MANUAL. landscape orientation. portrait orientation. metal roof mounting system for solar panels METAL ROOF MOUNTING SYSTEM. Rev

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1 MANUAL METAL ROOF MOUNTING SYSTEM EN landscape orientation portrait orientation metal roof mounting system for solar panels ESDEC BV 2018

2 CONTENTS 1. Introduction 1 2. General installation conditions 1 3. Product description 3 4. Parts overview Exploded view of mounting system in landscape orientation Exploded view of mounting system in portrait orientation Parts list for mounting system in landscape orientation Parts list for mounting system in portrait orientation 5 5. Preparation for mounting Check of tools and accessories Cleaning the roof Determining the position of the solar panels and measuring 7 6. Installing the mounting system in landscape orientation Positioning the mounting profiles Installing the mounting profiles Mounting the 1st solar panel on the mounting profiles Mounting the other solar panels on the mounting profiles Assembly / multiple rows horizontally Installing the mounting system in portrait orientation Positioning the mounting profiles Installing the mounting profiles Mounting the first solar panel on the mounting profiles Mounting the other solar panels on the mounting profiles Assembling the 1st row of solar panels horizontally Assembly / multiple rows vertically Appendix 19 page THIS INSTALLATION MANUAL SHOULD BE CAREFULLY SAVED FOR FUTURE USE! For details of the guarantee period and conditions, we advise you to contact your supplier. We also refer you to our General Terms and Conditions of Sale and Delivery, which are available on request. The manufacturer refuses to accept any responsibility for damage or injury as a result of failure to comply closely with this installation manual and not taking the customary precautions during transport, mounting and use of the mounting system. As a result of continuous striving for improvement, the details of the product can deviate from that which is described in this manual. For this reason, the instructions provided serve merely as a guideline for installing the product specified in this manual. This manual was compiled with the utmost care. The manufacturer cannot, however, accept any responsibility for any errors it may contain or the consequences thereof. Moreover, all rights are reserved and nothing from this manual many be reproduced in any way.

3 1. Introduction This manual describes the installation of the metal roof mounting system (for solar panels in landscape and portrait orientation). Read the manual carefully so that you are fully aware of its contents. Follow the directions in the manual carefully. Always carry out the steps in the proper order. Keep the manual in a safe, dry place. If you lose the manual, you can request a new copy from Esdec B.V. 2. General installation conditions General Failure to observe the requirements in this document can lead to the exclusion of all guarantees and product liability. The information, comments and recommendations in this document are binding and must be checked for completeness and timeliness. Esdec BV reserves the right to amend this document without further notice. Stability and condition of the roof The roof must be in good condition and strong enough to support the weight of the solar panels, incl. the additional equipment, wind and snow load. Check the stability of the roof and modify the roof/construction where required. When in doubt, call in a builder. Ensure that the load reserve of the roof is not exceeded either in locations or as a whole. Safety warnings As standard, the installation of the mounting system must be carried out by qualified technical personnel (at least 2 competent persons). Adding or removing parts can adversely effect the functioning and is strongly advised against! For installation of the solar panels, the roof must be clean, dry, flat and free from algae etc. Avoid installation in high winds and on a wet, slick roof surface. When working on a sloping roof, always use fall protection and, if required, safety nets and edge protection. Important! Never stand in the gutter. Wear shoes with reinforced toecaps and sturdy anti-slip soles. Always wear the proper protective clothing when carrying out the work. Always use a lifting aid/hoist installation when moving the material (solar panels etc.). Always place a ladder on a sturdy, stable surface. Always place the ladder at an angle of approximately 75º and allow the ladder to extend approximately 1 meter above the roof edge. If possible, secure the top of the ladder using a rope or strap. Work preferably according to the manual working safely on roofs. Scope of application Solar panels of all brands and models with a frame height of between 30 and 50 mm with maximum dimensions of 2 x 1m (2m2) per solar panel. Wind zone 1 through 3, terrain category II and III. (NEN ). Roof height (3-15m). If your roof is higher, you must contact your supplier. Type of roofing material: Steel sheet Screws for minimum steel thickness: 0.5 mm, Rivets / pop rivets for steel thickness < 0.5 mm Roof pitch: Between degrees (35 degrees is optimal) Edge zone Due to the wind load, the distance from the solar panels to the ridge and eave must be at least 30 cm. The distance of solar panels from the side of the roof must be at least 30 cm. No solar panels must be placed in this zone either entirely or partially. 01

