Assembly manual

snowflake flat roof system

Sol ar power Sol ar heat Assembly systems

snowflake flat roof system

english

Version date 01.001-2012 Article no.: Montage20

Contents

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4 5 6 7 8 10 10 10

Important information on intended use Overview of components and tools General information Step-by-step assembly
1. Measuring the system 2. Laying out the support rails 3. Installing the supports 4. Installing the facing plates 5. Ballast 6. Module installation 7. Earthing 8. Final installation check

Important information – general information and notes on safety
About this assembly manual The present assembly manual describes the correct installation of the snowflake flat roof assembly system on flat or flat sloping roofs. Installation work must only be carried out by specialist companies. The present assembly manual is specifically intended for the person installing the assembly frame. In addition to this assembly manual, you require • an installation drawing (included) • a ballast plan (included) • module mounting clamps with Allen screws and T-nuts appropriate for the modular design and the respective module type, and a module mounting assembly manual (not included as standard). Compliance with the present assembly manual is obligatory for installation of the snowflake flat roof assembly system and related guarantee claims or guarantees. Applicable standards and rules The relevant standards and rules relating to the installation of solar systems on flat and flat sloping roofs must be observed. Safety information The relevant safety regulations relating to the installation of solar systems on flat and flat sloping roofs must be observed. No specific further safety requirements apply to installation of the snowflake flat roof assembly system.

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Hotline +49 (0) 33 34.59 44 40

Subject to change without notice. Images and descriptions do not claim to be exhaustive.

Overview of components and tools

Components — the supplied assembly system consists of the following elements:

Standard support rail

Termination support rail

Assembly aid (2 aluminium rails)

Rear plate left

Rear plate right

Rear plate centre

Side plate left

Side plate right

Small support (side/ centre)

Large support

Ballast profile

Hexagon bolt

Required tools — To install the assembly system and the modules, you require the following tools:

Additional required material — Ballast for weighting in accordance with supplied ballast plan

In accordance with ballast plan, preferably 3.5 or 7 kg cement block

Cordless screwdriver (13 mm socket; extension) 10 mm open spanner

Cement block

When selecting the ballast, remember that it may not lie flat on the roof at any point, as in this case insufficient weight is applied to the assembly frame and the roof cladding may also be damaged. Prevent inadvertent tipping of cement blocks onto the roof.

Subject to change without notice. Images and descriptions do not claim to be exhaustive.

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General information before starting installation

When tightening the M6 hexagon bolts, note the recommended torque of 8 Nm. In the following description of the assembly steps, a direction looking north from the south is assumed, so that the left side of the assembly system is in the west and the right side in the east. Modules installed alongside one another in a line are called rows and run from east to west. The support profiles run in parallel from north to south.

promptly of any such changes, so that a new check of the structural stability can be carried out. If you do not do so, the guarantee for the structural stability of the assembly system will be voided. Checking the structural analysis of the roof Ensure that a roof structural analysis has been carried out and that the roof is suitable for bearing the additional load resulting from installation of the system. Checking the lightning protection

Cleaning the roof before beginning installation Before installing the assembly system, clean the roof with a view to sharp stones and moss. Integrity of the roof Ensure that the roof is free of defects. It should be in new or modernised condition. The snowflake flat roof assembly system may not be installed on damaged roofs. Look for puddles and water pools (build-ups of water), installation of the system is not permitted in this case. Subsequent modifications to the roof NOTE: The present ballast plan was drawn up for the exact state of the roof and its environment at the time of quotation/ commissioning and is binding for the manufacturer’s guarantee for the structural analysis of the assembly. Structural modifications to the building or buildings in the immediate vicinity, e.g. attachment of an advertising hoarding, may change the aerodynamics of the roof and thereby endanger the stability of the system. Structural modifications require recalculation of wind loads and may make changes to the ballast plan necessary. Please therefore inform mp-tec

Ensure that the necessity of lightning protection for the roof, including the solar installation, has been checked by a specialist company and, should this be the case, that the assembly system is linked into the lightning protection system. Checking the module suitability snowflake was developed for clamping the modules on the narrow end. Before installing the modules, check whether the module manufacturer has approved their modules for this type of attachment. Equipotential bonding and earthing the assembly frame The assembly frame must be earthed for the purposes of equipotential bonding. Interrupting installation prior to completion If you, for any reason, interrupt installation prior to completion, you must cover all modules which have already been installed with rear and side plates to ensure they can withstand interim exposure to wind.

Step-by-step assembly

1. Measuring the system
First mark out the future location of the system on the roof using chalk. While doing so, compare your work with the information in the supplied installation drawing/ ballast plan and pay particular attention to any blocked-off areas marked there.

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Hotline +49 (0) 33 34.59 44 40

Subject to change without notice. Images and descriptions do not claim to be exhaustive.

