Sigma II Installation manual

Transcription

1 Sigma II Installation manual

2 Table of Contents 1 Some preliminary remarks Validity of the installation instructions Standards and technical directives Definitions User group Meaning of the warnings and safety instructions Guidance notes 2 2 Safety Intended use Obligations of the principal Specific safety instructions 4 3 Check the scope of delivery 6 4 Description of the system parts Basic system view Foundation elements Clamping plates Legs Diagonals Rafter Module support clamps Module support Splice Module clamps Spacer (landscape installation) Lateral position locking device Bracings (optional) 13 5 Overview drawing and bill of materials 14 6 Basic installation requirements Safety instructions Required tools Tightening torques pplication conditions Foundation tolerances and height adjustment Foundation tolerances - average deviation Foundation tolerances - maximum deviation Tolerances for level territory with east-west slope Height adjustment 16 7 Portrait installation Safety instructions Foundation Positioning the ramming posts Positioning the screw foundations ttaching the foot plates Fixation of the legs ttachment to the ramming post and/or screw foundation ttachment to the foot plate Fixation of the rafters and diagonals Foundation variant ramming posts and/or screw foundation Foundation variant foot plate Fixation of the module supports Fixation of the modules ttachment of the bracings (optional) 24 8 Landscape installation Safety instructions Foundation Positioning the ramming posts Positioning the screw foundations ttaching the foot plates Fixation of the legs ttachment to the ramming post and/or screw foundation ttachment to the foot plate Fixation of the rafters and diagonals Foundation variant ramming posts and/or screw foundation Foundation variant foot plate Fixation of the module supports Fixation of the modules ttachment lateral position locking device ttachment of the bracings (optional) 33 9 Storage and transportation Safety instructions pproach Maintenance Safety instructions Maintenance steps Maintenance interval Maintenance work Disassembly Safety instructions Disassembly steps Disposal 37 Copyright Forwarding, as well as reproduction of this document, use and disclosure of the contents of these installation manual shall be prohibited, unless permitted by Mounting Systems. Contraven-tions shall be subject to compensation Mounting Systems GmbH Sigma II Open terrain system 2 Sigma II-M-ENG-1202

3 1. Some preliminary remarks 1.3 Definitions These installation manual describes the processes of mechanical installation, maintenance, and disassembly of photovoltaic systems with the Sigma II system. Please read this installation manual carefully prior to any installation, maintenance, and disas-sembly work. You will be provided with all information for safe and complete installation, mainte-nance, and disassembly. However, if you have any questions after having read this installation manual, please contact the Mounting Systems GmbH. 1.1 Validity of the installation manual These installation manual are only valid in conjunction with: the project-specific overview drawing (OD) the supplied material for Sigma II according to the bill of materials (BOM) 1.2 Standards and technical directives Please take into account the following standards and technical directives during installation, maintenance, and disassembly in Germany: DIN Plumbing work DIN Concrete and reinforced concrete work DIN Metalwork Please observe the corresponding national standards and directives during installation, maintenance, and disassembly outside of Germany. The following terms are used within these installation instructions: Term Photovoltaic system Mounting system Optional Overview drawing (OD) System parts Meaning photovoltaic system consists of: mounting system PV modules Electrical wiring Inverter (optional) Metal structure for the attachment of: PV elements Electrical wiring Inverter (optional) nti-theft device (optional) Optional use of system parts or accessories Sigma II systems for large-scale systems are project-planned specifically for each application. For this, a project-specific overview drawing (OD) is always developed and supplied to the installer of the photovoltaic system together with a bill of materials (BOM). The PV mounting system consists of standard parts (rails, rafters, etc.) and assembly material (screws, Quickstone, etc.) according to the BOM for the overview drawing. 1.4 User group These installation instructions are intended for the following persons (user group): Skilled personnel Instructed personnel Skilled personnel Skilled personnel are persons who, on the basis of their professional training, are able to execute installation, maintenance, and disassembly work properly. Instructed personnel Instructed personnel are persons who have been instructed and taught appropriately regarding the assigned tasks and the possible risks in the event of improper conduct. n instructed person must have received instructions regarding the required safety devices, precautions, relevant regulations, accident prevention regulations, as well as operating conditions and must have demonstrated his/her competence. The implemented work must be accepted by skilled personnel. Some preliminary remarks 1

4 1.5 Meaning of the warnings and safety instructions The warnings and safety instructions used within these installation manual have the following meanings: DNGER INDICTES N IMMEDITELY DNGEROUS SITUTION THE NON-OBSERVNCE OF WHICH WILL RESULT IN DETH OR SEVE- RE INJURIES. 2. Safety instructions 2.1 Intended use The Sigma II system was designed exclusively for supporting PV modules. The Sigma II system shall only be applied as open terrain installation. The concept of intended use also comprises the compliance with the specifications within these installation manual. Mounting Systems GmbH shall not reliable for damages caused by the non-observance of the installation manual, particularly the safety instructions, as well as improper use of the mounting system. WRNING CUTION INDICTES POSSIBLY DNGEROUS SITUTION THE NON-OBSERVNCE OF WHICH MY RESULT IN DETH OR SEVERE INJURIES. INDICTES POSSIBLY DNGEROUS SITUTION THE NON-OBSERVNCE OF WHICH MY RESULT IN MINOR OR LIGHT INJURIES. These actions are covered by the concept of intended use, if: the Sigma II system is installed according to the installation manual or applicable technical standards the Sigma II sysem is installed by qualified personnel disposing of the know-how mentioned within the installation manual the Sigma II system is transported, installed, assembled, tested, repaired, or operated exclusively in accordance with the recognized rules of engineering TTENTION INDICTES POSSIBLY DNGEROUS SI- TUTION THE NON-OBSERVNCE OF WHICH MY RESULT IN MTERIL D- MGES. the Sigma II system is used according to the stipulated technical specifications (project-specific overview drawing, bill of materials) or the designed purpose the Sigma II system is stored in accordance with the information provided within these installation instructions prior to and after installation 1.6 Guidance notes The following guidance notes enhance the orientation when handling these installation manual: Guidance note Figures Item numbers Courses of action Meaning Graphical emphasis The figures are not to scale and are intended for overview purposes only. Within the figures, individual parts are indicated by item numbers. ll actions that must be implemented in a specified sequence are identified with letters, e. g., B, C. interventions and/or modifications to the accessories are only implemented with the explicit consent of Mounting Systems GmbH only genuine components or genuine accessories are used for installation or repair purposes the Sigma II system is inspected and maintained by qualified personnel once a year the admissible application conditions are complied with (Mounting Systems GmbH shall not assume any liability caused by these conditions being exceeded.) the Sigma II system is not exposed to unusual environmental impacts (over-voltage, magnetic fields, or similar) the Sigma II system is used in an atmosphere that within the meaning of DIN EN (applicable in Germany ; outside of Germany, the national regulations must be observed) is rural, moderately industrialized, or moderately urban the Sigma II system is not used in an outdoor 2 Some preliminary remarks Safety instructions

