Installation manual for sloped Jurchen Technology GmbH Prinz-Ludwig-Straße 5 9764 Helmstadt
Index. Security note.... Hazard note.... Planning and installation notes.... Installation notes... 4. Outline of componenents and technical basics of installation as well as electrical DC - installation... 5. General notes... 5. Way of mounting and electrical wiring... 7. General assembly of substructure... 9. Installing profile rails... 0. Rail connector bracket... 0. Rail connector bracket pre-assembled.... Adjustment of the rail connector bracket....4 Fix cross connector....5 Adjustment of the fix cross connector...4.6 Butt connector SV I... 5.6. Butt connector SV II...6.6. Impact rail connector for module rail alpine...7 4. Installation: Module installment... 8 4. Installment of frameless modules... 8 4. Installment of frameless modules with pre-assembled module clips... 5. Installation possibilities of the roof connector... 5. Installation of the roof hook for tiled roofs... 5. Installation of hanger bolts for fiber cement corrugated sheet... 4 5. Installation of profiled sheeting fastener for profiled sheeting/ sandwich components...6 5.4 Installation of the solar fastener for profiled sheeting/ sandwich components... 7 5.5 Installation of rail adapter trapezoid for profiled sheet metal and sandwich component roofs... 0 5.6 Installation of fold clamps... 6. Table of figures...
. Security note Please read this instruction manual carefully prior to installation. The security guidelines and instructions are to be followed otherwise electric shocks, fire and / or severe injuries may occur.. Hazard note Danger through electric shock and electric arc: Solar modules generate electricity as soon as they are exposed to light. Protection against contact is guaranteed through isolated contact plugs. Nonetheless take care not to insert improper electrically conducting parts into the male and female connectors. Solar modules and cables may not be installed with moisturized male and female connectors. Adhere to the module manufacturer s installation guidelines High contact voltages can arise in the inverter even though it may be disconnected. Adhere to the manufacturer s installation guidelines. When opening a closed module string, electric arcs may arise. Never under any circumstance separate the solar generator from the inverter as long as it is still connected with the power line. While working on inverters, modules or cables please deal with caution and adhere to the installation guidelines of the manufacturer.. Planning and installation notes The included module fixing has been adapted to the roofing which has been indicated in the order. The life expectancy that can be calculated with is approx. 0 years or more, therefore the condition of the roof should also be checked. All modules should have the same alignment and position for not losing yield. There should not be any shadow on the entire solar generator. Also take into consideration the low winter sun. Even partial shadows from chimneys, dormer windows, pylons and radio masts may cause losses > 0 %. Make sure that the construction of the roof is suitable in regards to the carrying capacity (dimensioning, preservation), carrying structure and other affected coatings (e.g. insulation). Make sure that the drainage of rain water is not prevented. Consider structural-physical aspects (e.g. possible condense water pervading the insulation layers). Should you have any doubt please contact a consultant engineer. Install exposed cables in such a manner that they are protected against weather, ultraviolet light and mechanical damage. Do not install the cables across sharp edges and consider the permitted bend radius. We recommend enclosing the cables in uv-resistant plastic tubes or cable ducts.
