DICONAL PV - mounting system

Transcription

1 DICONAL PV - mounting system

2 DICONAL.de PV - mounting system - All DICONAL mounting components are made of high-quality material (stainless steel, aluminium) and are ideally suited for installation on almost any kind of roof. - We offer a ten-years warranty (in accordance with our terms & conditions) - Certified by TÜV - Qualified PV- mounting system - Regular check-ups Prior to mounting - The building s or roof s structure have to be checked by an expert as for their carrying capacity (see annex with profile data) - The plannings of roof construction, roof fastening points, solar modules and mounting system must be accurately aligned (see annex with profile data) - Special attention has to be paid to building physics conditions such as snow, precipitations, thaw, condensation etc., especially DIN To avoid potential power losses the modules need maximum exposure to direct sunlight - any shading will reduce module output considerably (trees, chimneys, power poles etc.) - In seashore areas anodized aluminium components must be used exclusively. Mounting - Mounting is to be carried out by qualified staff only (at least 2 persons) - Consideration of safety provisions - Consideration of VDE regulations and DIN standards (see page 17) - Roof fastenings are to be carried out by a roof slater - The expansion joints between the profiles must be of at least 10 mm - Bolts have to be firmly tightened (about 30Nm, at most 10Nm for the fastening of the modules) CONTECTA GmbH Telefon Rudolf Diesel Str. 1 Telefax Kirchberg info@contecta-shop.de Page 1

3 DICONAL Mounting System Page 3 Page 4 Page 5 Page 6 Page 7 Page 8 Page 9 A Rooftop fastening A.1 DHP and DHS hooks for slate, shingle, tile and pantile coverings A.2 Trapezoidal sheet metal roofs/roofs with corrugated sheetings A.2.1 GH-/300/400 Sliding support system A.2.2 Mounting with individual P30 profile pieces A.2.3 Mounting with S-10-KV hanger bolts A.3 Special constructions e.g. along house walls, support poles etc. B Single-layer profile framework B Double-layer profile framework with cross connector B.1 P40 profile B.1.1 KV-40 profile fastening B.1.2 KV-40 cross connector B.1.3 Profile lengthening clamp KV-80 Page 10 C Module fastening with DICONAL - system clamp Page 11 P1 statics Page 12 P40 statics Page 13 Snow load and wind zones Page 14 Regulations and provisions DIN standards Page 15 Product catalogue DICONAL PV- Mounting System Page 16 Product catalogue DICONAL PV- Mounting System Page 17 Application of DICONAL PV- Mounting System, survey Page 18 CONTECTA Contact Page 2

4 A Rooftop fastening The fastening of solar modules on rooftops has an impact on the existing roof cladding. It is thus especially important to check the roof construction in consideration of the additional load. Only authorized experts are entitled to mount such fastenings. When planning the fastening points, the dimensions of the solar modules, the framing of the profile construction and the positioning of the roof fastenings must be adjusted to the requirements of the roof s static and structural characteristics. Any data regarding position and number of the fastening points relate to the roof s normal range. Higher loads have to be considered for the roof s edges and corner areas. A.1 DHP und DHS hooks for slate, shingle, tile and pantile coverings - Roof hooks shall be professionally mounted in those spots where the supporting substructure is embedded in the roofing. - Fixing holes for the designated fastening points will be needed in the roof cladding and hooks will be professionally bolted down on the roof construction (with bolts according to DIBT Z ). The roof cladding has to be adjusted to the roof hooks by cut-outs. DHP-25 with KV-40 DHP-25, KV-40, P40, MMK For pantiled roofs please consider that the hooks have to be placed with a separation distance of at least 5 mm to the underlying tiles. In the event of load applied on the roof hooks (e.g. snow load) resting of the tiles will thus be avoided and no damage will be caused to the tiles. The roof hooks shall be fastened on the rafters with 3 bolts. For slate roofs - please consider that the roof hooks shall be fastened with 2 bolts. DHS-11 with KV-40 Page 3