5 environment that can be assigned to the corrosion category class C4/C5 according to DIN EN (applicable in Germany; outside of Germany, the national regulations must be observed) the load-bearing capacity of the soil is ensured prior to installation according to the recognized rules of engineering and according to the applicable technical standards The principal of the photovoltaic system must ensure that: the installation of the Sigma II system is implemented by trained and authorized persons only; the commissioned persons are able to assess the work they were assigned with and to identify possible dangers; The mounting system must only be installed, maintained, and disassembled in accordance with the installation manual. ny other use is deemed unintended. ny unintended use results in the forfeiture of any warranty claims. 2.2 Obligations of the principal the commissioned persons are familiar with the system parts and the assembly material; the installation manual are available during installation; the installation manual and particularly the safety instructions were read and understood by the commissioned personnel prior to the installation; the durability of the installed connections and the attachment of the mounting systems are provided for; suitable lifting gear is used for installation purposes; and only genuine system parts and assembly material from Mounting Systems GmbH are used even in the case of replacements. Otherwise, any warranty claims will be forfeited. Safety instructions 3

6 2.3 Specific safety instructions Please observe the specific safety instructions mentioned before the action steps for any action you implement. Risk of injuries and material damage due to improper inspection, maintenance, or repair! WRNING Omitted or improper inspection, maintenance, or repair may impair the operational safety of the photovoltaic system! Please ensure that inspection, maintenance, and repair work is only implemented by a qualified skilled worker! WRNING Risk of burning! The module surfaces will be hot during solar irradiation! Please wear protective equipment! Crushing, stumbling against and getting caught on metal parts! CHTUNG CUTION When the assembly material is handled improperly, extremities may be crushed, get stuck, or hit! Please observe the accident prevention regulations! Please wear protective equipment! CUTION Cuts caused by sharp-edged and bulky metal parts! The transportation of sharp-edged and bulky metal parts may result in cuts to the hands! Please observe the accident prevention regulations! Please wear protective equipment! CUTION Personal damages caused due to assembly material toppling over! ssembly material may topple over and injure persons due to improper storage! Please observe the accident prevention regulations by all means! Please observe stable and slip-resistant storage! Please wear protective equipment! CUTION Personal and material damages caused by accessing the mounting system! The process of accessing the frame system may result in personal and material damages! Do not climb on the mounting system! 4 Safety instructions

7 Damages caused by improper transportation! TTENTION Improper transportation may result in damages to the Sigma II system and the PV modules and impairments of the functionality! Check the packaging for externally visible damages! In the event of severe damages to the packaging, please inform the manufacturer immediately! In the event of minor or small transportation marks, unpack the material carefully! In the event of damages to the mounting system or PV modules, please inform the manufacturer immediately! Material damages caused by improper installation! TTENTION TTENTION Improperly screwed mounting systems may be unstable and cause damages! Please only use the materials specified by the manufacturer for all screwed connections (screws, washers, and nuts). Upon installation, check all screwed connections for firm seat! Material damages caused by improper tightening torque! Screwed connections attached with a too high tightening torque might fail or break! Screwed connections tightened with a too low tightening torque might come loose! Please comply with the tightening torque specified within the installation manual! TTENTION Material damages caused by the failure of Quickstone connections! Improperly installed Quickstone connections might fail! Please install all Quickstone connections according to the installation manual! TTENTION Module rupture caused by temperature fluctuations! PV Modules mounted over expansion joints may burst in the event of temperature fluctuations! Please do not install PV modules over expansion joints! TTENTION Material damage caused by improper installation! Inserting the module holder clips by tapping them in with a hammer might impair the functionality of the mod-ule holder clips and might result in the module holder clips shearing and the modules falling down!! Please always attach the module holder clips with the mounting aid, as described within these installation manual! TTENTION Damages to the PV modules! Improper disassembly might result in damages to the PV modules! Please have the disassembly implemented by skilled personnel! Safety instructions 5