Due to wind suction you should keep an appropriate distance to roof borders, especially the corners. The appropriate distance is evaluated as follows: View from above b a Usable area a h a = b/0 or h/5, the smaller value is essential a = t/0 or h/5, the smaller value is essential t If you fall below the needed distance to the roof border you have to calculate with a higher amount of fixing material. Distances < 0 cm are not allowed. In case of elevated constructions the distance has to be generally at least,00 m from the eave as well as the roof ridge (a) and,50 m from the gables (a). If protection against lightning already exists the photovoltaic system has to be integrated into it. Therefore a specialist for lightning protection has to be implicated.. Installation notes All work regarding the photovoltaic system should be exclusively done by specialists with the according skills. During installation you are to abide by the below stated accident prevention regulations: BGV A General Specifications BGV A Electrical systems and operating resources BGV C Construction work BGR 0 Work on the roof Secure persons on the roof through adequate protective equipment from falling down. Secure persons on the ground through shut-off devices from falling parts. The already existing roof construction has to meet the standards of ATV DIN 84 carpentry and the regulations of BGR 4 and BGR 0. Furthermore the following norms and directives have to be abided by: DIN 88 Work on roof covering and impermeability DIN 845 Work on scaffolding Please consider the engineering rules when mounting in roof area. 4
During electrical installation the following norms and directives have to be abided by: VDE 000 Establishing high voltage currents up to 000V VDE 085 Lightning protection systems DIN IEC 6446 Grid connected photovoltaic systems The connection of the pv-system to the public grid may be carried out exclusively through an authorized specialist. This specialist has to have a license from the power utility.. Outline of componenents and technical basics of installation as well as electrical DC- installation. General notes This installation guide is designed for the installation of frameless modules. To achieve maximal flexibility during mounting, the rails are assembled -ply in a cross connection. The modules are arranged vertically. Eaves Ridge Fig. : Horizontal arrangement of the modules 5
Fig. : Vertical arrangement of the modules The desired position of the module will be marked to the roof according to the outer edge of the module with chalk or a chalk line. When arranging the roof profile rail as cross rail please make sure that enough cross points are available for placing the necessary amount of fixing points. Decisive here is the maximal permitted span length of the module carrier section and the maximal permitted jut at the end of the module field. The roof profile rail may not have a jut over more than 0, m from the last fixing point. Please also take into account the static advices of the implementation plans. 6
. Way of mounting and electrical wiring The following steps have to be accomplished when installing a photovoltaic system: Step - Preparation Before beginning with the installation read the instructions carefully. Check all implementation plans and mark special notes. During the installation, implementation plans and installation instructions always have to be ready to hand. Secure the plans against weather e.g. rainfall and wind. Check the delivered material of its completeness. Check the indicated dimensions in the plans comparing them with the factual conditions at the place of installation. In case of doubt please inform your system designer. We recommend assembling the module clip loosely before beginning installation. Therefore please consider our further recommendations that indicate which work can already be done on the ground. Step - Marking of module area and fixing points Define the position of the module area on the roof according to the module layout. Mark the vertices with chalk or a chalk line. Bring into position the roof fastener according to the module layout adapted to local conditions. Tolerated border distances, juts and span lengths have to be respected. Step Installation of the roof fastener Roof fasteners have to be installed on the marked positions. Attend to the installation notes. Pay attention to the uniform alignment of the fixing points. As support you can use a cord or a laser. Step 4 - Installation of the roof profile rail as a cross rail Arrange the roof profile rail in alignment. If necessary install the rail connector between two profiles. Attend to the installation notes. Align the construction in height to receive a field. The module rails may not be installed on the cross rails with tension. As support you can use a cord or a laser. Step 5 Mounting of roof profile rail as module carrier rail Install the module rail to the pre-assembled cross connectors on the cross rail. According to the module layout carrier rails have to be mounted per module with a distance of 650 mm. The length of the rail per module is evaluated as follows: Lmodule rail => Quantity of module arrays x 60 mm + 00 mm 7
