installation instructions English

Transcription

1 installation instructions English

2

3 Safety instructions 04 General notes 07 Material & tool requirements 08 System overview 10 installation of HANGER BOLTS 12 Maintenance 23

4 04 INTENDED USE Creotecc mounting systems are solely intended for the purposes of mounting photovoltaic modules and associated anchoring systems on buildings or on the ground. To ensure that the mounting system is used correctly, the user must comply with the safety instructions and maintenance instructions (see chapter 7 Maintenance ) listed in these installation instructions. To comply with the requirements for intended use the user must adhere to these instructions and the installation guidelines provided by the module manufacturer. Among other aspects, this applies to the mechanical attachment of the modules, the maximum loads that the module is capable of withstanding and other details such as orientation, rear ventilation, cable routing, wiring, choice of inverter etc. INAPPROPRIATE USE Any use other than those described in the previous paragraphs is regarded as inappropriate use. All claims relating to damage incurred through inappropriate use will be rejected. Inappropriate use voids all liability, warranty and guarantee claims against the manufacturer and the user is liable for any damage to the mounting system incurred during the installation and operation of the system, as well as any subsequent damage to other parts of the system, the roof, the building and any personal injuries. GENERAL SAFETY INSTRUCTIONS Read the installation instructions fully and carefully before commencing any installation work. Make sure you have understood all the installation steps and instructions. Clarify any questions before you start the installation, then proceed according to the instructions and complete the various steps in the correct order. The mounting system must be installed by qualified personnel. Ensure that the personnel performing the installation have read and understood the installation instructions and the safety instructions and that they are aware of and able to recognise any potential dangers. The installation must comply with all industrial safety regulations, accident prevention requirements, norms, building regulations and other relevant directives. The connection of all electrical equipment must comply with the relevant VDE guidelines and the safety regulations specified by the electrical industry. Safety clothing that complies with the relevant national regulations must be worn at all times during the installation. Make sure there is always a second person present throughout the entire installation, who can provide assistance in the case of an accident. Leave at least one copy of the installation instructions near the installation site for the personnel to refer to. Only use original parts and accessories authorised by the manufacturer. Keep a copy of the installation instructions in a safe and accessible place for documentation and maintenance purposes.

5 SPECIFIC SAFETY INSTRUCTIONS SPECIFIC SAFETY INSTRUCTIONS FOR PHOTO- VOLTAIC MOUNTING SYSTEMS Ensure that the installation follows a plan drawn up by a professional. In particular, the configuration of the mounting system (selection of materials and components, width, thickness of fastening elements) must be appropriate for the site conditions (snow and wind loads, roof and module tilt angle, other factors such as atmospheric and chemical stress and, if applicable, earthquakes). For installations on buildings, all personnel must adhere to the relevant building regulations; among others these include the technical regulations of the roofing industry and the timber construction industry (DIN EN 1995 among others) and the steel construction industry (DIN EN 1993 among others). The structure must be able to withstand the additional load of the PV system. If there are no exact planning guidelines available, the manufacturer or the user can generate a design for the mounting system using software. However, such measures are merely non-binding recommendations and are no substitute for a plan drawn up by a professional engineer. Before beginning the installation, check the plausibility of the structural design in relation to the local conditions. Ensure that the conditions of use specified in these installation instructions are adhered to. Take into consideration the installation guidelines for the other system components, e.g. modules, cables, plug connecters and inverters. When installing the cabling, you must comply with the relevant VDE guidelines and electrician industry safety regulations, as well as the manufacturer s instructions regarding the modules, cables, plug connectors and inverters being used. SPECIFIC SAFETY INSTRUCTIONS FOR WOR- KING ON ROOFS Secure the construction site to prevent unauthorised access. Safeguard the roof working space if the eaves height is 3 metres or more. Among other measures, this involves the installation of a personal fall protection system. If a fall protection system cannot be used for practical working reasons then a safety net for falling persons must be installed. If the installation of a safety net is impractical then a safety harness connected to suitable safety anchoring points may be used. However, this is only permissible for short-term work. Secure all objects on the roof against falling. The ground underneath the safety net must also be cordoned off. Check the load bearing capacity of the roof surface, the roof structure and other building components that will have to bear the weight of personnel or materials during the installation. 05