8 3. Check the scope of delivery fter having unpacked the delivery, check whether it contains all parts and the assembly mate-rial are according to the BOM/delivery note and immediately inform the supplier in the event of discrepancies. 4. Description of the system parts 4.1 Basic system view s a matter of principle, the Sigma II systems always consists of: 1. Rafter 2. Legs 3. Clamping plates 4. Foundation elements 5. Diagonals 6. Module supports 7. Splices * 8. Spacers (for landscape installation only) * 9. Module support clamps and module clamps/module end clamps or module holder clips (MHC) * 10. Lateral position locking device (for landscape installation only) * 11. ssembly material * * Not shown in the system view. The system views illustrated below show an exemplary standard Sigma II system. Within these installation manual, the system viewsshow the principal correct basic position of the individual parts. Deviations as well as the technical data can be found in the overview drawing. Portrait installation Landscape installation Fig. 1 Exemplary system view Sigma II, portrait and landscape installation of the modules Fig. 2 Exemplary lateral view (landscape installation) 6 Check the scope of delivery Description of the system parts

9 4.2 Foundation elements The following foundations are possible: Ramming post Screw foundation Foot plate Ramming post Screw foundation Foot plate Fig. 3 Foundations, variants Ramming post Connection elements Clamping plate Comment The figures for the foundations are exemplary only. You will find the project-specific designs in your OD. Screw foundation Foot plate Clamping plate Legs Fixing anchor Diagonal (rear foot plate) The figures for the foundations are exemplary only. You will find the project-specific designs in your OD. The figures for the foundations are exemplary only. You will find the project-specific designs in your OD. Please observe the dowel arrangement instructions. 4.3 Clamping plates The clamping plates are intended to attach the legs. No clamping plates are used for the foot plates, because the legs are attached directly. Clamping plate for ramming posts Clamping plate for screw foundation Fig. 4 Clamping plates, variants Clamping plate for ramming posts Clamping plate for screw foundation Connection elements Legs ramming posts Legs screw foundation Comment The figures for the clamping plates are exemplary only. You will find the project-specific designs in your OD. Description of the system parts 7

10 4.4 Legs The rafters are positioned on the legs. The front and the rear legs are connected with diagonals for stabilization purposes. Fig. 5 Leg Leg Connection elements Clamping plate or foot plate Diagonal Rafter Bracing (rear legs, optional) Comment Pre-drilled by default If required, height-adjustable legs without pre-drilled holes can also be supplied alternatively (see projectspecific OD). 4.5 Diagonals The diagonals used are depending on the foundation type and are intended for stabilizing the Sigma II system. Regarding the ramming post and/or screw foundation types, the diagonals are screwed to the rear leg and the front leg together with the rafter. Regarding the variant with the foot plate, the diagonal is screwed to the rear foot plate and the front leg together with the rafter. Fig. 6 Diagonal Diagonals Connection elements Front and rear legs Rear foot plate Comment Pre-drilled by default When using height-adjustable legs without pre-drilled holes, height-adjustable diagonals without pre-drilled holes will be supplied as well (see project-specific OD). 8 Description of the system parts

11 4.6 Rafter The rafters are attached to the front and rear legs. They form the basis for the module supports. Fig. 7 Rafter Rafter Connection elements Front and rear legs Module support with module support clamps Comment Pre-drilled by default 4.7 Module support clamp The module support clamps are intended for the connection of rafter and module support. Fig. 8 Module support clamp Connection elements Comment Module support clamp Module support Rafter Pre-assembled Description of the system parts 9

12 4.8 Module support The module supports are mounted to the rafter. Ultimately, the PV modules are attached to the module supports. The module supports vary in the designs Portrait or Landscape. Depending on the project, different variants of the module supports can be used. These differ regarding their lateral height and partially (for landscape installation) regarding their shape. The lateral height of the module supports depends on the table lengths and the environmental conditions. The following variants are possible: Portrait installation: Portrait installation Module supports with lateral heights 65, 85, or 106 mm Module supports, lateral height 65 mm Module supports, lateral height 85 mm Module supports, lateral height 106 mm Landscape installation Module support straight, lateral height 65 mm Landscape installation: Module supports straight, lateral height 65 mm Module supports conical, lateral height 85 mm Landscape installation Module support conical, lateral height 85 mm Fig. 9 Module support, variants Module support - Portrait installation Connection elements Rafter with module support clamps Modules with module clamps/module end clamps Comment Extendable with splice Module support - Landscape installation Rafter with module support clamps Modules with module holder clips (MHC) Extendable with splice 10 Description of the system parts

13 4.9 Splice The module supports are interconnected with the splices. Depending on the project, different variants of the splices (in analogy to the module supports) can be used. These differ regarding their lateral height and partially (for landscape installation) regarding their shape. The following variants are possible: Portrait installation: Splice with lateral height 65 mm Splice with lateral height 85 mm Splice with lateral height 106 mm Portrait installation Splices with lateral heights 65, 85, or 106 mm Landscape installation: Splice straight, lateral height 65 mm Splice conical, lateral height 85 mm Landscape installation Splice straight, lateral height 65 mm Landscape installation Splice conical, lateral height 85 mm Fig. 10 Splices, variants Connection elements Comment Splice - Portrait installation Module supports for portrait installation Pre-drilled by default Splice - Landscape installation Module supports for landscape installation Pre-drilled by default Description of the system parts 11

14 4.10 Module clamps The module clamps are intended for attaching the PV modules to the module supports. Portrait installation Inter module clamps Portrait installation Module end clamps Landscape installation Module holder clips Landscape installation Press-in tool for mounting the module holder clips Fig. 11 Module clamps, variants Connection elements Comment Module clamp - Portrait installation Module support PV module Screwed connection The screw length of the module clamp varies according to the height of the module frame. Module end clamp - Portrait installation Module support PV module Screwed connection The overall height of the module end clamp varies according to the height of the module frame. Module holder clip - Landscape installation Module support PV module Snap-in connection, installation with press-in tool (see Fig. above) The overall height of the module holder clip varies according to the height of the module frame. 12 Description of the system parts