If necessary install rail connectors between profiles. Attend to the installation notes. Check all mounting points for firm halt. Check randomly if the necessary torque has been maintained. If necessary tighten any screws of the roof panel which may have become loose during installation of the construction. Check the roof for possible damages. Step 6 Installation of the DC-Connection Part Install the cable splice for parallel connection of the strings according to the notes in your cable layout and adapted to the local conditions. Repeat this step for the cables leading to the inverters. Cables have to be fixated with uv-resistant cable straps or cable clips. Install the positive and negative cables separated from each other. In those places where the cable does not lie underneath of the module field (expansion gabs, maintenance access, roof entering) they have to be protected against weather by an installation tube. Also secure the cables against sharp edges. The minimum bend radius (5 x cable diameter) may not be decreased. Consider local fire protection determinations, especially for orifices through the wall. Electrical installation may only be done by a specialist. Step 7 Installation and Wiring Part The Modules Modules are mounted on the carrier rail by module clips. You have to start with the bottom module in the first line. Modules are mounted line by line from bottom to top. Take special care when arranging the first line so you can align all the other modules to it. Check the arrangement of the construction after each module line. Connect the module cables from module to module while installing them. Make sure that the module cables are fixated with UV-resistant cable straps and are not lying on the roof panel. Measure the strings and document your measurements. Should the measured short circuit current or open circuit voltage differ from the acceptable range, then please measure every single module. If you find a faulty module mark it and document it. Please inform your retailer about the faulty module, so that this may be replaced. Connect module strings with the according adapter to the cable splices. Adhere to the cable layout plan. Consider polarity and keep male and female connectors dry during installation. Electrical installation may only be done by a specialist. 8
. General assembly of substructure 5 6 4 Fig. : Detail assembly of substructure Materials and components: Pos => First solar module, x 0,6 m, frameless, size = 6,8mm Pos => x Rail connector bracket aluminium Pos => Roof profile rail 47 x 0 mm, aluminium Pos 4 => Roof hook stainless steel A Pos 5 => Module clip MK A 70 Pos 6 => Hammer head screw M0 x 0 + DIN 69 lock nut M0 9
. Installing profile rails. Rail connector bracket Two profile rails are generally mounted cross to each other. The first rail (crossbar) is always mounted as horizontal rail parallel to the eave and roof ridge. On this the second rail (module rail) is mounted in a 90 angle parallel to the gable board (gable). The crossing point is established by rail connector brackets, internal hexagon screws with spring lock washers and railing nuts. 6 4 5 5 Fig. 4: Detail crossing pont for twofold railing system Materials and components: Pos => x DIN 9 Allen head screw M8 x 6 A Pos => x DIN 5 flat washer M8 A Pos => x Rail connector bracket Ø 0,5 aluminum Pos 4 => x railing nut M8 aluminum Pos 5 => Roof profile rail 47 x 0 mm, aluminum Pos 6 => x DIN 7 spring lock washer M8 Tools: Torque wrench with Allen head attachment SW5 Torque >0Nm Notes: Before screwing the roof profile rail on the roof fastener all necessary railing nuts M8 for the quantity of rail cross connectors have to be inserted into the cross rails in the corresponding position. The module carrier rail is screwed to the roof profile rail once you are on the roof. After the system has been aligned, all screw may be tightened. The torque of the screw connection is 0Nm. 0
. Rail connector bracket pre-assembled Alternative to the installation of the rail connector bracket with straight rail nuts, you have the option of installing this to the cross connection with a pre-assembled rail connector brackets. 4 Fig. 5: Detail Rail connector bracket pre-assembled Materials and components: Pos => DIN 9 Allen head crew M6 x 8 Pos => DIN 7980 spring lock washer M6 Pos => Rail connector bracket Ø 7 aluminium Pos 4 => Rail nut M6, 45 slant aluminium Notes: The pre-assembled rail connector bracket can be installed on any part of the roof profile rail without having to position them at the exact position. The installation of the module carrier profile takes place on the roof. After the alignment of the system, tighten all loose screws. The torque for this is 0Nm.