5 A.2 Fastening on trapezoidal roofs / on roofs with corrugated sheeting As will be described below, three different systems are available for roof fastenings on sheet roofs: GH-/300/400 sliding support system, individual P30 profile part mounting and S-10 hanger bolt mounting. A.2.1 GH-/300/400 sliding support system Tools / auxiliary material: drilling machine, rivet gun Applied on self-supporting trapezoidal sheet roofings that are not accessible for reasons of lacking surface stability. Fastening will occur in three steps: 1. Fastening of the GH-300/400 fixed elements on the roof surface. 2. GH- sliding supports are then fitted on the profiles prior to mounting Insertion of the profile in the fixed elements, positioning and fastening of GH-. Illustration a, GH-300 Illustration b, GH- Illustration c, GH- - Fits system profile mounting at right angles with the bead. - Continuous rail systems provide for a uniform distribution of any load exerted on the raised beads (Ill. a). - Load application through positive locking of the system profiles with the sliding supports. The sliding supports are fastened on the roofing by means of appropriate blind rivets. - The number of sliding supports used is determined, in compliance with the degree of utilization, by the minimum number of rivet Illustration d, GH- and P40 connections on the sheeting. This depends on the roofing s sheet thickness. - A PV array should not exceed a continuous profile length of 12.5 m (corresponds to 2 system profiles). - Each system profile has to be firmly connected by a sliding support (fixed element). This fixed element is to be fastened to the roof sheet with 4 rivets on at least 2 raised beads and with 2 rivets respectively to each system profile (Ill. e). - This may occur by means of two GH up to a length of 6 m (Ill. d). Illustration e, GH-400 and P40 For lengths exceeding 6 m the fixed element has to be centered in the array by a GH 300/400 (Ill. e). - The remaining sliding supports shall not be firmly fastened to the system profile so as to compensate for the thermal expansion of the profile. - The exclusive use of rivets approved in the manufacturer s instructions is required. Page 4

6 A.2.2 Mounting with individual P30 profile parts Tools / auxiliary material: drilling machine, rivet gun Fits accessible trapezoidal sheet roofings with sheet metal shell. Solar panels are mounted directly on P30 profiles by means of MMK and MEK system clamps. - Minimal equipment - Optimal statical load distribution on the roof surface - This mounting method allows a suction effect reduction on the roofing shell amounting to the PV-installation s dead load. - Profile parts are mounted on 2 raised beads at each panel joint. - Fastening occurs with 4 appropriate blind rivets. - Problems with thermal expansion do not arise given that no continuous rail systems are used. P P and MEK P and MEK A.2.3 Mounting with S-10-KV hanger bolts Tools / auxiliary material: SW 15 wrench Fits corrugated or trapezoidal sheetings for which rivet mounting reveals inappropriate. Hanger bolts with KV hooks allow an immediate mounting of the profile framework with P40 profiles. - Depending on the model, hanger bolts may both be fastened on wood or steel beams (pre-drilling is required). - Appropriately distanced beams are required in the roof construction. - Hanger bolts come with a pre-mounted EPDM-seal and a KV-40 clamp thus allowing an immediate fastening of the P1 system profiles. - In the event that P40 system profiles are mounted with hanger bolts they are generally mounted parallel to the bead. S-10-KV with P40 S-10-KV with P40 S-10-KV with P40 Page 5

7 A.3 Custom-made constructions - The attachment of constructions to house walls, facades, supporting roof trusses etc. is effected according to the instructions of the structural engineer, the architect or the construction engineer. - Our mounting system will then be adjusted according to the required instructions in a way to allow the use of our system profiles and clamps in the further course of the mounting. Illustration a Example I Mounting of a PV installation using the roof supporting steel construction. The roofing has been opened in a few spots to provide for an immediate mounting of the double insulated mounting poles on the supporting substructure (Ill. a+b). Subsequent to this the poles have been professionally sealed and the P1 system profile with a span length of 5 m fastened (maximum span length of 7 m, see profile data sheet). MMK and MEK clamps can be fastened immediately. Illustration b Illustration c Bottom of P1 construcion Top of P1 construction Illustration e Illustration f Example II Mounting of a PV installation on renovated industrial structure roofs. P40 profiles were fastened to custom-made triangular support structures for maximum exposure to direct sunlight (Ill. d, e, f). Illustration d Page 6