15 4.11 Spacer (landscape installation) The spacers define the lateral clearance between the PV modules for landscape installation. Op-tionally, these can be ordered made of aluminum or plastic. Spacers aluminum Fig. 12 Spacer, variants Spacers aluminum Connection elements Module support PV module Spacers plastic Comment For landscape installation only Spacers plastic Module support PV module For landscape installation only 4.12 Lateral position locking device The lateral position locking device secures the outer modules against sliding out of the module holder clips at landscape installation Bracings (optional) The east-west bracings are used if the Sigma II system is exposed to increased protection requirements in east-west direction. Fig. 13 Lateral position locking device Fig. 14 East-west bracing Connection elements Comment Connection elements Comment Lateral position locking device Module support For landscape installation only East-west bracing Rear legs Not pre-drilled, 2 units per frame unit; connection with self-drilling screws Description of the system parts 13

16 5. Overview drawing and bill of materials The project-specific documentation is part of the delivery and contains all information required for installing the system: 6.3 Tightening torques Observe the tightening torques by any means. When implementing the screwed connections, please observe the following tightening torques: Bill of materials System overview drawing exact module configuration used variants, e. g. foundation variant parts for the screwed connections to be used in your project dimensions and clearances. The dimensions depending on the exact module dimensions should be checked on site when installing the first unit.the real dimensions may deviate from those given in the OD, because of production tolerances regarding the PV module dimensions. We recommend positioning modules on a sample table, on the basis of which the exact real dimensions can be taken. The further required project planning documents, e. g. module layout and wiring diagram, must be provided by the customer. 6. Basic installation requirements 6.1 Safety instructions Please observe all specific safety instructions specified in chapter 2.3. Screw diameter M10x25 M10x65 M10x80 M10x90 M10x130 Quickstone connections Fixing anchors Tightening torques differing from those mentioned herein may be applicable. Please refer to your project-specific OD. 6.4 pplication conditions Tightening torque 17 Nm 10 Nm 17 Nm 17 Nm 17 Nm 8 Nm 50 Nm s a matter of principle, a structural engineering calculation must be implemented for the respective location. For detailed information, please contact the Mounting Systems GmbH or a structural engineer on site. The building ground at the planned installation site must be suitable for the use of the foundation elements mentioned within the project plan. For this, a project-related building ground survey with pull-out tests is required. The survey must detail the anchoring depth of the foundation elements. The customer is responsible for proof of suitability of the foundation. 6.2 Required tools In order to be able to mount the Sigma II, the following tools are required: Ladder Power drill/electric screwdriver Folding rule / measuring tape Spirit level 6 mm llen key Press-in tool (landscape installation) Wrench The installation site must be roughly level. Minor differences in height can be compensated by the height of the ramming posts. 6.5 Foundation tolerances and height adjustment You must comply with the specified tolerances in order to ensure the correct installation of the open terrain system Sigma II. Please observe the values for the average possible and/or maximum possible deviations mentioned within these installation manual that are specified in your project plan. 14 Overview drawing and bill of materials Basic installation requirements

17 6.5.1 Foundation tolerances - average deviation For the foundation, the majority of the foundation points of a frame unit must be within the speci-fied tolerances. Position tolerance north-south direction: max ± 1 cm Position tolerance east-west direction: max ± 2 cm Height (with anchored posts): max ± 1 cm per post Skew: max ± 1 per post Vertical: the centre axis may deviate from the perpendicular position by a maximum of ± 1 in all directions Fig. 15 Foundation tolerances, average deviation Foundation tolerances - maximum deviation maximum of 2 foundation points of a frame unit may be characterized by the higher tolerances mentioned below. The remainder of the foundation points must be within the average deviation (see 6.5.1). Position tolerance north-south direction: max ± 2 cm Position tolerance east-west direction: max ± 5 cm Height (with anchored posts): max ± 2 cm per post Skew: max ± 2 per post Vertical: the centre axis may deviate from the perpendicular position by a maximum of ± 2 in all directions Fig. 16 Foundation tolerances, maximum deviation Basic installation requirements 15

18 6.5.3 Tolerances for level territory with east-west slope Bei der Gründung muss der Großteil der Gründungspunkte einer Gestelleinheit innerhalb der unten aufgeführten Toleranzen liegen. Horizontal: admissible deviation (east-west direction): max ± 1.5 Sample calculation: with a table length of 12 m, 30 cm difference in height (horizontal deviation) are admissible. Fig. 17 Tolerances for territory with east-west slope Height adjustment Height adjustment is only possible when using ramming posts or screw foundations. When using ramming posts, minor surface irregularities can be compensated by ramming-in the posts with different depths. The upper edges of all posts of a frame unit mustfall in one line, horizontal if possible. Post height after ramming in: Projection: 35 cm (+ 15 cm, - 10 cm). You can compensate irregularities of the territory of + 15 cm to - 10 cm by adapting the post height. For each unit, the posts must be tolerated with the average/ maximum deviations mentioned above. The clamping plates attached to the ramming posts and the screw foundations do not allow for any height adjustment by default. However, the option for this can be agreed upon in a project-specific manner. Fig. 18 Ramming post tolerances, height adjustment 16 Basic installation requirements