. Adjustment of the rail connector bracket Mount the rail connector bracket on both sides in the border area. At the field range the rail connector bracket is mounted on one side in change. Fig. 6: Detail adjustment of rail connector bracket Materials and components: Pos => Roof profile rail 47 x 0 mm, aluminium Pos => x rail connector bracket Pos => x rail connector bracket
.4 Fix cross connector The fix cross connector is pre-installed and saves time for the installation of the module carrier rail onto the cross rail. The module carrier rail is screwed with only one screw on each side. Fig. 7: Detail Fix cross connector Fig. 8: Detail Fix cross connector Materials and components: Pos => Roof profile rail 47x0 mm aluminum Pos => Fix cross connector FKV I (pre-assembled with a screw DIN 9 M6 x 6, spring lock washer DIN 7980 M6, Rail connector bracket Ø 7 aluminium and Rail nut M6, 45 slant aluminium)
Tools: Torque wrench with Allen screw adapter SW6 Torque > 0 Nm Notes: The fix cross connector analog to the pre-assembled rail connector bracket can be installed at any position of the roof rail. After the fix cross connector has been arranged vertically to the roof rail and the T-guide fixed into the rail channel, a 90 turn is carried out and the rail nut M6 45 is threaded into the rail channel. Following the module rails will be installed. After the system is aligned you can tighten all screws. Required torque for the screws 0Nm..5 Adjustment of the fix cross connector At the field range the fix cross connector is mounted on one side. Fig. 9: Detail Adjustment of fix cross connector Materials and components: Pos => Roof profile rail 47 x 0 mm, aluminium Pos => x fix cross connector 4
.6 Butt connector SV I The single rails will be connected through butt connectors with each other. Based on the thermal expansion of aluminium you are allowed to interconnect a max. of m. You are to plan an expansion gap of 0cm every m. The expansion gap in the cross rail is not allowed to be between module carrier rails. This causes damage to the module. 4 Fig. 0: Detail fixing butt connector SV I Materials and components: Pos => 4 x Hammer head screw M0x0 A Pos => Roof rail 47x0 mm aluminium Pos => Butt connector SV I A Pos 4 => 4 x Self-locking nut M0 A DIN 69 Tools: Combination wrench SW 5 Torque > 0 Nm 5
.4 Butt connector SV II 4 Fig. : Detail fixing butt connector SV II Materials and components: Pos => x Hammer head screw M0x0 A Pos => Roof rail 47 x 0 mm aluminium Pos => Butt connector SV II A Pos 4 => x Self-locking nut M0 A DIN 69 Tools: Combination wrench SW 5 Torque > 0 Nm 6
.6. Impact connector for alpine module rail 4 Fig. : Detail fixing impact connector for alpine module rail Materials and components: Pos => 4x Counter sunk screw DIN 60 M0 x 0 Pos => Module rail Alpine Pos => Impact connector for alpine module rail Pos 4 => 4x DIN 69 locking nut M0 A Tools: Combination wrench SW 5 Torque > 0 Nm 7
4. Installation: Module installment 4. Installment of frameless modules The module clip MK A fits all 6,8 mm laminates. Generally use the middle clip (MK A M) between two modules and the end clip (MK A E) for the installation at the end of a module row. 5 4 6 Fig : Detail fixing module Materials and components: Pos => Allen screw M8 x 6 DIN 9 Pos => Spring lock washer M8 DIN 7980 Pos => Module clip MK A M 70-9 Pos 4 => Rail nut M8 straight aluminium Pos 5 => Thin film module, x 0,6 m, frameless, thickness = 6,8mm Pos 6 => Roof rail 47x0 mm aluminium Tools: Torque wrench with Allen screw adapter SW 6 Torque > 0 Nm 8
Notes: The modules will be installed with 4 fixation points on the long side. The distance of the module clip from the border of a First Solar module is 75mm ±5 mm. Please adhere to the manufacturer installation notes when installing other module types on this rail system. Fig. 4: Composition of the pre-assembled module clip The module clips can already be installed hand-tight to the module carrier rail on the ground. After the system is aligned on the roof, the screws will only have to be tightened. Required torque of the screws 0 Nm. 9
95 60 95 95 60 95 Installation manual for sloped Notes: At the long side of the module you have to fix the modules with four clips, at the short side you have to fix it with a safety chain. The distance from the clips of the border is, using a Abound Solar modules, 95 + 5-45 mm. If using other module types you have to attend manufacturer-specific installation information. 00 Fig. 5: Vertical arrangement of the modules with pre-assembled module clip 0
4. Installment of frameless modules with pre-assembled module clips The installation of the modules with pre-assembled is the time saving option to the laminate installation. Fig. 6: Detail fixing with a pre-assembled module clip Materials and components: Pos => Pos => Module clip MK A M SE (pre-assembled with Allen screw M6 x 6 DIN 9, spring lock washer M6 and rail nut M6 45 slanted) Pos => Thin film module, x 0,6 m, frameless, thickness = 6,8mm Pos => Roof rail 47x0 mm aluminium Tools: Torque wrench with Allen screw adapter SW 5 Torque > 0 Nm Notes: The pre-assembled module clip can be installed on any part of the with the rail nut. After the thin film module has been inserted into the clip, the module can be fixed through the Allen screw. The rail nut has to be in its ending position after the installation.
