LEICHTmount TM EU 2.0 S 5 /10 /15

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1 Photovoltaic Mounting Systems Assembly Instructions LEICHTmount TM EU 2.0 S 5 /10 /15 Flat Roof Mounting System for PV Installations IN. LMEU S US inquiry@sflex.com S:FLEX 06/2014 / design and engineering is subject to change 1

2 Introduction Thank you for choosing the S:FLEX LEICHTmount TM EU 2.0 mounting system. Please read these instructions carefully before starting the installation and make sure that you can meet the required guidelines in this installation manual. An important part of this installation manual is the additional designed project report with the structural analysis based on the project location. Please make sure that the position of the modules on the roof and the ballast distribution is installed as required in the project report. In case the module layout changes due to circumstances like obstructions, the ballast calculation needs to be modified with the LEICHTmount EU software. The technical documentation is part of the product. The company S:FLEX is not liable for damages occurring from non-compliance with the installation instructions, particularly the safety instructions, as well as from misuse of the products. In addition to this installation manual the current general terms as well as the warranty conditions apply. The current versions are available upon request or at Faults and damage as well as problems with the operability of the system as a result of the assembly that is faulty and/or deviating from the installation instructions and/or the project report (LEICHTmount EU Tool) that preclude a material defect, is not the responsibility of S:FLEX. With an unprofessional installation, all rights of the purchaser shall expire. The required compressive strength of the roof insulation and the maximum structural roof load needs to be checked before starting the installation. Photovoltaic flat roof systems are not maintenance free. Maintenance, particular the right position of the ballast blocks and the building protection pads should be conducted annually. For exceptional high-wind events, we recommend to do a maintenance and system check right after the storm event. The system warranty shall be effective only if all system components were purchased from S:FLEX. The system requires that the module can also be used with this type of assembly (clamping to the short sides of the module). This release can be present either generally within the scope of module certification or may in some circumstances also be provided project-specifically by the module manufacturer. The aluminum coating of the building protection mat that is included in the scope of delivery prevents any leaking of plasticizers. Because of the variety of different sealing types previously and currently customary in the market, compatibility and the minimum required friction coefficients between the protective building mat and the roof structure of the building must be ensured by the assembly company / buyer. A (wet) friction coefficient of at least 0.7 for TPO roofs and 0.4 for Bitumen roofs must be adhered to in order to ensure system stability. If the Roof-Gravel is located right on the water-bearing roof the LEICHTmount EU System can not be installed on the gravel layer. The gravel must be removed in this case in the area of the Aluminum Brackets. In case of doubt, please contact the S:FLEX Team directly at inquiry@sflex.com or call

3 Advantages the unbeatable flat roof solution YOUR BIG ADVANTAGE + 25 years product warranty + Best price value available + The fastest installation in the industry + Inclusive protection pads with aluminum sheeting + Optimal water drainage + Optimized wind suction, therefore less ballasting than other systems + Suitable for roof edge zones + ETL certified, conforms to UL Wind tunnel tested for up to 150 mph + Patent pending + Without roof penetration + Optimal module ventilation + Module clamps with integrated grounding + TUV certified + Complimentary ballast calculation inclusive roof layout with our unique LEICHTmount TM software tool 3

4 Technical Details Technical Details Mounting Tilt: LEICHTmount EU 2.0 S: 5, 10 and 15 LEICHTmount EU 2.0 EW: 10 Inter-Row Spacing: LEICHTmount EU 2.0 S at 5 : 13.2 inch (335 mm) LEICHTmount EU 2.0 S at 10 : 15 inch (380 mm) LEICHTmount EU 2.0 S at 15 : 22.5 inch (571 mm) LEICHTmount EU 2.0 EW at 10 : 18.3 inch (464 mm) Min. Array Size: LEICHTmount EU 2.0 S: 2 rows with 3 modules / 3 rows with 2 modules LEICHTmount EU 2.0 EW: 2 rows with 2 double modules Roof Edge Zone: Roof areas F and G can be used Module Dimensions: mm x mm (width - length) Max. Roof Slope: 4 Degree Roof Height: max. 60 ft Wind Load: up to 50 psf (design load as a load combination of dead load and wind suction) Snowload: LEICHTmount EU 2.0 Standard up to 50 psf LEICHTmount EU 2.0 Alpine up to 92 psf (design load as a load combination of dead load, wind and snow pressure) Module approval: Please request approved module list from the module manufacturer or S:FLEX Materials: Supporting materials made of aluminum EN AW 6060 T64, module-clamps aluminum EN AW 6063 T66, stainless steel screws, wind-deflector galvanized steel Shipping: approximately 40 KW per pallet, 700 KW per truckload System Requirement: Proof of structural load capacity of the roof and the insulation needs to be provided by customer. General terms / warranty conditions and usage agreement apply. 4