4 Standards, rules and regulations In order to avoid accidents, it is important to follow the installation instructions and the corresponding standards when installing the mounting system. Pay particular attention to the following standards, rules and regulations: Dutch Buildings Decree PPE Personal Protective Equipment KEMA Certification of Electrotechnical Materials DIN 1055 Design loads for buildings DIN General rules for all construction sectors. DIN Scaffolding Removal and disassembly Dispose of the product in accordance with local legislation and regulations. Warranty Guarantee according to the warranty conditions and general terms and conditions of Esdec BV. These conditions can be found at the website Liability The manufacturer cannot accept any liability whatsoever for damage or injury caused by not taking adequate safety precautions or (accurately) following the instructions given, or resulting from negligence during the installation of the product and any corresponding accessories specified in this document. Printing errors reserved 02

5 3. Product description The mounting system is constructed of mounting profiles and the necessary mounting materials to mount the solar panels in landscape or portrait orientation on the metal roof. The metal roof mounting system can be used for all steel roof sheets, including the common corrugated steel sheets and trapezoidal roof sheets. (The sheet thickness must be at least 0.4 mm.) Roof mounting The mounting profiles will be installed on the steel sheets using self-tapping screws or blind rivets/pop rivets. Because the mounting profiles cannot be mounted on the roof trusses or purlins, you are free to choose the location of the solar panels on the roof yourself. The undersides of the mounting profiles are equipped with EPDM sealing tape that serves as a water barrier. Mounting of the panels The solar panels will be installed on the mounting profiles by means of universal module clamps. 4. Parts overview 4.1 Exploded view of mounting system in landscape orientation

6 4.2 Exploded view of mounting system in portrait orientation

7 4.3 Parts list for mounting system in landscape orientation 1. Solar panel 2. Mounting Profile Landscape Item no.: Self-tapping screw 6.0 x 25 mm Torx 30 Item no.: End clamp support grey Item no.: Module Clamp Universal grey Item no.: Parts list for mounting system in portrait orientation 1. Solar panel 2. Mounting Profile Portrait Item no.: Self-tapping screw 6.0 x 25 mm Torx 30 Item no.: End clamp support grey Item no.: Module Clamp Universal grey Item no.:

8 5. Preparation for mounting 5.1 Check of tools and accessories The following is a list of the necessary tools / mounting aids: Marker / chalk Brush Measuring Tape Cordless screwdriver T30 Metal saw Protective gloves Safety helmet Safety glasses Protective clothing Safety shoes Respirator Hearing protection Scaffold or stable safety ladder 5.2 Cleaning the roof Clean the steel roof plates using a brush. Remove algae, moss and so on to minimise unevenness during the installation! 06

9 5.3 Determining the position of the solar panels and measuring When determining the location of the solar panels on the sloping roof, it is very important to bear in mind the exposure to sunlight throughout the entire day and throughout the entire year. Place the panels on a roof surface that has no shade. Shade from a chimney, dormer, trees and adjacent buildings will have an adverse effect on the yield of the solar panels. Measuring and outlining For the placement of the solar panel (in landscape or portrait orientation), you require space of approximately 160 x 80 cm or 160 x 100 cm or 200 x 100 cm (depending on the type of solar panel). Be sure to leave a minimum of 30 cm of free space around the solar panels on the roof, in other words, 30 cm from the ridge and the eave and 30 cm from the sides due to the turbulent wind load. Mark out the contours of the panel array on the tiles using chalk or a marker. Marking out in landscape orientation: Mark out the contours of the panel array on the steel plates using chalk or a marker. Mark out the lines where the mounting profiles will be placed (see section 6.1). Follow the instructions of the calculator regarding the distance between the individual mounting profiles; these instructions are determinative. min. 30 cm min. 30 cm min. 30 cm min. 30 cm Marking out in portrait orientation: ark out the lines where the mounting profiles will be placed (see section 7.1). Follow the instructions of the calculator regarding the distance between the individual mounting profiles; these instructions are determinative. min. 30 cm min. 30 cm min. 30 cm min. 30 cm 07