5. Installation possibilities of the roof connector 5. Installation of the roof hook for tiled roofs When dealing with tiled roofs, the installation is done with roof hooks, which will be installed according to the static specifications. The roof hook is generally for the most roof tiles i.e. flat roof tiles, interlocking tiles and concrete tiles. Eaves 4 Ridge 5 Fig. 7: Detail fixing roof hook Materials and components: Pos => Roof rail 47x0 mm aluminium Pos => Self-locking nut M0 A Pos => Hammer head screw M0x0 A Pos 4 => 4 x flat head screw 8x80/0 A Pos 5 => Roof rail 47x0 mm aluminium
Tools: Portable electric drill with depth control stop and Allen crew adapter SW 6 Drill with 5mm wooden bit Ratchet wrench SW 5 Notes: The roof hooks will be installed to the rafter. The hook is available as a standard for battens with 0 mm x 50 mm. The shortened version can be used for 4mm battens. For battens > 0mm the base plate can be placed underneath of the hook. In any case there has to be a minimum of 60mm anchoring depth for the screw. When reaching the max. load, the hook lies on the roof tiles. Damage to the roof tile cannot be expected when installing according to DIN-EN04 which gives a min. load of, kn. Also the min. distance between the roof hook and the roof tile should be approx. -5mm when not being set out to load. If the roof tile does not fulfill the min. load requirements then it will have to be replaced with a metal roof tile. The reinforced roof hook 5x8 is used in regions with higher snow-loads. We recommend replacing the roof tile on which the roof hook is installed with a metal roof tile in such regions. The following steps have to be attended to: Step : The cross rail positions must be determined from eave to ridge. Therefore you must adhere to the static specification in the plans or the calculating table. The latticing spacing is determined by the measurements of the roof tile and lies between 0,m and 0,46m. The following guideline values are to be considered: Quantity of cross rail in longitudinal direction Max. allowed spacing of the cross rails Max. allowed jut of the module carrier rail in the border area ( eave, roof ridge) of 0 mm The roof hook will be distributed vertically according to the cross rail position. Horizontally you generally install to each rafter. Also, you have to adhere to the static specifications in the plans or the calculation table.