5 Technical Details

6 Introduction We recommend you read the following information carefully because it is very important in dealing with the product. The installation system LEICHTmount TM EU S is a robust rack system for mounting PV modules on flat roofs. It consists of prefabricated aluminum retaining brackets with glued on protective mats including plasticizer barrier, deflector plates and all required small parts that assure a safe installation. This system allows installations on flat roofs with large surfaces and without roof penetration. This innovative system uses the frame structure and aerodynamic effects to ensure stability. LEICHTmount TM EU S is designed for systems facing South with an inclination of 5, 10 and 15. It can be used for most framed PV modules of leading manufacturers with the following dimension: LEICHTmount TM EU S module width x module length inch x inch ( mm x mm) The LEICHTmount TM EU S5, S10, S15 system is designed for maximum snow loads of up to 50 psf. The Alpine LEICHTmount TM EU S15 system is designed for maximum snow loads of up to 113 psf. Therefore, check the snow load zone of your location beforehand. The system is wind-tunnel tested and conforms to UL Minimum installation size: Max. permissible roof slope: Max. permissible building height: 2 rows of 3 modules 4 degree 60 ft Can be used for the following flat-roof coverings: foil roof, bitumen roof, gravel roof, green roof Our offer for the LEICHTmount TM EU S system includes a project report that shows the design and its structural calculations for the racking system as well as the required ballast weights and system parts list. If you have any questions, please make use of the LEICHTmount TM EU professional and comprehensive consulting services. Our competent sales team and engineers will be happy to help. PLEASE MAINTAIN THE FOLLOWING TORQUE REQUIREMENTS WHEN INSTALLING THE BOLTS AND SCREWS: 15 NM M8 (A2-70 or A4-70) R E Q U I R E D T O O L S Cordless Screwdriver T40 Torx Allen Key or Driver Torque Wrench String Line Pen/ Chalk Tape Measure 6

7 Safety Information It is imperative that you install personindependent fall arrest systems or reception system according to country-specific safety regulations. If person-independent fall arrest systems or reception systems are not available for workrelated reasons then safety harnesses must be used! Use only safety harnesses (harnesses and catching belts, connecting ropes/belts, fall absorber, rope cutter) marked and tested by authorized testing laboratories. If person-independent fall arrest systems or reception systems are not available and safety harnesses are not used, it can result in falls from great heights and therefore to severe or deadly injuries! Leaning ladders can cause dangerous falls, if the ladder caves in, slips, or falls over! Work in close proximity of live, electrical overhead power lines, with which you can come in contact, only if power is turned off and that condition is guaranteed for the time of the work the parts under power are protected through covers or barriers. the safety distances are not too short. Radius of voltage: 1 m in 1,000 Volt of voltage 3 m in 1,000 to 11,000 Volts of voltage 4 m in 11,000 to 22,000 Volts of voltage 5 m in 22,000 to 38,000 Volts of voltage > 5 m if the voltage is unknown The manufacturer hereby agrees to take back for recycling all products that are marked with the eco-label as well as all materials used herein. Only the approved heat transfer medium may be used! If at all possible, the safety harness must be fastened above the user. Fasten safety harnesses only on building elements or fastening points that can carry the load! Do not use defective ladders, e.g. cracked steps and rails of wooden ladders, bent and kinked metal ladders. Do not fix partially broken steps, rails and braces! Safely place a leaning ladder. Make sure the installation angle is correct (68-75 ). Secure leaning ladders against sliding, falling, slipping and sinking e.g. by using enlarged bases, feet braces of ladders that are adapted to the ground, fastening devices. Lean ladders only against secure support points. Secure ladders in traffic areas with barriers. Touching live electrical overhead lines can result in death. Wear safety goggles when drilling! Wear safety shoes for the installation! Wear cut-proof work gloves when installing the collectors! Wear a helmet during installation! 7