19 7. Portrait installation This chapter describes the installation of the Sigma II system with portrait orientation of the modules. The installation with landscape orientation of the modules differs significantly in some parts and is described completely in chapter 8. This installation manual exclusively deal with the mechanical installation of the mounting system. The wiring and connection of the modules can be found in the wiring diagram of the module manufacturer. 7.1 Safety instructions CUTION Instability of the mounting system! If the foundations are positioned incorrectly, the mounting system may become unstable! Please observe the specified tolerances! Please observe the clearance between the foundations! Please wear protective equipment! Personal and material damages caused by accessing the mounting system! CUTION The process of accessing the mounting system may result in personal and material damages! Do not climb on the mounting system! TTENTION Material damages caused by improper installation! Improperly screwed mounting systems may be unstable and cause damages! Please only use the materials specified by the manufacturer for all screwed connections (screws, washers, and nuts). Upon installation, check all screwed connections for firm seat! TTENTION Material damages caused by improper tightening torque! Screwed connections attached with a too high tightening torque might fail or break! Screwed connections tightened with a too low tightening torque might come loose! Please apply the tightening torque specified within the installation manual! 7.2 Foundation Positioning the ramming posts Ram-in the ramming posts according to the following figure; in two rows with the opening in an eastern direction. You will find the clearances between the ramming posts in the projectspecific OD. In this, please observe the specified foundation tolerances (see chapter 6.5). Fig. 19 Eastwards orientation of the ramming posts for Sigma posts (standard) Portrait installation 17

20 7.2.2 Positioning the screw foundations Screw-in the screw foundations in two rows. The position of the drilled holes in the screw foundation after being screwed-in depends on the selected screw foundation and must be agreed upon in a project-specific manner. You will find the position of the drilled holes in your project-specific OD. In this, please observe the foundation tolerances (see chapter 6.5) ttaching the foot plates Use the screws to attach the foot plates to the foundations in a way that the openings point in a north-south direction. The drilled holes for the diagonals (rear foot plate) must point towards south. In order to attach the foot plates to the foundation, please use fixing anchors (4 per foot plate). Please observe the dowel arrangement instructions. You will find the clearances between the foot plates in the project-specific OD. Fig.19a Orientation of the foot plates towards south 7.3 Fixation of the legs ccording to the selected type of foundation, there are 2 different attachment methods for the legs. If using ramming posts and screw foundations, the legs are attached to the respective foundation using clamping plates. Regarding the foot plates, the legs are attached directly to the foundation ttachment to the ramming post and/or screw foundation Clamping plates are used to attach the legs to the ramming post and/or screw foundation. Screw the clamping plates to the ramming posts and/or screw foundations (see Fig. 20, 21). The connection material may deviate depending on the project. Compare the details to your project-specific OD. Fig. 20 Ramming posts, attaching clamping plates and leg 1 Washer large (DIN 9021) 2 Nut M10 3 Washer large (DIN 9021) 4 Ramming post 5 Screw M10 x 90 6 Screw M10 x Clamping plate 8 Leg 18 Portrait installation

21 1 Washer large (DIN 9021) 2 Nut M10 3 Washer large (DIN 9021) 4 Screw foundation 5 Screw M10 x 90 6 Screw M10 x Clamping plate 8 Leg B Place the leg between the clamping plates and screw the leg to the clamping plates (see Fig. 22, 23). Fig. 21 Screw foundation, attaching clamping plates and leg If you want to adjust the heights of the legs, please order legs without pre-drilled holes. dapt the drilled holes on site. Fig. 22 Ramming post, leg attached Fig. 23 Screw foundation, leg attached ttachment to the foot plate Insert the leg into the foot plate and screw the leg to the foot plate (see Fig. 24,25). 1 Leg 2 Nut M10 3 Foot plate 4 Washer large (DIN 9021) 5 Screw M10 x 80 Fig. 24 Foot plate, attaching legs Portrait installation 19

22 7.4 Fixation of the rafters and diagonals Foundation variant ramming posts and/or screw foundation Regarding these foundation variants, the diagonals are only attached to the front and the rear legs and not to the foundation. Fig. 25 Foot plate, leg attached B C D E Position the rafter on the front and rear legs (rear leg see Fig. 26). Screw the rafter to the rear leg. fterwards, position the diagonal on the rear leg and the rafter supported by the front leg. Screw the diagonal to the rear leg. fterwards, screw the diagonal, the rafter, and the front leg with one screwed connection (see Fig. 27). Please note that the diagonal must always be installed on the western side, i.e. above the ramming post and/or screw foundation. Fig. 26 Position rafter on rear leg and tighten it 1 Screw M10 x 65 2 Rafter 3 Rear leg 4 Nut M10 with washer large (DIN 9021) 1 Screw M10 x 65 (nut M10 with washer large (DIN 9021)) 2 Rafter 3 Diagonal 4 Front leg Fig. 27 ttaching rafter and diagonal, ramming post and/or screw foundation 20 Portrait installation

23 7.4.2 Foundation variant foot plate Regarding this foundation variant, the diagonals are screwed to the rear foot plate and the front leg, together with the rafter. B Position the rafter on the front and rear legs (see Fig. 28). Screw the rafter to the rear leg. 1 Screw M10 x 65 2 Rafter 3 Rear leg 4 Nut M10 with washer large (DIN 9021) Fig. 28 Position rafter on rear leg and attach it Fig. 29 ttaching the diagonal, attaching rear foot plate/rafter and diagonal 1 Rafter 2 Nut M10 with washer large (DIN 9021) 3 Screw M10 x 65 4 Rear foot plate 5 Diagonal (attachment rear with screw M10x25/washer large (DIN 9021) 6 Rear leg C D fterwards, position the diagonal on the rear foot plate. Screw the diagonal to the rear foot plate (see Fig. 29). Please note that the diagonal must always be installed on the western side on the rear foot plate. E fterwards, screw the diagonal, the rafter, and the front leg with one screwed connection (see Fig. 29). Portrait installation 21