Step : The roof hook will be installed onto the rafter by pushing the roof tile up. The base of the roof hook lies in the swale of the of the roof tile. There should be a gap of -5 mm between the roof tile and base of the hook. You might have to put the base plate underneath. If you have higher snow loads, the roof tile should be exchanged with a metal roof tile. The roof hook will be installed to thee rafter with flat head screws 8x80/0. The rafter will be pre-drilled with 6mm, / of the total screw depth. The anchoring depth of the screw into the rafter is min. 60mm. Eventually you will have to use longer screws. Step : After the roof hook is installed, the roof tile is placed back. It might be necessary to abrade the roof tile so that the roof tile, including the roof hook is bond again. You can use an angle grinder with a diamond grinding wheel to do this. 5. Installation of hanger bolts for fiber cement corrugated sheet Installation sets consisting of hanger bolts and an adapter plate are used for roofs with fibre cement corrugated sheeting. 5 6 7 4 EavesRidge Fig. 8: Detail fixing hanger bolts 4
Materials and components: Pos => Roof rail 47 x 0 mm aluminium Pos => Hammer head screw M0x0 A Pos => x Self-locking nut M0 A DIN 69 Pos 4 => EPDM gasket Pos 5 => Adapter plate for hanger bolts 80x0x5 A Pos 6 => Hex nut A, spring lock washer M0 A and flat washer large M0 A Pos 7 => EPDM gasket Tools: Portable electric drill with depth control stop and Allen crew adapter SW 6 Drill with: 4mm drill bit for fibre cement corrugated sheeting 6mm drill bit for wood Ratchet wrench SW 5 and SW 7 Notes: The roof membrane will be perforated (hole Ø 4mm through screw M0) in the according areas. The perforation will be made on the elevations of corrugated sheet and not in the water bearing pits. You may not install the hanger bolts in the butt of two fiber cement corrugated sheets. Through the installation drill hole you will drill the fixation into the purlin (6mm). The hanger bolt should at least be screwed into the purlin about 60 to 80 mm. According to DIN 05 the spacing from either edge of the wood has to be three times the Ø of the hanger bolt. Screw the hanger bolt until only the metric screw thread shows, which will be used for the EPDM gasket. To seal the hole, the EPDM gasket will be pushed all the way down and pressed against the roof through the washer, spring lock washer and the hex nut. Please take caution to only press very lightly when working with fiber cement corrugated sheeting, because this will brake very easily. The fiber cement corrugated sheet, especially the fixations have to be able to hold up to the higher wind suction, which arise through the installation of the photovoltaic system. If necessary, further fixation points have to be set. During installation you should lay planks. For later service works on the photovoltaic system we recommend you plan the installation of a lath floor. 5
5. Installation of profiled sheeting fastener for profiled sheeting/ sandwich components The profiled sheeting fastener can be used as an alternative to the solar fastener if there is no possibility to screw onto the purlin. You have to check the suitability of the roof for this installation method. 4 Ridge Eaves 5 6 Fig. 9: Detail fixing profiled sheeting fastener Materials and components: Pos => x Hammer head screw M0x0 A Pos => 4 x Self-tapping sheet-metal screws 6,x5 with shortened drill points Pos => Profiled sheeting fastener, horizontal with EPDM Pos 4 => Cross rail 47x0 Pos 5 => x Self-locking nut M0 A DIN 69 Pos 6 => 4 x Washer with sealing Notes: The components have to take up exact defined loads. Therefore, the following points have to be taken into account: When installing the fastener onto the sheet-metal, the fastener has to be bonded completely. (Carrying the snow-loads) The screws are not allowed to rev at any time during the installation. When screwing, make sure to pressure the sealant a little. Work with depth stop. 6