8 Components System Components 1 LEICHTmount EU S Front Bracket 2 LEICHTmount EU S Back Bracket 3 LEICHTmount EU S Connector Bracket 4 LEICHTmount EU S Wind Sheet 5 LEICHTmount EU S Ballast Tray 6 LEICHTmount EU S Ballast Tray Long 7 Pre-Assembled 8 Pre-Assembled 9 Torx Screw M8x20 Grounding End-Clamp Grounding Mid-Clamp 10 Washer 8,4 11 Cable Tie with Clip Function 12 Connector Clip for Wind Sheet 13 Rivet Nut 14 M8 Flathead 15 Allen Head Nut 16 Alpine Back Bracket Screw 17 Alpine Front Bracket 18 Protection Pad 19 Ballast Block (not included in delivery) 8

9 System Overview E ND CLAMP END OR MID CLAMP M8 Screw PV Module WINDSHEET Ballast Block 16 x 8 x 2 inch Screw M8 for Windsheet suitable for Ballast Tray and grounding Rivet NUT M8 Rivet Nut M8 LEICHTmount FRONT SUPPORT BRACKET PROTECTION PAD Aluminum Coating LEICHTmount BACK SUPPORT BRACKET Snowload > 2,4 kn BACK SUPPORT BRACKET Ballast Tray Ballast Tray LEICHTmount ENDBRACKET Snowload > 2,4 kn FRONT SUPPORT BRACKET LEICHTmount CONNECTOR LEICHTmount FRONTBRACKET 9

10 Installation Measurements prior to Installation and Placement of Components Step 1: Measure the Roof Surface Prior to starting the installation, the roof surface must be measured in accordance with the planning documents and the first fastening point is to be determined. It is recommended to mark the front base line with the chalk line and then measure the bordering line on the side in a 90 degree angle and marked accordingly. Attention: Due to the thermal expansion of the materials, a maximum of only 12 modules can be continuously connected in each direction. After every 12 th module in a continuous connection, a new solar array field has to be started. Step 2: Measure the Distance between Brackets After the entire surface of the system is determined, mark the distance to the front fastening supports (LEICHTmount EU Front Bracket), position them and apply ballast. To protect the roof surface, a safety membrane must be placed under the ballast block on each side of the bracket. The distance between the initial brackets in East-West direction is the same as the length of the module. 10

11 Installation Measurements prior to Installation and Placement of Components Step 3: Placement of LEICHTmount EU S Connector Brackets Measure the distance between the initial front bracket and in North-South direction following connector bracket, position them and apply ballast accordingly. The distance will change dependent on the LEICHTmount EU version and module size diagrams as seen below will be provided with each project report. The brackets can be still adjusted during the installation of the modules. The distance between the connector brackets in East-West direction is the same as the length of the module. Module width Module length 11

12 Installation Installation of Modules Step 4: Placement and Installation of Modules Place the module in landscape onto the supporting brackets and align them flush to the LEICHTmount EU S Connector Bracket or the LEICHTmount EU S Back Bracket. In order to make it easier to align the modules, there are notches for the lower module edge on the front support brackets and connector brackets. The module edge must be attached to the appropriate notch on those brackets according to the modules size and instructions! Place the End-Clamps and Mid-Clamps on the shorter side of the module and attach them lightly with the M8 bolts. However do not tighten them fully yet! With the placement of the second module, the module cables should be connected and with Cable-Tie Clips secured to the module frame see picture A and B. The End-Clamps and Mid-Clamps on the previous module can be now fully tightened according to the torque requirements and another module can be placed. Once the last module in each row has been aligned, End-Clamps will be attached and tightened according to the torque requirements. Click the Cable-Tie onto the module frame Picture A Picture B NOTE: For easy alignment place the modules on the lower end on the marking notch. 12