8 B Profile framework Tools / auxiliary material: SW 15 wrench The profile framework constitutes the basis for solar panel mounting. Prior to fastening of the clamps see information supplied by the manufacturer. Single-layer P40 profile framework with roof hooks, hanger bolts and KV 40 On single-layer profile frameworks, system profiles are mounted horizontally. Mounting generally occurs upright given that most module manufacturers allow clamp fastening only along the module s long sides. DHP-25-KV Mounting P40 Profile Profile framework Roof hooks / hanger bolts and profile framework are connected by means of a KV-40 clamp. Displace the clamp plate in a way to insert the P40 system profile (Ill. a+b). Position the clamp plate and fasten the system profile with the bolt (Ill. c+d). Illustration a Illustration b Illustration c Illustration d KV-40 is used for single-layer profile frameworks with: - DHP and DHS roof hooks - S-10 hanger bolts - washers. Single-layer P40 profile frameworks with GH sliding supports GH-/300/400 sliding supports form the basis for P40 profile frameworks on inaccessible trapezoidal sheet roofings. See also A.2.1 / page 4 Page 7

9 Double-layer profile framework with KV-40 cross connector: In the event that an upright mounting reveals impossible, this is your solution: - The basis consists in a single-layer profile framework, see page 7 - The KV-40 clamp is used for the cross connection - For this purpose the KV-40 clamp has to be inserted into the groove of the lower P40 system profile. GH- + KV-40 DHP-25-KV + KV-40 DHP-25-KV + KV-40 DHP-25-KV + KV-40 DHP-25-KV + KV-40 Page 8

10 B.1 P40 profile The P40 system profile is used for single-layer and double-layer profile frameworks. It fits as well for fastening with hanger bolts (see A.2.3). Framework P-40 with GH- Framework P-40 mit GH- B.1.1 KV-40 profile fastening P40 profile fastening requires the use of the KV-40 clamp which can be hooked and fastened in any position. No bolts are needed to do so! In the system profile is mounted with roof hooks or hanger bolts t he KV-40 clamp will be supplied with pre-mounted hooks. Profile mounting does thus not require to carry along any connectors on the roof. A simple SW15 wrench will do. DHP-25-KV B.1.2 KV-40 cross connector A double-layer profile framework requires a crosswise mounting of the profiles. For this purpose the KV-40 clamp has to be inserted into the profile groove of the first profile framework. The profiles of the second layer will then be fastened with a clamp. DHS-11-KV and cross connector B.1.3 Lengthening of KV-80 profiles Lengthening of the system profiles occurs by means of a KV-80 connector. Should a profile joint be situated on top of a roof hook or on a hanger bolt - no problem! Given that the KV-80 connector is structured just like the KV-40 clamp they are easily interchangeable and fit for profile lengthenings. Lengthenings of the sliding support system are effected by means of a GH- 300 / GH-400 on the fixed element. DHP-25-KV and KV-80 Page 9

11 C Module fastening with DICONAL - MMK and MEK Tools / auxiliary material: hexagon socket 6mm DICONAL - system clamps MMK and MEK offer perfect handling properties rapid, safe and easy to install with a few movements. - See information supplied by the manufacturer! 1. Pre-mounted DICONAL clamp elements are positioned in the profile with an L -movement and are then pushed forward until stop. 2. Turn the screw 2-3 times (up to the marking line). By doing so, the DICONAL - system clamp is kept in place within the profile but may still move its position may be varied to the left or to the right it is however secured from falling out. wrong right 3. A spring integrated in the DICONAL - system clamp retains the middle clamp sufficiently upright to allow an easy positioning of the solar panels. The clamp is then fastened in a last step, the bolt being tightened with a maximum of 10 Nm. DICONAL - system clamps MMK and MEK may be fitted immediately and in any position in P40, P1 and P30 system profiles! Page 10

12 z y y Evenly distributed allowable load z Distance between supports P1 Wy: 86,36 cm 3 Iy: 647,69 cm 4 Wz: 46,20 cm 3 Iz: 184,79 cm 4 Distance between supports L in meter 4,00 m 5,00 m 6,00 m 7,00 m Maximum allowable point loading in KN/m for an even distribution 4,53 2,79 1,61 1,02 for LFH & U<l/100 Dimensioning example - maximum distance between supports in m Roof tilt angle 20, distance between supports e=1,00m, height of construction h=8,00m wind load zone 1, inland, normal range max f= l/100 Hight above sea level snow load zone I snow load zone II H=300 6,85 6,35 H=400 6,85 5,80 H=0 6,45 5,35 Page 11

13 z y y allowable point loading in the centre z Distance between supports P40 Wy: 3,85 cm 3 Iy: 7,69 cm 4 Wz: 3,18 cm 3 Iz: 6,36 cm 4 Distance between supports L in meter 0,80 m 1,20 m 1,60 m 2,00 m max. allowable point loading in KN/m 2,02 1,35 1,01 0,65 Dimensioning example - maximum distance between supports in m Roof tilt angle 20, distance between supports e=1,00m, construction height h=8,00m wind load zone 1, inland, normal range max f= l/100 Hight above sea level snow load zone I snow load zone II H=300 1,70 1,60 H=400 1,70 1,45 H=0 1,60 1,35 Page 12