6 06 SPECIFIC SAFETY INSTRUCTIONS FOR WOR- KING ON ELECTRICAL SYSTEMS Observe the relevant VDE regulations and guidelines. Be especially sure to observe the following instructions: Even at low levels of solar irradiation, photovoltaic modules generate significantly high voltages and series connections of several modules are designed for voltages of up to 1,000 volts. Touching open connectors can therefore increase the risk of an accident or even cause life-threatening electric shocks. For this reason you should establish the series connection of the modules as late as technically possible during the installation process, avoid lying or hanging cables and plugs and secure open electrical contacts against being touched. High DC currents flow in the circuits connected to photovoltaic modules and disconnecting these circuits can result in life-threatening arcing. Do not connect these circuits, e.g. to the inverter or generator junction box, until installation of the framing and modules has been completed. Always use the appropriate circuit breaker at the inverter or generator junction box to disconnect this circuit, e.g. for maintenance purposes. Do not perform any electrical connection work with moist or wet cable ends, sockets or plugs. Only install the modules under dry weather conditions. classification OF DANGER NOTICES INTO DANGER CLASSES Dangerous situations are identified using corresponding danger notices in these installation instructions: Danger classes as per ANSI Z DANGER indicates a directly dangerous situation that can lead to death or serious injury if not avoided. DANGER WARNING indicates a possibly dangerous situation that can lead to death or serious injury if not avoided. CAUTION indicates a possibly dangerous situation that can lead to light injury if not avoided. CAUTION attention refers to a situation that may lead to material damage if not avoided. ATTENTION

7 PRODUCT DESCRIPTION / AREA OF APPLICA- TION Hanger bolts can be used for roof structures made of trapezoidal sheeting, corrugated sheets, sandwich elements or corrugated fibre cement panels with any roof pitch on purlins made of wood. Depending on the conditions on site, purlin intervals of over 3 m can be covered. The GPS1 is an adapter element for fastening mounting rails to hanger bolts, wherein one hanger bolt is used for each rail fastening point as a connecting element to the roof. On the GPS1, PV mounting systems can be structured as a single-layer or dual-layer (intersecting) design. With the single-layer system, the PV modules are directly fastened to the mounting rails with module clamps, preferably in landscape position. In the intersection, either insertion rails or a further level consisting of mounting rails lie horizontally over the mounting rails. As a result, all standard PV modules can be mounted in portrait and/or landscape position. Depending on the shape and pitch of the roof, wind suction loads > 2,400 Pa (as per EN ) can occur on the roof edges and corners in regions of wind zone 3 or more, and most PV modules are not certified for this. Check this information for every project and, if in doubt, do not install on the roof edges and corner regions. Hanger bolts and solar fasteners on roofs covered with corrugated fibre cement bituminous roofings apply higher loads to purlins and rafters, as these have to carry the entire bending momentum. Therefore the roof construction should be examined carefully by a professional on site. Older fibre cement roof coverings (corrugated profile, tiles) can contain asbestos. Working on these materials (drilling, cutting, screwing) or even cleaning them can release asbestos fibres. These fibres are extremely harmful, and can cause potentially fatal long-term damage. As a result, only qualified specialist companies may work on these roofs, and all work must comply with strict requirements. FIRE HAZARD DUE TO ELECTRIC ARCS As a result of the high voltage, electric arc discharges of several hundred volts may occur on the DC side of the PV system s wiring due to poor electrical bonding or damaged insulation. The high temperatures generated by the arc can cause a fire. Bitumen-based roofing products have proven to be particularly prone to this risk. Therefore, special care is required to ensure both proper plug connections and a protected installation of string cables on roofs with bituminous membranes or tiles. Further sensible measures include keeping a safety distance from the roof cladding (for example, by attaching plugs and cables to the rails of the PV system), and appropriate protection mechanisms (for example, enclosed metal cable ducts). A periodic review of the condition of the wiring during maintenance work is necessary. CORRECT EDITION OF THE INSTALLATION IN- STRUCTIONS The mounting systems from Creotecc GmbH are continuously improved and optimised. Therefore installation procedures can change at short notice. Please compare the printed installation instructions with the currently valid instructions available on our website at www. creotecc.com. If you do not have access to the internet, we would be happy to send you an up-to-date printed copy of the instructions upon request. If you encounter any difficulties during the installation process please do not hesitate to contact us. by Creotecc GmbH 07

8 MATERIAL SYSTEM COMPONENTS ITEM ITEM NAME + NUMBER DESCRIPTION 1 STH M10x200 GPS Hanger bolt A2 for wood, base plate pre-mounted 2 RL ALUVER Standard Mounting rail 30x50, length AVS PC1-Set CMC-M Connector set for RL AluVer Standard Module middle clamp, CITO mm, packing unit: 20 5 CMC-E Module end clamp, CITO mm, packing unit: 25 6 CMC-DS Module end clamp spacer, CITO mm, packing unit: 25 MATERIAL OPTIONAL COMPONENTS ITEM ITEM NAME + NUMBER DESCRIPTION 7 TOP AV Standard End cap for RL AluVer Standard

9 TOOL REQUIREMENTS ITEM ITEM NAME + NUMBER DESCRIPTION A On-site Open-end wrench, size 15 mm B On-site Tape measure C On-site Chalk line D On-site Folding ruler 09 E On-site Electric screwdriver F On-site AW 30 bit G H SNL BIT 1/4 6KT, 1/2 4KT mm Hex socket, 76 mm long, 1/2 drive Adapter 1/4, hexagonal to 1/2, square, Cr-V steel, grey sandblasted

10 Static load design To calculate maximum rail spacing, minimum fixation density, rail lengths to be cut, and a bill of materials for an individual project, please use our dimensioning software CREOTOOL whenever possible. Contact our sales team if you need support in case of non-standard mounting solutions that cannot be designed using CREOTOOL.

