert. To achieve the optimal draining of rain water, a minimum roof inclination of 10 degrees is required. When using the edge plates for tiles, the minimum required roof inclination is 15. The TRI-ROOF mounting system is optimised for plane surfaces. If a roof is uneven due to age or other reasons, we recommend to consult an expert. Make sure that aeration and ventilation of the roof exists or will be built in. TRI-DESIGN Dimensioning Software The TRI-DESIGN dimensioning software calculates and designs the TRI-ROOF mounting system according to the standards of DIN 1055 *. The relevant directives are DIN * for wind loads and DIN * for snow and ice loads, which affect the photovoltaic system and its substructure. The software calculates all sizes and distances relevant for the installation. In addition, the dimensioning software allows us to design the system optimally for the individual roof and thus to select the best version of the mounting system. Under the warranty terms and conditions, all TRI-ROOF systems must have been dimensioned using the TRI-DESIGN dimensioning software.
6 6_Installation: Introduction INSTALLATION: INTRODUCTION Tools Cordless screwdriver Drill 3.3 mm Rivet gun Open-ended spanner 15 mm Open-ended spanner 17 mm (for installation on steel beams) TS edging tool (see annex) Allen key 3 mm Allen key 5 mm Metal shears Installation procedure The roof integration system TRI-ROOF is installed in eight steps: 1. Measuring of the module field 2. Laying of the Perform 3. Installation of the SafeClicks and vertical UP-I profiles 4. Fixation of the bottom edge plates to the first row of SafeClicks 5. Insertion of the horizontal retainers TR-H and TS profiles 6. Installation of the slats for the top connection plates 7. Installation of the lateral end plates and roof ridge plates 8. Laying of cables and insertion of modules
7 Installation_7 INSTALLATION Measuring the module field The size of the module field is determined by the number of modules to be installed. The exact size of the field can be gathered from the TRI-DESIGN dimensioning. After measuring the module field on the roof, the existing roofing if any is removed. Laying of the Perform The perform is laid over the roofing adjacent to the bottom of the module field. The material must overlap the roofing by a minimum of 10 cm. The perform is glued to the roofing using Perform adhesive. To install the Perform between module field and tiles, a supporting board must be installed from the bottom edge of the module field and the connecting edge of the tiles. In some cases it is recommended to install a tiling batten at the top edge of the perform, in order to affix it easily and cleanly. To achieve the optimum impermeability of the bottom edge of the system, the Perform must extend to at least 100 mm beneath the system. The roofing adjacent to the system must also be covered for at least 100 mm.
8 8_Installation Installation of the vertical UP-I profiles In the case of systems of low depth without UP-I joints, the SafeClicks can be pre-installed on the ground or in the workshop. The installation of the Safe- Clicks is described in the section Fixation of the bottom edge plates to the first row of SafeClicks. Based on the dimensioning of the system, the UP-I profiles are installed at the calculated places. Using a plumb line, the profiles are oriented in such a way that they are at the same height horizontally and at a right angle to the bottom edge vertically. It is recommended to check the correct right angle by measuring the diagonal. To ensure greater precision, we recommend to use a gauge to adjust the horizontal distance between two profiles exactly. The following rules of thumb allow the determination of distances between profiles: End field clearance: Module laying width (in mm) 254 mm Central field clearance: Module laying width (in mm) 168 mm If due to the depth of the module field, several UP-I profiles must be mounted on top of each other, they will be pushed into each other and glued together with TRI-ROOF special adhesive for ridge plates and form-fittingly connected in the centre by means of flat connectors, sliding nuts M10 and hexagonal screws M10 x 25 A2. If a SafeClick is located on the rail joint, the flat connector can also be connected to the lateral or lower groove of the UP-I profile by means of hammer head bolts and self-locking nuts with serrated bearing surface. Depending on the roof, there are different methods of fixation. For example, the fixation depends on the roof s sub-structure and the number of fixation points is dependent on the static conditions. The following methods of fixation are used for the respective roof constructions. The respective installation of the fixation aids is described below. Tiling battens: Steel roof beams: Universal profile retainer TR-U and button-head screw 5.0 x 30 A2 Z adapter TR-Z Wood roof beams: Universal profile retainer TR-U and flat-head screw 8.0 x 80