13 Installation Option: Alpine Version Measurements prior to Installation and Placement of Components Step 4 A: Placement of LEICHTmount EU S Alpine Snow Load Brackets and Sheets If the installation has been designed or planned for increased wind or snow loads, additional snow load supports (LEICHTmount S Alpine Snow Load Brackets and LEICHTmount S Alpine Snow Load Sheets) have to be used. Position the LEICHTmount S Alpine Snow Load Bracket in the center of the module. Similarly, the LEICHTmount S Alpine Snow Load Sheet needs to be placed on the fastening support at the top end of the module (on top of the LEICHTmount EU S Connector Bracket or LEICHTmount EU S End Bracket). The next LEICHTmount S Alpine Snow Load Sheet for the following module needs to be installed and will overlap the first sheet. See pictures below. 13

14 Installation Installation of the Wind Sheet Step 5: Placement and Installation of the Wind Sheet The LEICHTmount EU S Wind Sheets will overlap each other when installed onto the LEICHTmount EU S Connector Brackets and LEICHTmount EU S Back Brackets. The wind sheets will be affixed to the brackets with the Hexagon Socket Screw M8x20 and the Washer 8,4 for Wind Sheets that are part of the delivery. Please tighten the screws fully according to the torque requirements once the respective row has been fully installed. There are two types of LEICHTmount EU S Wind Sheets for the various module sizes: Article Number Description Module Width x Module Length for for for 15 LEICHTmount EU S Wind Sheet ( mm) x ( mm) for for for 15 LEICHTmount EU S Wind Sheet ( mm) x ( mm) Attention - In order to keep the installation time low, the wind sheet is always simultaneously mounted with the ballast trays. See installation guideline for ballast tray on the following page. 14

15 Installation Step 6: Installation of Ballast Trays The ballast trays are used as soon as a certain amount of ballast blocks per module is exceeded. A distinction is made between the standard or long ballast tray depending on the ballast amount per module. In the structural report, these modules are color-coded. The ballast tray is also used when the point load for the roof membrane is too low. Thus, the weight is distributed evenly over the module length. The ballast tray at the front bracket is mounted with the Flathead Screw over the square hole. Plug the screw from behind through the square and tighten the allen-head nut and the washer. Because of shadowing reasons max. 5 ballast blocks can be installed in the front ballast tray. Glue the protection pads on the right and left side underneath the ballast tray. The Glue is already on the pads for an easier installation. The ballast tray on the connector and end bracket are installed over the screw of the wind sheet. The tray is bolted between the brackets and the wind sheet. A maximum of 7 blocks per tray can be installed. 15

16 Installation Step 6A: Installation of Long Ballast Tray As soon as more than 7 blocks per bracket are required the long ballast tray needs to be installed. The tray is installed in front of the wind sheet and tightened with the same torx screw. The tray is bolted additionally in the center of the wind sheet over the rivet nut, torx screw and washer. Install the wind sheet clip at the overlapping point of the sheets. Step 7: Installation of Last Row During the assembly of the last row, the end bracket is used instead of the connector. The installation of the modules, and the Wind sheet / Ballast Tray takes place the same as before. End Bracket, last row 16

17 Installation Step 8: Ballasting Laydown all required ballast blocks according to the structural calculation of the project report on the front, connector and end bracket. Place the protection pads always on the right and left side underneath the blocks and ballast trays. We recommend 2 mats per ballast block or ballast tray. For the long ballast tray 4 mats are provided. The optimal block size for the LEICHTmount system is 16 x 8 x 2 inch and a weight of 15 pounds. The used ballast blocks must comply with the local weather conditions and have to have a compressive strength of min. 21 N / mm 2. A B C NOTE Option A: Standard ballast without tray, ballast is placed directly on the bracket. Option B: Ballast tray up to max. 7 blocks. Option C: Long ballast tray up to max. 16 blocks WARNING Don t leave the construction side before the modules and wind sheets are tightened and all the required ballast blocks are placed according the project report. Without installation of the wind sheets and ballast blocks the stability of the module array is not guaranteed. The correct position of the ballast blocks and building protection pads must be checked at the annual maintenance inspection. It is the responsibility of the installer to check the required ballast block specification and weight. Step 9: Grounding of the Array After completing the installation, the entire system must be grounded and connected to the in-house lightning protection system. One grounding connection per module array, however max. 40 modules is recommended. The LEICHTmount system needs to be grounded according to the valid regulations of the country in which the plant will be built. Tighten the grounding wire with the same screw used for the wind sheet Grounding pins NOTE It is important to ensure that the installed PV system does not impair the effect of the existing lightning protection system. It is also necessary to ensure that the PV system is designed that it can be included within the scope of the building lightning protection system. The NEC in regards to the separation distance between the PV system and the lightning protection system must be observed. S:FLEX is not liable for damages that may result from lightning strikes or grounding issues. Due to the UL certified grounding clamps and the UL certification for the array it is not necessary to install grounding wires between the modules. 17