24 7.5 Fixation of the module supports Position the module supports across the rafters (see Fig. 30). Please observe that the wider contact face of the module support points upwards (see Fig. 30). B Please find details on the position of the module supports in your project-specific OD. Please ensure the right position and orientation of the module supports, both regarding the position of the module supports on the rafter and the lateral projection of the module support over the outer rafter. ttach the module support to the rafter with 2 module support clamps in each case from bottom to top. For this, insert the Quickstone of the module support clamp into the Quickstone channel of the rafter (see Fig. 31, 32). Fig. 30 ttaching module supports to rafter 1 Module support 2 Rafter 3 Module support clamps C Please observe that the screw is flush with the lower edge of the Quickstone when inserting the module support clamp. If inserted properly, the Quickstone is positioned flush within the Quickstone channel of the module support. In order to extend the module supports, position the splice up to the centre of the module support (see Fig. 33). Fig. 31 ttaching module supports, inserting module support clamps into the Quickstone channel Fig. 32 Inserting module support clamp 1 Module support 2 Module support clamp 3 Quickstone 4 Rafter with Quickstone channel The use of splices is only required if these are specified within the project-specific OD. D Screw the splice to the module support on one side using self-drilling screws (see Fig. 33). E Insert the second module support into the splice in a way that both module support ends make contact. No expansion joint! Fig. 33 Connecting module supports with splice 1 Self-drilling screw 2 Splice 3 Module support 22 Portrait installation

25 F fterwards, screw the splice to the module support using self-drilling screws (see Fig. 34). 1 Module support 2 Splice 3 Self-drilling screw 7.6 Fixation of the modules CUTION Fig. 34 Module supports connected with the splice Personal and material damages caused by accessing the mounting system! The process of accessing the mounting system may result in personal and material damages! Do not climb on the mounting system! Insert the module end clamps into the Quickstone channel of the module support and slightly fix these using the llen key (see Fig. 35). Please observe that the screw is flush with the lower edge of the Quickstone when inserting the module end clamps. If inserted properly, the Quickstone is positioned flush within the Quickstone channel of the module support. Fig. 35 Inserting module end clamps 1 Module end clamp 2 Module support B C Insert the PV modules into the module end clamps (see Fig. 36). fterwards, tighten the outer PV modules with the module end clamps and the llen key. The outer PV modules must be fixed with the module end clamps to the outside first and then with the intermodule clamps to the inside. Fig. 36 PV module inserted into module end clamp 1 PV module 2 Module end clamp 3 Module support Portrait installation 23

26 Material damages caused by the failure of Quickstone connections! TTENTION Improperly installed Quickstone connections might fail! Please install all Quickstone connections according to the installation manual! Please observe the specified torque (see chapter 6.3) D Insert the inter-module clamps into the Quickstone channel of the module support and push it against the PV module (see Fig. 37). E F Please observe that the screw is flush with the lower edge of the Quickstone when inserting the inter-module clamps. If inserted properly, the Quickstone is positioned flush within the Quickstone channel of the module support. Insert further PV modules and fix these with inter-module clamps and the llen key (see Fig. 38). gain use module end clamps at the end of each module row. Fig. 37 Inserting the inter-module clamps into the Quickstone channel of the module support 1 Inter-module clamps Fig. 38 ttaching further modules 7.7 ttachment of the bracings (optional) The use of bracings is required if these are designed within the project plan. Screw the bracings to the rear legs using self-drilling screws (1st leg bottom, following leg top) (see Fig. 39). When installing the bracings, please observe that the two bracings per frame unit are mounted in a mirrorinverted manner in each case. Fig. 39 Bracings attached 1 Bracing 24 Portrait installation

27 8. Landscape installation This chapter describes the installation of the Sigma II system with landscape orientation of the PV modules. The installation with portrait orientation of the modules differs significantly in some parts and is described completely in chapter 7. This installation manual exclusively deal with the mechanical installation of the mounting system. The wiring and connection of the modules can be found in the wiring diagram of the module manufacturer. 8.1 Safety instructions Instability of the mounting system! CUTION CUTION If the foundations are positioned incorrectly, the mounting system may become unstable! Please observe the specified tolerances! Please observe the clearance between the foundations! Please wear protective equipment! Personal and material damages caused by accessing the mounting system! The process of accessing the mounting system may result in personal and material damages! Do not climb on the mounting system! TTENTION Material damages caused by improper installation! Improperly screwed mounting systems may be unstable and cause damages! Please only use the materials specified by the manufacturer for all screwed connections (screws, washers, and nuts). Upon installation, check all screwed connections for firm seat! TTENTION Material damages caused by improper tightening torque! Screwed connections attached with a too high tightening torque might fail or break! Screwed connections tightened with a too low tightening torque might come loose! Please apply the tightening torque specified within the installation manual! TTENTION Material damages caused by improper installation of the module holder clips! Improperly installed module holder clips might result in damages. Only insert module holder clips with the mounting aid! Landscape installation 25

28 8.2 Foundation Positioning the ramming posts Ram-in the ramming posts according to the following figure; in two rows with the opening in an eastern direction. You will find the clearances between the ramming posts in the projectspecific OD. In this, please observe the specified foundation tolerances (see chapter 6.5). Fig. 40 Eastwards orientation of the foundations for Sigma posts (standard) Positioning the screw foundations Screw-in the screw foundations in two rows. The position of the drilled holes in the screw foundation after screwedin depends on the selected screw foundation and must be agreed upon in a project-specific manner. You will find the position of the drilled holes in your project-specific OD. Please observe the foundation tolerances (see chapter 6.5) ttaching the foot plates Use the screws to attach the foot plates to the foundations in a way that the openings point in a northsouth direction. The drilled holes for the diagonals (rear foot plates) must point towards south. In order to attach the foot plates to the foundation, please use the fixing anchors (4 per foot plate). Please observe the dowel arrangement instructions. You will find the clearances between the foot plates in the project-specific OD. Fig.40a Orientation of the foot plates towards south 8.3 Fixation of the legs ccording to the selected type of foundation, there are 2 different attachment methods for the legs. If using ramming posts and screw foundations, the legs are attached to the respective foundation using clamping plates. Regarding the foot plates, the legs are attached directly to the foundation. 26 Landscape installation