Step-by-step assembly

2. Laying out the support rails
Required components

Standard support rails

Termination support rail

Assembly aid

Hexagon bolts

To start, lay out the support rails in the shape of an L. The left side and the frontmost rail row first.

Interconnect the support rails, i.e. lengthen them using 2 hexagon bolts each.

When laying out the frontmost row of support rails, as well as when aligning the rails relative to one another, the supplied assembly aids should be used as spacers. The laid-out L now approximately covers the surface area of the future system. Check now to see whether this estimated position precisely matches the later, desired position of the system. Ensure that any blocked-off areas marked in the installation drawing/ ballast plan, e.g. at the edge, are clear.

Now lay out all the remaining support rails while using the assembly aid.

Subject to change without notice. Images and descriptions do not claim to be exhaustive.

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Step-by-step assembly

3. Installing the supports
Required components

Small and large support

Hexagon bolts

Small side support

Small centre support

ATTENTION: There are two different types of small support, which differ in the number of holes they contain.

Install the short and long supports responsible for the tilt angle of the modules with 2 hexagon bolts each. The short supports at the front, the long ones behind.

Depending on the supplied type, the fully assembled supports set a module inclination of either 10° or 15° to the horizontal plane.

NOTE: The spacing between the future module rows, also known as the shading distance, need not be measured. It is predetermined in the course of planning by the length of the support rails and cannot be modified by the owner.

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Hotline +49 (0) 33 34.59 44 40

Subject to change without notice. Images and descriptions do not claim to be exhaustive.

Step-by-step assembly

4. Installing the facing plates
Required components

Rear plate left

Rear plate centre

Rear plate right

Side plate left

Side plate right

Hexagon bolts

Lay out the facing plates. Note the various types: side plate left, side plate right, rear plate centre, rear plate left and rear plate right. TIP: Check the precise distance between the rails over the entire length of the rails using the assembly aid. Ensure that all the rails terminate in line at the front.

Installation rear plate left: now install the facing plates in their corresponding positions using the included hexagon bolts. TIP: Installation of some side plates should only be carried out after installing the modules. This makes it easier to cable the modules, and the ballast can then also be more easily corrected.

Installation side plate left

Installed rear and side plates

Subject to change without notice. Images and descriptions do not claim to be exhaustive.

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Step-by-step assembly

5. Ballast
Required components

NOTE: For practicable ballasting in accordance with the mp-tec ballast plan, we recommend the following types of cement block: 200 x 100 x 80 mm: 7 kg 100 x 100 x 80 mm: 3,5 kg
Cement blocks Ballast profile

Sample ballast plan

The required ballast per rail below a module can be found on the ballast plan.

ATTENTION: The information in the ballast plan is binding. Deviations require recalculation of the assembly frame and/or roof structural analysis.

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Hotline +49 (0) 33 34.59 44 40

Subject to change without notice. Images and descriptions do not claim to be exhaustive.

Step-by-step assembly

(1)
Sample ballast plan

Ballasting is carried out before installing the modules. The mandatory amount of ballast can be found on the ballast plan.

Distribute the ballast on the support rails below the modules towards the back of the module. At the sides, use the supplied ballast profiles (1) as shown to stabilise the position of the cement blocks.

TIP: If there is insufficient space below the module for ballasting, the rail behind the module can also be used for this purpose.

ATTENTION: The ballast may not lie flat on the roof at any point, as in this case insufficient weight is applied to the assembly frame and the roof cladding may also be damaged. In particular, prevent inadvertent tipping of cement blocks etc. onto the roof.

Subject to change without notice. Images and descriptions do not claim to be exhaustive.

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Step-by-step assembly

6. Module installation
NOTE: snowflake has been precisely preassembled in the factory for your desired module type and may only be constructed with this module!

ATTENTION: snowflake was developed for clamping the modules on the narrow end. Before installing the modules, check whether the module manufacturer has approved their modules for this type of attachment.

7. Earthing
The earthing of the assembly frame must be carried out by a specialist. Earth connection points are the open boreholes in the support rails. Alternatively, extra boreholes can be made in the support rails for the purpose of earthing.

8. Final installation check
Finally, check that: • all components have been fully assembled • all screwed connections have been tightened • the ballast has been completely applied and at the right position.

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Hotline +49 (0) 33 34.59 44 40

Subject to change without notice. Images and descriptions do not claim to be exhaustive.

Planning

Space for drawings

Subject to change without notice. Images and descriptions do not claim to be exhaustive.

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Publisher: mp-tec GmbH & Co. KG Copyright by mp-tec © 2012

mp-tec GmbH & Co. KG Solar system company Wilhelm-Conrad-Röntgen-Straße 10-12 16225 Eberswalde, Germany Telefon: + 49 (0)33 34.59 44 40 Telefax: + 49 (0)33 34.59 44 45 sales@mp-tec.de www.mp-tec.de

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