18 Installation Seismic Attachments and Penetration Points Step 10: Installation of Penetration Points If seismic attachments are required or the maximum allowed roof weight is exceeded due to the PV system, S:FLEX provides a hybrid solution. This combination of penetration points and ballast reduces the overall weight of the system. Furthermore, this option is used in areas with seismic activity to prevent movement of the system due to vibrations from earthquakes. Quick Mount Penetration Point LEICHTmount 2.0 S5 / S10 / S15 Option A with Stand-off point Bracket cm 7, 5 Washer Socket Nut M Torx M8x25 5 cm 2 inch Flat head screw M8x20 Bracket OMG Penetration Point Option B with membrane point LEICHTmount 2.0 S5 / S10 / S15 Bracket mm 3 inch 21,5 cm 8,5 inch Socket Nut M Washer Torx M8x Flat head screw M8x20 Bracket NOTE The position of the attachment points are calculated by S:FLEX and must be strictly installed according to the structural report to be code compliant. 18

19 Installation Step 11 - Optional: Installation of Side Deflectors As a visually attractive solution it is possible to close the end of the rows with side deflectors. This version is also installed in areas where the mounting system must be fire tested according to UL1703. Clamp the side deflectors between the bracket and the module clamp on the end of each array. NOTE The fire test according to UL1703 requires the installation of the side deflectors on the end of each row. The side deflector must be ordered separately and are not included in the regular quote and delivery. The system has achieved a Class A fire rating when installed with UL1703 Fire Classification Type 1 modules. The system achieves a UL1703 Class A fire rating when installed in the manner specified in these instructions 19

20 Important Notes SAFETY INFORMATION AND WARNINGS PLEASE FOLLOW THESE INSTRUCTIONS! We recommend you read the following information carefully because it is very important in dealing with the product. Please inform yourself about the safety requirements of other system components. The LEICHTmount EU flat-roof system is only designed to hold PV modules. Any other use is considered improper. Proper use also means adhering to the contents of this installation manual. S:FLEX accepts no responsibility for damages incurred as a result of noncompliance with the installation instructions or of using the product improperly. Approval from the module manufacturer is required to use PV modules with the LEICHTmount EU system. S:FLEX won t do this. S:FLEX accepts no responsibility for performance degradation or damage to the module of any kind whatsoever. We require the use of a roof insulation with a high load capacity (e.g. Type DAA-ds). When any work is done to the PV installation, these instructions should be exactly followed. The modules may only be installed, started, serviced and repaired by people who are properly trained and authorized. Please observe the applicable regulations and safety requirements. Please adhere to the appropriate accident prevention guidelines: All general rules Any regulations for electrical installations and equipment Any regulations for construction work (e.g. individual protective equipment to prevent falls) Any trade association rules for health and safety at work (e.g. working on roofs or equipment for accessing roofs) Any work clothes and industrial safety regulations pursuant to the rules of the trade association The following country/state specific norms must be complied with: Country/State specific General rules for all types of building work Country/State specific Roof covering and roof sealing work Country/State specific Steelwork and locksmith work Country/State specific Fire behavior of building materials and structural elements Work on LEICHTmount EU systems may only be carried out by authorized personnel. The operator of the installation has the following safety obligations: Carrying out maintenance regularly once a year: e.g. checking the cables, screw connections or the roof surface. The racking system may only be installed by people with the appropriate training, skills and knowledge of mechanics. The operator must ensure that the contracted personnel is able to judge the tasks assigned to them and recognize any potential dangers. The operator must ensure that the installation instructions are available during the installation. The installation instructions are an integral part of the product. The operator must ensure that the installation instructions and particularly the warnings were read and understood by the engaged personnel prior to installation. The local health and safety at work regulations and codes of practice must be observed. Suitable lifting equipment and ladders are to be used for the installation. No freestanding and nonattached ladders may be used. It is necessary to arrange for a qualified professional engineer to assess the building s existing structural loading characteristics with regards to the additional loads of a PV system. Any general load reduction measures specified by S:FLEX (e.g. the need to clear snow, to limit the snow load) are to be observed. 20