10 6. Installing the mounting system in landscape orientation 6.1 Positioning the mounting profiles The position of the mounting profiles will be based on the location of the solar panels on the roof. The mounting profiles must be positioned at distance B in height from each other on the steel roof. The mounting profiles must be positioned at distance A in width from each other on the steel roof. Distribute the mounting profiles (per panel) widthways evenly in the line in which the solar panels will be placed. Important! Ensure that the mounting profiles are jointly aligned. Important! For the number of screws per mounting profile, the calculator is determinative (see also the table in the appendix). B A B A Clamping range specified by module manufacturer For the number of screws, the calculator is determinative (see also the table in the appendix). 08

11 6.2 Installing the mounting profiles 1. Mark the centre of the crest of the roof plate and, using chalk or a marker, draw a straight line to indicate where the mounting profiles must be installed. 2. Install the mounting profiles along the marked line on the roof. Ensure that the mounting profiles are placed parallel to the crest. Important! Ensure that the mounting profiles are jointly aligned. 3. Screw the mounting profiles onto the roof plate, using 6.0 x 25 mm self-tapping screws. Use a cordless screwdriver with Torx 30. Important! Ensure that the screwdriver is set to the slipping clutch with a maximum torque of 3Nm so that the screw does not become stripped. When the rubber on the screw begins to deform, the screw is tight enough and the roof is watertight. Important! For the number of screws per mounting profile, the calculator is determinative (see also the table in the appendix). T30 too loose good! too tight crooke B B A A A 09

12 6.3 Mounting the 1st solar panel on the mounting profiles 1. Click the universal module clamp onto the top two mounting profiles. 2. Slide the end clamp support onto the mounting profiles and slide the end clamp support over the universal module clamp. 3. Turn the lip of the universal module clamp to the rear. 4. Place the first solar panel on the top four mounting profiles and slide the panel against the two end clamp supports. Choose the right height so that the universal module clamp connects to the solar panel. Screw on the module (end) clamps securely. Ensure that the mounting profile protrudes 20 to 30 mm. Important! The tightening torque of the screw connection is 4.5 Nm. 5. Next, click the universal module clamps onto the mounting profiles on the underside of the solar panel. Choose the right height so that the universal module clamp connects to the solar panel. 6. Important! Do not yet tighten these universal module clamps. Important! The minimum panel thickness Y=29 mm and the maximum panel thickness X=50 mm. T mm Click! Y X 5. Click! 6. 10

13 6.4 Mounting the other solar panels on the mounting profiles 1. Slide the next solar panel between the mounting profiles and the universal module clamps. Next, tighten the universal module clamps. Important! The tightening torque of the screw connection is 4.5 Nm. Repeat this step if there are multiple intermediate panels. 2. Click universal module clamps on the bottom mounting profiles and slide these against the solar panel. 3. Slide the end clamp support onto the mounting profiles. Slide the end clamp support over the universal module clamp against the solar panel. Choose the right height so that the universal module clamp connects to the solar panel. 4. Turn the lip of the universal module clamp to the front. 5. Tighten the module (end) clamps. Ensure that the mounting profile protrudes 20 to 30 mm. Important! The tightening torque of the screw connection is 4.5 Nm. Important! Ensure that the solar panels are lying straight before you screw in the Torx screw! T Click! 11

14 6.5 Assembly / multiple rows horizontally 1. To achieve a closely interconnected solar panel surface, slide the adjacent solar panels against the row of solar panels. 2. Repeat the steps in sections The panel array is now complete! T Click!

15 7. Installing the mounting system in portrait orientation 7.1 Positioning the mounting profiles The position of the mounting profiles will be based on the location of the solar panels on the roof. The mounting profiles must be positioned at distance A in width from each other on the steel roof. Ensure that the hole pattern of the mounting profile corresponds with the centre pitch from the centre of the crest of the roof plate. Also ensure that the flange of the mounting profile is facing upwards. Distribute the mounting profiles (per panel) widthways evenly in the line in which the solar panels will be placed. The mounting profiles must be positioned at distance B in height from each other on the steel roof. Important! Ensure that the mounting profiles are jointly aligned. Important! For the number of mounting profiles, the calculator is determinative (see also the table in the appendix). B A top B Depending on pitch of steel roof A Clamp range specified by module manufacturer 13