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15 Regulations and provisions for the erection and operation of a photovoltaic system Building license Prior to the start of constructions the building authorities have to be Guidelines of the German Association of Property Insurers (VDS) informed about the planned erection of a photovoltaic system. VDS 2023 Guidelines for fire protection in structural works A building license for the PV installation may reveal necessary. VDS 2024 Guidelines for fire protection for the installation of electrical operating materials Information on the statics of the roof DIN 4102 Fire behavior of building materials and elements Prior to the mounting of the photovoltaic system it has to be checked whether the statics of the roof on top of which the photovoltaic system is to be erected is designed in a way to bear the additional DIN standards and VDE regulations loads. DIN VDE Construction of power systems with nominal voltages up to 1000 Volt part 300, 410, 420, 430, 520, 523, 540, Safety provisions to comply with 600, 712, 729, 732, 737 During the works to be effected on the roof, the provisions and DIN VDE 0105 (part 1/07.83), (part 1, section 12), safety instructions in effect must be complied with. To be considered DIN VDE 0106 (part 100/03.83), in particular are the safety provisions and directives of the DIN VDE 0126 Solar energy systems for domestic use Employer s Liability Insurance Association for the electronics, textile DIN VDE 0185 Lightning conductors and precision mechanics sector (esp. BGV A1, BGV A2, BGV C22) DIN VDE 0190 (part 5/86), and of the Employer s Liability Insurance Association for the building DIN VDE 0298 (part 3/08.83), DIN General information sector (esp. BGI 663, BGI 757 and BGI 807). for construction of lightning conductors VBG 4 (04.79), VBG 37 (04.77), VBG 74 (10.70), VBG 109 (04.79) DIN Construction and operation (earthing) of antenna The provisions and directives of VDEW (Association of German installations electric power companies) on the parallel operation of photovoltaic DIN VDE 0413 (part 1-7), energy generating systems with the low voltage mains of the electric DIN VDE 0603, DIN VDE 0680 (part 1/01.83 and 2/03.78), power company, especially the technical connection conditions TAB. DIN VDE 0701 (part 1-260), Final inspection of the PV installation by an electrician accredited by DIN VDE (part 2/07.85), the network operator DIN VDE (part 1/05.84), Provisions on the general terms of electricity supply to end DIN 18012, consumers AVBEItV DIN (part 1/11.84), Planning aid for the technical connection conditions of the DIN 400 (part 07.80), respective electric power companies DIN 4420 (part 1/03.80, part 2/03.80), VGB 4 Safety provisions for electrical installations and equipment DIN 18382, DIN General guidelines DIN Aluminium constructions DIN 1052 (Parts 1 and 2) Wood constructions DIN 1055 Design loads for buildings Disclaimer DIN Carpentry and timber construction works Given that the circumstances and methods at the moment of DIN Roofing and roof weather-proofing mounting, putting into operation, use and maintenance of the DIN Mounting of metal structures construction kit and module supporting framework lie outside the DIN Scaffolding works range of responsibility of CONTECTA, we expressly disclaim liability ZVDH Rules and regulations of the central association of German for loss, damage or expense arising out of or in any way from an roof slaters incorrect mounting, operation, use or maintenance. VDI 6012 Local energy systems in buildings The whole solar energy plant is to be constructed according to the generally recognized state of the art. Page 14