21 Important Notes IMPORTANT NOTES WARRANTY / PRODUCT LIABILITY (EXCLUSION) The information on sizing the systems provided in the instructions are only related to information from daily use and practice. We can provide binding structural designs with our tools and with verification by a professional engineer. As an installer, you are responsible for the precise execution of the installation. S:FLEX is not liable for the sizing information contained in the offers. As an installer, you are responsible for the mechanical durability of the connections mounted onto the building s structure/roof members. In particular, this includes that those connections are leak-tight. The components of LEICHTmount EU are designed for the expected loads and they are in compliance with the effective state of the art. For this purpose, you have to specify in writing all general technical conditions within the project documentation form/technical planning aid (e.g. information about the support structure, the snow and wind loads, the building heights, etc.). S:FLEX is not liable if the installed components are not properly handled. Any use close to the sea is excluded because of the increased risk of corrosion. S:FLEX grants a 2-year product warranty on the service life and durability of the racking system, if the components are properly handled, the sizing of the system complies with the structural conditions and normal environmental conditions as well as normal conditions of the surroundings exist. This applies within the generally prevalent weather and environmental conditions. Warranty on material and workmanship: S:FLEX grants a limited product warranty of 10 years on material and workmanship. For additional information, please consult the Warranty Terms and Conditions. ADVISE FOR THE ELECTRICAL INSTALLATION Only if you are a qualified electrician, may you perform any electrical work. The applicable country/state specific standards, regulations, guidelines, accident prevention regulations and the regulations of the local utility company must be applied. 21

22 Important Notes IMPORTANT NOTES IMPORTANT WARNINGS Solar modules produce electricity as soon as they are subjected to light and are always energized. Although touch protection is provided in the form of the fully insulated plug contacts, you must be aware of the following when handling solar modules: Do not insert any conductive parts into the sockets and connectors. Do not install solar modules and cables with wet sockets and connectors. Perform any work on cabling with extreme caution. Do not perform any electrical installation work in damp conditions. Even if there is only little light, very high direct voltages arise at the series connection of modules, which can be life life-threatening in case of direct contact. Especially the danger of secondary damage in case of electric shocks has to be considered. Even when the inverter is switched off, high contact voltages may still be present inside the inverter: Be particularly careful when working on the inverter and the cables. After switching off the inverter, it is essential to wait for the time interval specified by the manufacturer before beginning any further work to allow the high-voltage components to discharge. Please also observe the installation guidelines provided by the inverter manufacturer. When breaking a connected string of modules (e.g. when disconnecting the DC line from the inverter under load), a lethally strong arc can occur: Never disconnect the solar generator from the inverter as long as it is connected to the mains. ADVISE FOR THE RACKING INSTALLATION When installing a system on a roof, you must adhered to the applicable structural engineering rules, in particular the requirements set out in the country/state specific rules and regulations of the roofing trade. Check to see if all screw connections are tightened correctly. Apply the specified torques. Notwithstanding a verifiable structural letter, it is your responsibility to ensure that the product meets the local structural requirements before every installation. Weight and surface loads of building materials, components and support materials, wind loads, snow and ice load, basis of design, safety concept and design rules. The mounting structure is designed in accordance with the applicable aluminum manuals and the current International Building Codes ASCE 7-05 and ASCE Ensure that the substructure, support structure and other affected layers (such as an insulation layer) have adequate load capacity (based on dimensions, condition and suitable material properties). Make sure that the runoff of rainwater is not impeded. Consider structural aspects (e.g. possible condensation if insulation layers are penetrated). NORMS AND GUIDELINES Observe the current national norms and guidelines and its amendments. PRODUCT LIABILITY A technical documentation is part of the supplied project. S:FLEX accepts no responsibility for damages incurred as a result of noncompliance with the installation instructions or of using products improperly. Furthermore, the general terms and conditions apply and are available upon request or at 22