16 7.2 Installing the mounting profiles 1. Mark the centre of the crest of the roof plate and, using chalk or a marker, draw a straight line to indicate where the mounting profiles must be installed. 2. Install the mounting profiles along the marked line on the roof. Ensure that the mounting profiles are at a right angle to the crest. Important! Ensure that the mounting profiles are jointly aligned. Ensure that the hole pattern of the mounting profile corresponds with the centre pitch from the centre of the crest of the roof plate. 3. Screw the mounting profiles onto the roof plate using 6.0 x 25 mm self-tapping screws. Use a cordless screwdriver with Torx 30. Important! Ensure that the screwdriver is set to the slipping clutch with a maximum torque of 3Nm so that the screw does not become stripped. When the rubber on the screw begins to deform, the screw is tight enough and the roof is watertight. Important! For the number of mounting profiles, the calculator is determinative (see also the table in the appendix). T30 too loose good! too tight crooke B B A A A 14

17 7.3 Mounting the first solar panel on the mounting profiles 1. Click the universal module clamp onto the two top-left mounting profiles and slide the clamp to centre of the mounting profile. 2. Slide the end clamp support onto the mounting profiles and slide the end clamp support over the universal module clamp. 3. Turn the lip of the universal module clamp to the left. 4. Place the first solar panel on the top four mounting profiles and slide the panel against the two end clamp supports. Choose the right height so that the universal module clamp connects to the solar panel. Screw on the module (end) clamps securely. Important! Ensure that the mounting profile always sticks out far enough so that the outer screws are still visible. Important! The tightening torque for the module clamp is 4.5 Nm. 5. Next, click the universal module clamps onto the mounting profiles on the other side of the solar panel. Choose the right height so that the universal module clamp connects to the solar panel. 6. Important! Do not yet tighten these universal module clamps. Important! The minimum panel thickness Y=29 mm and the maximum panel thickness X=50 mm. T30 X Y Click! outer two screws visible after mounting 5. Click! 1st 2nd 6. 15

18 7.4 Mounting the other solar panels on the mounting profiles 1. Slide the next solar panel between the mounting profiles and the universal module clamps. Important! Ensure that the module clamp are always lying between the screw locations. Tighten the universal module clamps. Important! The tightening torque of the screw connection is 4.5 Nm. 2. Next, click the universal module clamps onto the mounting profiles on the other side of the solar panel. Choose the right height so that the universal module clamp connects to the solar panel. 3. Important! Do not yet tighten these universal module clamps. Repeat this step if there are multiple intermediate panels. Important! Ensure that the solar panels are lying straight before you screw in the Torx screw! Repeat this process with the remaining solar panels. T Click! 3. 16

19 7.5 Assembling the 1st row of solar panels horizontally 1. Slide the last solar panel in the row between the mounting profiles and the universal module clamps. Next, tighten the universal module clamps. Important! The tightening torque of the screw connection is 4.5 Nm. 2. Click the universal module clamp onto the two top-right mounting profiles and then slide them to the solar panel. 3. Slide the end clamp support onto the mounting profiles and slide the end clamp support over the universal module clamp against the solar panel. Choose the right height so that the universal module clamp connects to the solar panel. 4. Turn the lip of the universal module clamp towards the right side. 5. Tighten the module (end) clamps. Important! Ensure that the mounting profile always sticks out far enough so that the outer screws are still visible. Important! The tightening torque for the module clamp is 4.5 Nm. Important! Ensure that the solar panels are lying straight before you screw in the Torx screw! T Click!

20 7.6 Assembly / multiple rows vertically 1. To achieve a closely interconnected solar panel surface, slide the solar panels underneath against the upper row of solar panels. 2. Repeat the steps in sections The panel array is now complete! T30 2. Click!

21 8. APPENDIX General conditions: Wind zone 1 through 3, terrain category II and III. (NEN ) Solar panels in landscape orientation Maximum surface solar panel in m2 1,65 2,08 Maximum height in m Maximum wind load (thrust pressure) in N/m Number of mounting profiles per single solar panel 4 Number of screws per mounting profile Solar panels in portrait orientation Maximum surface solar panel in m2 1,65 2,08 Maximum height in m Maximum wind load (thrust pressure) in N/m Number of mounting profiles per single solar panel Number of screws per mounting profile 4 19