9 Installation_9 Fixation using universal profile retainer TR-U and button-head screw 5.0 x 30 A2 The universal profile retainers are fixed to the battens using the button-head screws 5.0 x 30 A2, according to the static data on number and distance. In addition, a hammer-head screw M10 x 20 A2 with self-locking nut with serrated bearing M10 A4 is installed above the universal profile retainers, in order to prevent sliding of the UP-I profiles. Fixation using Z adapter TR-Z The Z adapters are inserted into the rear side of the UP-I profiles using hammer-head screws M10 x 20 A2 and self-locking nut with serrated bearing M10 A4, and pushed to the T profiles as far as they will go and tightened. Then the hexagon-head screw M10 x 25 A2 is screwed into the thread of the Z adapter, in order to make the connection fully restraint and pressure-resistant. In the case of deep module fields (>12 m), only the hexagon-head screws close to the roof ridge are firmly tightened. The bottom screws should only be tightened finger-tight to allow the heat expansion of the UP-I profiles. Fixation using universal profile retainer TR-U and flat-head screw 8.0 x 80 The universal profile retainers are fixed to the wood roof beams using flathead screws 8.0 x 80, according to the static data on number and distance of fixation points. In addition, a hammer-head screw M10 x 20 A2 with self-locking nut with serrated bearing M10 A4 is installed above the universal profile retainers, in order to prevent sliding of the UP-I profiles. Fixation of the bottom edge plates to the first row of SafeClicks The edge plates are installed at the bottom of and flush with the UP-I profiles. They are fixed to the UP-I profiles using the SafeClicks. To achieve a continuous bottom edge of the module field, the plates must overlap and be riveted. It is important that the edge plates overlap by a minimum of 10 cm each. To install the SafeClicks, it is also recommended to use a gauge. Starting with the lower SafeClicks, the SafeClicks are installed at the specified distance (module insertion length minus 57.5 mm). They are inserted into the profile from the top and fixed in the relevant place using an Allen key. SafeClicks can also be installed before the installation on the ground or in the workshop.
10 10_Installation Insertion of the horizontal retainers TR-H and TS profiles The water-bearing TR-H carrier profiles are directly installed on the UP-I profiles using the TR-C Clips. The profiles are clamped above the already installed SafeClicks using the clips. Since two TR-H profiles are always fixed with a TR-C clip in the module field, it is recommended to click in the clip into the profile only after the second profile has been inserted. To ensure the best possible drain-off of rain water under the hoizontal module joints, the horizontal TR-H carrier profiles must be installed so that they converge at an angle. The angle is achieved by attaching the TR-C clips alternatively at the top stop angle or the second bar of the T-H carrier profiles. Determination of the RH groove length in end fields: Module insertion width minus 155 mm Special case of only one vertical module line: Module insertion width minus 241 mm Determination of the TRH groove length in centre fields: Module insertion width minus 69 mm When all TR-H profiles have been installed, the TS profiles are clicked into the SafeClicks. For a firm connection between the SafeClicks and TS profiles it is sufficient to insert the profile into the grooves of the SafeClicks and press it down until it clicks into place. To ensure the safe installation of the modules on the roof, the correct orientation of the TS profiles is essential. The profiles must be clicked into place in such a way that the longer flange of the module retainer points towards the bottom edge of the roof, and the shorter towards the roof ridge. Depending on the width of the module field, it might be necessary to extend the TS profiles. To link two TS profiles, the insertion profile connector must be installed between the two profiles. With the setscrew oriented towards the bottom, the TS-C connector is pushed into an installed TS profile until it is flush with the TS profile. Subsequently, the next TS profile is installed with a 3 mm space to the one before; the TS-C connector is pushed into the new TS profile up to its centre marking and then unilaterally connected with a setscrew. With this type of connection, the TS profiles are able to expand or contract relatively stress-free in hot or cold conditions. The modular loads will be transmitted nonetheless.
11 Installation_11 Installation of the slats for the top connection plates Blanking plates can only be used with standard tiles. In some cases slats must be installed before the roof ridge plates can be mounted. The bottom edge of the roof ridge plates must later be inserted into the TS profile and fixed at the top end using the aluminium brackets. If the fixation by means of aluminium brackets at the top end of the ridge plate is impossible, slats must be installed on the roof to enable the fixation. Installation of the lateral end plates and roof ridge plates The lateral plates are laid flush with the TS profiles and fixed to the roof using the aluminium brackets. The length of the lateral plates is adjusted to the height of the module field by letting the plates overlap. They should overlap by at least 15 cm. The plates are telescoped until the desired length is reached. To achieve optimum drainoff of the water, it is important that the top plate is put on top of the adjoining lower plate, when the plates are positioned on top of each other. The lateral plates are flush with the bottom edge of the bottom outer plates at the bottom end of the module field. The top end of the lateral plates is flush with the top end of the ridge plates. Begin the installation of the ridge plates in one of the two corners of the module field with FL (ridge plate left) or FR (ridge plate right). The bottom end of the ridge plate is inserted into the topmost TS profile. Ridge sheets must be laid such that the sheets are provided with a lateral space of 5 mm.