Limited to the approval of the screws there is a thickness of sheet-metal for aluminum of 0,6 mm and for steel-sheets 0,5 mm needed. (DIN Standard) The roof has to be able to take the additional load of the photovoltaic system. The sheet-metal has to be able to take up the higher wind suction which results through the installation of a photovoltaic system. When dealing with sandwich components, you have to make sure there is a sufficient adhesion between the layers. The profile sheeting fastener is not allowed to be installed between the butt of two profiled sheet plates. 5.4 Installation of the solar fastener for profiled sheeting/ sandwich components The solar fastener is preferred for the installation of the photovoltaic system onto the profiled sheet / sandwich components because the load of the system is transferred to the purlin and not the roof membrane. The solar fastener is available for wooden and steel sub construction. The fixation spacing depends on the static specifications, the measurement of the profile and the alignment of the purlin. Please consider the notes in the layouts or in the static calculation. 5 6 First Traufe 4 Fig 0: Detail fixing solar fastener 7
Material and components: Pos => Roof rail 47x0 mm aluminium Pos => Hammer head screw M0x0 A Pos => x Self-locking nut M0 A DIN 69 Pos 4 => Calotte with gasket seal Pos 5 => Adapter plate 80 x 0 x 5mm A Pos 6 => Solar fastener JT-SBA-L/L E9 Tools: Portable electric drill with depth control stop and Allen crew adapter SW 6 Drill with: a bit for 0,7 x screw diameter for wooden purlins a bit for steel purlins diameter depends on the thickness of the sub construction Ratchet wrench SW 5 Notes: The following steps are to be taken into account: Step : The solar fastener will be screwed vertical to the slope of the roof when viewing from the side. The hole has to be drilled straight and should be in center position of the purlin. Before drilling determine the course of the purlin and mark the fixation points. Already installed screws can be replaced. Therefore you should consider the diameter of the pre-drilled hole. Pre-drilled hole diameter: Wooden structure (purlin): 0,7 x screw diameter according to DIN 05 Min. screw in depth = 8 x screw diameter Steel structure (purlin): The pre drill hole according to the thickness of the purlin Purlin thickness Diameter of the pre-drill hole,5-5,0 mm 6,8 mm 6,0 mm 7,0 mm 8,0 mm 7, mm 0 mm 7,4 mm 8
Step : The calotte will be laid on the raised bead at the respective hole. Following the solar fastener will be screwed in with a portable electric drill with depth stop. Percussion drills are not allowed. The screw will be anchored into the sub-construction and will transfer all push and pull forces to the sub-construction. The screw is to be tightened until light pressure is seen on the gasket seal.it could be possible that you may not be able to install calottes on the purlins at the eave or ridge of the roof because they may be covered from flashings. In this case you will have to place a washer and gasket to be able to seal up. Step : The adapter plate will be clamped with the round hole to the solar fastener on the top thread bolt with selflocking nuts M0. Due to the more favorable force distribution it should be orientated towards the roof ridge. Before tightening the adapter plate to the thread bolt you should align the construction. The oblong hole of the adapter plate is used for the installation of the cross rail with a hammer head screw M0x0 and a self-locking nut. Before installing the module carrier profile, hammer head screws M0x0 for the connection of the cross rail connector have to be threaded in. Adhere to the installation note Installing profile rails. Step 4: Installation of the solar support If the purlin spacing is,50 m or the jut of the end of the field is to great, the solar support is used for installation. Please attend to the layout plans and the static calculation. The solar support is used to transfer additional accruing forces to the roof membrane (i.e. snow loads). The solar support will not be anchored to the roof membrane or the purlin. The installment of the cross rails will be done as described in Step. After installment of the module carrier rail, the adapter plate will be orientated in such a manner that the module carrier rail has a light tension. This prevents flapping of the module field caused by changing push and pull forces. 4 Ridge Eaves 5 Fig : Detail fixing solar support 9