16 Product catalogue DICONAL PV-mounting system 1 Art.Nr. P roh P EV1 P C14 Amount Unit Designation Aluminium support profile 40x40mm, raw Aluminium support profile 40x40mm, alu anodized silver Aluminium support profile 40x40mm, alu anodized black length 6200mm P roh P EV1 P C Aluminium support profile1x80mm, raw Aluminium support profile1x80mm, alu anodized silver Aluminium support profile1x80mm, alu anodized black length 6000mm GH--EV1 GH--C Sliding supports length mm, alu anodized silver Sliding supports lenght mm, alu anodized black for P40 fastening points with adhesive sealing band for immediate mounting with blind rivets on steel sheet profiles GH-300-EV1 GH-400-EV Sliding supports length 295mm, alu anodized silver Sliding supports length 395mm, alu anodized silver for P40 fastening points with adhesive sealing band for immediate mounting with blind rivets on steel sheet profiles GH-SV-EV1 GH-SV-C14 Rail connectors sliding support system, alu anodized silver Rail connectors sliding support system, alu anodized black length 125mm, width 33,5mm, thickness 2,0mm Tightly fastened connection of the support profiles with blind rivets P roh 40 Mounting profile, length 400mm, pre-drilled D 5mm, raw incl. of 4 self-adhesive sealing bands MMK-xx-EV1 MMK-xx-C14 Module middle clamp, alu anodized silver Module middle clamp, alu anodized black possible clamping height 30-60mm, Unit is pre-mounted, ready for mounting, immediately insertable into the support construction replace xx in Art.Nr by Solar modul hight MEK-xx-EV1 MEK-xx-C Module end clamp, alu anodized silver Module end clamp, alu anodized black possible clamping height 30-60mm, Unit is pre-mounted, ready for mounting, immediately insertable into the support construction replace xx in Art.Nr by Solar modul hight PA-45-EV1 PA-45-C14 Profile end, support profile P40, alu anodized silver Profile end, support profile P40, alu anodized black pre-mounted profile end, incl. of clamping screw Page 15

17 Product catalogue DICONAL PV-mounting system 2 Art.Nr. Amount Unit Designation KV-40-EV1 Cross connector, alu anodized silver KV-40-C14 Cross connector, alu anodized black Connector is insertable in the support construction in any position. KV-80-EV1 25 Connection clamp duo, alu anodized silver KV-80-C14 25 Connection clamp duo, alu anodized black Connector is insertable in the support construction in any position. Additionally this connector may connect 2 profiles. (even directly on an already mounted roof) DHP-25-KV 25 Roof hook, V2A, pre-mounted pantile with KV-40-EV1 DHP-30-KV 25 Oblong hole 11mm ø DHS-11-KV 25 Roof hook, V2A, pre-mounted slate with KV-40-EV1 Oblong hole 11mm ø DP Washers, thickness 5mm (green) DP Washers, thickness 10mm (brown) NS-VA-M6 Sliding bloc, V2A, for stat. supporting joints M6 NS-VA-M8 Sliding bloc, V2A, for stat. supporting joints M8 for P40 and P1 support profiles BN Blind rivets, 4.8x12 Alu/V2A for fastening of sliding supports HS-880-VZ Wood screws, Spax 8.0x80mm with flat head, galvanized for fastening of roof hooks May be used without pre-drilling along the edges 3 bolts / fasteners, in the centre 2 bolts / fasteners. S-10xxx-KV 25 Hanger bolts, M10x140, 160, 180, 200 V2A incl. of EPDM sealing for hanger bolts to be mounted on corrugated or trapezoidal sheetings, with KV-40-EV1 pre-mounted KV-40 is insertable in the support construction in any position. Replace xxx by bolt length. Page 16

18 Application of DICONAL PV-mounting system, survey Pantiled roof Slate roof Trapezoidal sheets / inaccessible Trapezoidal sheets / accessible Corrugated sheetings Facades Industrial building roofs / roofing foils P40 P1 GH- GH-300 GH-400 GH-SV P KV-40 KV-80 DHP-25-KV DHP-30-KV DHS-11-KV Blind rivet Wood screw S-10xxx-KV special solution MMK-xx MEK-xx Page 17

19 DICONAL the PV - mounting system by CONTECTA GmbH

20 CONTECTA GmbH Rudolf-Diesel-Str Kirchberg Contact Web / Sale How to find us - from North Telefon Telefax info@contecta-shop.de Arriving from North, South or East you take A 61, exit Rheinböllen, Simmern. You will automatically follow B direction Simmern. Please take the 2nd exit Kirchberg about 10km after Simmern. Turn to your right, industrial area direction, continue for about 400 m and turn left in the industrial area. Then turn left twice until you reach the CONTECTA administration. Trier A 48 M o s B421 e l B327 A 61 Simmern B Kirchberg Koblenz R h e i n A 3 Abfahrt Rheinböllen Mainz from West From the West you take B 327 (Hunsrückhöhenstr.), direction Koblenz. After having passed Hirschfeld (station), turn right towards Simmern and follow B, leave at exit Kirchberg. Turn to your right, industrial area direction, continue for about 400 m and turn left in the industrial area. Then turn left twice until you reach the CONTECTA administration.