29 8.3.1 ttachment to the ramming post and/or screw foundation Clamping plates are used to attach the legs to the ramming post and/or screw foundation. Screw the clamping plate to the foundations (see Fig. 41, 42). The connection material may deviate depending on the project. Compare the details to your project-specific OD. B 1 Washer large (DIN 9021) 2 Nut M10 3 Washer large (DIN 9021) 4 Ramming post 5 Screw M10 x 90 6 Screw M10 x Clamping plate 8 Leg Place the leg between the clamping plates and screw the leg to the clamping plates (see Fig. 43, 44). Fig. 41 Ramming posts, attaching clamping plates and leg If you want to adjust the heights of the legs, please order legs without pre-drilled holes. dapt the drilled holes on site. Fig. 42 Screw foundation, attaching clamping plates and leg 1 Washer large (DIN 9021) 2 Nut M10 3 Washer large (DIN 9021) 4 Screw foundation 5 Screw M10 x 90 6 Screw M10 x Clamping plate 8 Leg Fig. 43 Ramming post, leg attached Fig. 44 Screw foundation, leg attached ttachment to the foot plate Insert the leg into the foot plate and screw the leg to the foot plate (see Fig. 45, 46). 1 Legs 2 Nut M10 3 Foot plate 4 Washer large (DIN 9021) 5 Screw M10 x 80 Fig. 45 Foot plate, attaching legs Landscape installation 27

30 Fig. 46 Foot plate, leg attached 8.4 Fixation of the rafters and diagonals Foundation variant ramming posts and/or screw foundation Regarding these foundation variants, the diagonals are only attached to the front and the rear legs and not to the foundation. B C D E Position the rafter on the front and rear legs (rear leg see Fig. 47). Screw the rafter to the rear leg. fterwards, position the diagonal on the rear leg and the rafter supported by the front leg. Screw the diagonal to the rear leg. fterwards, screw the diagonal, the rafter, and the front leg with one screwed connection (see Fig. 48). Please note that the diagonal must always be installed on the western side, i.e. above the ramming post and/or screw foundation. Fig. 47 Position rafter on rear leg and tighten it 1 Screw M10 x 65 2 Rafter 3 Rear leg 4 Nut M10 with washer large (DIN 9021) 1 Screw M10 x 65 (nut M10 with washer large (DIN 9021)) 2 Rafter 3 Diagonal 4 Front leg Fig. 48 ttaching rafter and diagonal, ramming post and/or screw foundation 28 Landscape installation

31 8.4.2 Foundation variant foot plate Regarding this foundation variant, the diagonals are screwed to the rear foot plate and the front leg, together with the rafter. B Position the rafter on the front and rear legs (see Fig. 49). Screw the rafter to the rear leg. 1 Screw M10 x 65 2 Nut M10 with washer large (DIN 9021) 3 Rear leg 4 Rafter Fig. 49 Position rafter on rear leg and attach it Fig. 50 ttaching the diagonal, attaching rear foot plate/rafter and diagonal 1 Rafter 2 Nut M10 with washer large (DIN 9021) 3 Screw M10 x 65 4 Rear foot plate 5 Diagonal (attachment rear with screw M10x25/washer large (DIN 9021) 6 Rear leg C D fterwards, position the diagonal on the rear foot plate. Screw the diagonal to the rear foot plate (see Fig. 50). Please note that the diagonal must always be installed on the western side on the rear foot plate. E fterwards, screw the diagonal, the rafter, and the front leg with one screwed connection (see Fig. 50). Landscape installation 29

32 8.5 Fixation of the module supports Position the module supports across the rafters (see Fig. 51). Please observe that the raised contact face of the module support points downwards. B Please find details on the position of the module supports in your project-specific OD. Please ensure the right position and orientation of the module supports, both regarding the position of the module support on the rafter and the lateral projection of the module support over the outer rafter. ttach the module support to the rafter with 2 module support clamps in each case from bottom to top. For this, insert the Quickstone of the module support clamp into the Quickstone channel of the rafter (see Fig. 52, 53). Fig. 51 ttaching module support to the rafter 1 Module support 2 Rafter 3 Module support clamps C Please observe that the screw is flush with the lower edge of the Quickstone when inserting the module support clamp. If inserted properly, the Quickstone is positioned flush within the Quickstone channel of the module support. In order to extend the module supports, position the splice up to the centre of the module support (see Fig. 54). Fig. 52 ttaching module support, inserting module support clamps into the Quickstone channel Fig. 53 Inserting the module support clamp 1 Module support 2 Module support clamp 3 Quickstone 4 Rafter with Quickstone channel The use of splices is only required if these are specified within the project-specific OD. D Screw the splice to the module support on one side using self-drilling screws (see Fig. 54). E Insert the second module support into the splice in a way that both module support ends make contact. No expansion joint! Fig. 54 Connecting module support with splice 1 Self-drilling screw 2 Splice 3 Module support 30 Landscape installation

33 F fterwards, screw the splice to the module support using self-drilling screws (see Fig. 55). 1 Module support 2 Splice 3 Self-drilling screw 8.6 Fixation of the modules CUTION Fig. 55 Module supports connected with the splice Personal and material damages caused by accessing the mounting system! The process of accessing the mounting system may result in personal and material damages! Do not climb on the mounting system! ttach the module holder clips to the lower side of the module support using the press-in tool (see Fig. 56, 57). Please use the press-in tool for inserting the module holder clips by all means. Never tap-in the module holder clips with a hammer. Please check the module holder clips for firm seat. The dimensions for positioning the module holder clip is specified within the project-specific OD. Fig. 56 Inserting module holder clips with press-in tool 1 Module holder clip 2 Module support 3 Press-in tool Fig. 57 Inserting module holder clips Landscape installation 31