Materials and components: Pos => Roof rail 47x0 mm aluminium Pos => Hammer head screw M0x0 A Pos => x self-locking nut M0 A DIN 69 Pos 4 => Adapter plate 80x0x5mm A Pos 5 => Solar support with calotte and EPDM M0 5.5 Installation of rail adapter trapezoid for profiled sheet metal and sandwich component roofs The multi-functional rail adapter trapezoid can also be used alternatively to the solar fastener in case there is no installation to the purlin possible. This fits for most trapezoid profiled sheeting and sandwich components. The components have to transfer exact defined forces. Therefore you have to consider the following points: The adapter has to lie on the raised bead completely before riveting to the roof. The roof has to be able to take the additional load of the photovoltaic system. The sheet-metal has to be able to take up the higher wind suction which results through the installation of a photovoltaic system. When dealing with sandwich components, you have to make sure there is a sufficient adhesion between the layers. The rail adapter trapezoid is not allowed to be installed between the butt of two profiled sheet plates. Based on the thermal expansion of aluminum you are allowed to interconnect a max. of 6m. You are to plan an expansion gap of 0cm every 6m. The expansion gap in the cross rail is not allowed to be between module carrier rails. This causes damage to the module. 0
4 Ridge Eaves 5 Fig. : Detail rail adapter trapezoid Materials and components: Pos => Roof rail 47x0mm aluminium Pos => x Blind rivet D=4,8mm Pos => Rail adapter trapezoid aluminium Pos 4 => Hammer head screw M0x0 A Pos 5 => Self-locking nut M0 A DIN 69 Tools: Ratchet wrench SW 5 Hand riveter or electrical riveter Notes: As a preparation to the installation drill two holes centered on the raised bead (Ø 5,mm) with a spacing of 70mm. Following the rail adapter with the cell rubber will be laid onto the raised bead, so that the holes lie on top of each other and the flap with elongated hole pointed towards the eave of the roof. With the delivered GESIPA blind rivets (PG4, 8x5 F K Alu Delta Seal Black) you rivet the rail adapter to the roof using the hand riveter or electrical riveter (recommendation: GESIPA power Bird or GESIPA Accu Bird). The usage of other rivet types will have to be checked. After the installation of the roof adapter on the raised bead, the roof rails will be connected using hammer head screws and self-locking nuts. Elongated hole in the flap is usable to balance bumps in the roof.
5.6 Installation of Fold clamps For the installation on KalZip roofs we use fold clamps. The fold clamp will be installed on the fold and has the advantage of not having to penetrate the roof membrane. The fold clamp will be delivered pre-assembled. The components have to be able to transfer exact defined forces. In this case you have to attend to the following points: The roof has to be able to take the additional load of the photovoltaic system. The installation of the fold clamp has to be able to take up the higher wind suction which results through the installation of a photovoltaic system. 4 Fig. : Detail fold clamps Materials and components: Pos => Hammer head screw M0x0 A Pos => Roof rail 47x0mm aluminium Pos => Self-locking nut M0 A DIN 69 Pos 4 => Fold clamp aluminium Tools: Ratchet wrench SW 5 Ratchet wrench SW Notes: The pre-assembled fold clamp will be clamped onto the fold, aligned and tightened with the ratchet wrench (SW) as seen in the picture. The roof rail will be installed with a hammer head screw and a self-locking nut and tightened with the ratchet wrench (SW5).
Table of figures Figure No. Description Page Horizontal arrangement of the modules 5 Vertical arrangements of the modules 6 Detail assembly of substructure 9 4 Detail crossing pont for twofold railing system 0 5 Detal adjustment of rail connector bracket 6 Detal rail connector bracket pre-assembled 7, 8 Detail fix cross connector 9 Detail adjustment of fix cross connector 4 0 Detail fixing butt connector SV I 5 Detail fixing butt connector SV II 6 Detail fixing impact connector for alpine module rail 7 Detail fixing module 8 4 Composition of the pre-assembled module clip 9 5 Vertical arrangement of the modules with pre-assembled module clip 0 6 Detail fixing with a pre-assembled module clip 7 Detail fixing roof hook 8 Detail fixing hanger bolts 4 9 Detail fixing profiled sheeting fastener 6 0 Detail fixing solar fastener 7 Detail fixing solar support 9 Detail rail adapter trapezoid Detail fold clamps
Contact Should you have any questions regarding the installation manual for sloped roofs or other products of Jurchen Technology GmbH, please do not hesitate to contact us: Switchboard: Ms. Rösch +49 969-989-660 Indoor sales service: Ms. Hebenstreit +49 969-989-6676 Sales representatives: Mr. Heidel +49 70-78957 Under you will find more information to our products. Hotline: + 49 (0) 969 989-660 All data may be subject to alterations and errors. 0_07_EN 4