12 12_Installation After the ridge plates have been laid, they are fastened with aluminium grips on the roof. This is done either on one of the existing roof battens or on the mounting battens installed beforehand. The ridge plates are fastened on the TS profile by means of self-tapping screws 6.3 x 25 A2 DS, at a distance of 50 cm. Four pieces per FM, two pieces per FR and / or FL ridge plate. Important: In the area of the TS insertion profile butt joint, the overlapping area of the ridge sheet must not be screwed together with the following TS profile. Installation of the ridge plates is completed by fastening the joint cover plates on the butt joints formed between the individual plates. To give the system impermeability, the joint cover plates receive two lines of adhesive (TRI-ROOF special adhesive for ridge plates) at their lateral edges and are then bonded together firmly.
13 Installation_13 The butt plates may only be riveted on one side with the ridge plates so that heat expansion is possible in the ridge area. For the riveting of the lateral end plates (AS) they are pushed to the sides of the TS profiles. It is important that the AS angles are inserted under the TR-C clips from bottom to top. Here an overlap of 5 cm is sufficient. Then the AS angles and lateral plates are drilled every 50 cm and riveted together. Finally the connection between ridge plate and lateral plate is sealed using the weather-proof adhesive tape FLEX-DICHT 3D. When all ridge and lateral plates are mounted, they are fixed in place by riveting.
14 14_Installation After installation of the ridge and lateral plates, they are covered with collar sealing strips. These collar sealing strips prevent moisture from penetrating the roof via the lateral and ridge plates in case of heavy rain or snow. By means of the TS edging tool, the TS-profiles must now each be edgetrimmed to the left and right of a SafeClick located in the middle of the rail. This measure will limit subsequent creeping of the rails due to heat and cold. Laying of cables and insertion of modules All cables must be run under the profiles and not over the UP-I profiles and TR-H carrier profiles. In addition, the strain relief and good attachment of all cables are significant. To connect the cables to the UP-I profiles, a cross cable clip block is used. This is attached to the side of the profile and fixes the cables by means of a cable tie. When the string cables have been laid, the modules can be inserted and connected. For the easy cabling of modules they are put on the top TS profile and then connected.
15 Installation_15 Installation of the TRI-ROOF spacers (TR-D): The dimensioning specifies the installation of the spacers. Spacers are easy to mount if there is already a module to the left or right of the specified place. It can then be inserted with a 90 turn into the centre duct of the UP-I rail, and the next modules can be inserted and wired up to the next following TR-D. The final insertion of the modules is carried out in three steps: Insertion of the module into the top TS profile Depositing the module on the bottom TS profile Insertion of the module into the bottom profile The modules are held by the force of gravity in the TS profiles and are securely fixed in place without screws or rivets. A 2 mm space must be kept between the modules so that they can expand tension-free. If necessary, filler pieces are installed after laying of the modules and the TR-D spacers. The filler pieces are inserted in the still open places exactly like the modules; after that, the filler piece is riveted with two TRI-ROOF rivets to the lateral angle AS.
16 16_Annex Annex: Use of the TS bending tool The TS profiles must each be edge-bent per profile left and right of a SafeClick located in the centre of the TS rail. This measure will limit the movement of profiles as a result of temperature changes. 1. Fix TS profile in place Push bending tool into the lower leg of the TS profile. Turn the bending tool by 8 10 cm toward the bottom. Pull out the bending tool again and repeat the same steps on the left side of the SafeClick.
17 Annex_17 2. Subsequently loosen SafeClick Push bending tool from the top over the flat spring of the SafeClick. Turn the bending tool toward the bottom all the way to the stop. Push TS profile toward the top and remove.
18 The General Terms and Conditions and Guarantee Conditions of TRITEC apply. Made in Switzerland Version 3.1 Subject to technical changes. Artikel-Nr
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