34 B Insert the PV modules into the module holder clips (see Fig. 58). Start with inserting the modules of the lowermost row. C Insert spacers between the PV modules on the module support and align the PV modules (see Fig. 59). Fig. 58 Inserting PV modules, correct seat of the module holder clip 1 PV module 2 Module holder clip 3 Module support Fig. 59 Inserting spacers 1 Spacer 2 Module support 3 PV module D Insert further module holder clips and PV modules in the same sequence as described above. Module holder clips must be inserted both between the modules and at the top end of the upper module rows (see Fig. 60, 61). Fig. 60 Inserting further PV modules, correct seat of the module holder clip Fig. 61 Top row of the PV modules, correct seat of the module holder clip 32 Landscape installation

35 8.7 ttachment lateral position locking device ttach the lateral position locking device to the module support using self-drilling screws (see Fig. 62). The lateral position locking device is only necessary for the outer modules (see Fig. 63). Optionally, the lateral position locking devices can be riveted as anti-theft devices. Fig. 62 ttaching the position locking device 1 Self-drilling screws 2 Lateral position locking device 3 Module support Fig. 63 Overview over the attached lateral position locking devices 1 Lateral position locking devices attached 8.8 ttachment of the bracings (optional) The use of bracings (east-west bracing) is required if these are specified within the project-specific OD. Screw the bracings to the rear legs using self-drilling screws (1st leg bottom, following leg top) (see Fig. 64). When installing the bracings, please observe that the two bracings per frame unit are mounted in a mirrorinverted manner in each case. Fig. 64 Bracings attached 1 Bracings Landscape installation 33

36 9. Storage and transportation 9.1 Safety instructions Personal damages caused due to assembly material toppling over! CUTION ssembly material may topple over and injure persons due to improper storage! Please observe the accident prevention regulations by all means! Please observe stable and slip-resistant storage! Please wear protective equipment! Damages caused by improper transportation! TTENTION 9.2 pproach Improper transportation may result in damages to the Sigma II system and the PV modules and impairments of the functionality! Check the packaging for externally visible damages! In the event of severe damages to the packaging, please inform the manufacturer immediately! In the event of minor or small transportation marks, unpack the material carefully! In the event of damages to the mounting system or PV modules, please inform the manufacturer immediately! Implement storage and transportation in a way that the stored material cannot topple over and persons cannot be injured. transportation, lifting, and lowering are only implemented with suitable lifting gear and lifting means appropriate for the weight. 34 Storage and transportation

37 10. Maintenance 10.1 Safety instructions Risk of injuries and material damage due to improper inspection, maintenance, or repair! WRNING Omitted or improper inspection, maintenance, or repair may impair the operational safety of the solar photovol-taic system! Please ensure that inspection, maintenance, and repair work is only implemented by a qualified skilled worker! Please observe for each maintenance step all specific safety instructions in chapter 7 and Maintenance steps The maintenance includes the following maintenance steps: visual inspections controls Maintenance step Visual inspection for: Maintenance action Damage to all components Obvious changes to the material Corrosion of all parts and the foundation Minor corrosion or tarnish are no signs for corrosion, because these are surface reactions without any need for action. Control for: Firm seat of all module attachments and screwed connections randomly on 0.1% of the entire surface area at different locations in the field (margin, field area, north, east, south, west). Check of the tightening torques randomly on 0.1% of the entire surface area at different locations in the field (margin, field area, north, east, south, west) according to the table in chapter 6.3 on page Maintenance interval Maintain the Sigma II system annually. Implement maintenance work according to chapter If, during maintenance, an increasing number of damages are found, the maintenance intervals for the system must be shortened reasonably. If required, additional maintenance steps should be carried out after severe storms, earthquakes, floods, or other natural disasters with the power of damaging the Sigma II system and the foundation. Maintenance 35

38 10.4 Maintenance work s a matter of principle, carry out the following maintenance work: If you detect damages or obvious material deteriorations, please contact the builder of the system who will then contact the Mounting Systems GmbH so that the possibly required ap-propriate replacement or repair work can be implemented. Remove coarse contaminations with the potential to impare the functionality of the photovoltaic system. If you detect soil erosion, above-average submergence of ground, or a deflection of the foundation elements, please inform the builder of the system who will then contact the Mounting Systems GmbH. If, during random checks of 0.1% of the surface area, deficiencies are determined, increase the number of random checks by the factor of 10. If, as a result of the random checks multiplied with the factor of 10, the error rate is more than 1%, implement extensive maintenance work. Re-tighten displaced or loose screwed connections. If you detect that the screwed connections must be replaced due to deficiencies, then replace them. 11. Disassembly 11.1 Safety instructions Damages to the modules! TTENTION Improper disassembly might result in damages to the modules! Please have the disassembly implemented by skilled personnel! Disconnect all electrical cables of the PV modules from the mounting system before starting any disassembly activities Disassembly steps Implement the following basic disassembly steps: B C Remove additional attachments. Remove and safely store the modules. Disassemble the mounting system and safely store all parts. 36 Maintenance Demontage

39 12. Disposal Please dispose of the mounting system with a waste management company (WMC) only. Please observe the standards and directives applicable on national level. Disposal 37

40 Mounting Systems GmbH Mittenwalder Straße 9a D Rangsdorf Tel. +49 (0) Fax +49 (0) info@mounting-systems.de Subject to technical alterations 2012 Mounting Systems GmbH