11 1 STH M10x200 GPS1 5 CMC-E RL ALUVER Standard 6 CMC-DS AVS PC1-Set 7 TOP AV Standard 11 4 CMC-M HANGER BOLT SIZES The correct hanger bolt is selected depending on the load conditions and the height of the roof cladding. total HEIGHT OF ROOF CLADDING up to 60 mm CORRECT HANGER BOLT M10x200 up to 50 mm M12x mm M12x mm M12x300

12 LF BF 5 m Hypotenuse MEASURING THE ROOF Mark the areas on the roof that will be covered by each continuous module array. Calculate the length and width of the field using the formulae LF = (module length + 20) x number of modules 20; BF = (module width + 20) x number of modules 20. [all dimensions in mm] 3 m Leg 4 m Leg TIP: You can measure an accurate right-angle using a sample right-angled triangle with sides of length d Check the PV module documentation to determine the points on the module where it must be clamped. Typical clamping points are on the long sides and lie at a distance d from the frame corners, where d = 1/4 to 1/5 of the module length. d Mark the positions of the clamping points for the lowest row of modules at the sides of the module array (minimum clearance to lower roof edge: 80 mm). Using a chalk line (item C), plot out the correct distribution on the roof.

13 POSITIONING THE HANGER BOLT To enable you to mount the hanger bolts (item 1) correctly and according to the configuration plan, you must if necessary remove roof fastening bolts at the relevant position, and then successively replace them with the hanger bolts. Drill according to the size of the hanger bolt. For hanger bolts with a metric thread M10, select the following diameter n 7 mm for the wood substructure, and n 13 mm for the roof cladding. 13 For hanger bolts with a metric thread M12, select the following diameter n 8,4 mm for the wood substructure, and n 14 mm for the roof cladding. Then screw the pre-mounted hanger bolts (item 1) into the bore holes tightly enough that the bolt does not protrude more than 100 mm out of the roof cladding. 100 mm Now align the clamping device in such a manner that the profile mount points in the required direction. For mounting which conforms to the standards, always take into account with the minimum distance of 3xd from the purlin s edge (d = diameter of the metric thread) and the minimum screw-in depth of 40 mm for hanger bolts with an M10 thread, or 48 mm for hanger bolts with an M12 thread.

14 MOUNTING THE HANGER BOLT Screw only to the dead stop position, at low torque and low speed. The EPDM seal under the screw head should only be lightly compressed but should not squash out from under the washer. Screws inserted at an angle do not provide sufficient holding force and are not watertight. 14 Only in case of large height differences between the clamping devices of the adjacent GPS1 and with a short distance between them should you compensate the height in this stage of the mounting process. Low height differences can be very easily offset in the final mounting stage. note: First check that you can implement the following mounting stages without any problems arising, and as far as possible, only compensate any height differences in the final mounting stage.

15 INSTALLING THE RAILS First place the mounting rail on the base plate of the GPS1. Spring Base plate click Now, with a sweeping movement, latch the mounting rail into the clamping device of the GPS1 which is pre-tensioned using spring force. A click -sound assures you as an additional acoustic signal that the rail has latched into place. 15 Clamping profile Check that the clamping profile is sitting correctly in the groove of the mounting rail. Ensure that the mounting rail is tensioned between the base plate and the clamping profile, and that there is no slack (marked circle in adjacent illustration).

16 CONNECTING THE MOUNTING RAILS Slide the connector (item 3) halfway into one of the rails to be joined (item 2) and fasten it in position using a self-drilling screw. For this purpose, position the self-drilling screw (item 3) in the side drill groove of the rail so that the screw can easily penetrate the connector. 16 Slide the other rail (item 2) fully onto the connector (item 3) so that no gap remains between the rail segments. Fasten the second rail to the connector as described above. NOTE: The connection is rigid and does not function as an expansion joint. Connect all rails in the manner described. Fully installed rail level. Do not create rigidly connected rails to a length greater than 12 metres to avoid damage caused by heat expansion of the aluminium. After 12 metres, create either a maintenance gap or fasten the connector only on one side to create an expansion gap; note that in the latter case no module may then be positioned over this expansion gap.

17 fastening THE CLAMPING DEVICE - WIT- HOUT HEIGHT COMPENSATION Using a long nut (item H/G), tighten the nut above the clamping device. FASTENING THE CLAMPING DEVICE - WITH HEIGHT COMPENSATION A lesser height compensation of up to 5 mm (spring travel) is achieved by moving the nuts above and below the clamping device towards each other as required. 17 A greater height compensation is achieved when the nuts above and below the clamping device are turned in the same direction. Fasten the clamping device with a torque of between 20 and 25 Nm. The nut above must always be positioned in its entire thread length on the thread of the hanger bolt. Then check that the clamping profile is sitting correctly in the groove of the mounting rail.

18 MOUNTING THE MODULE CLAMPS First fully assemble the end clamps. To do this, slide a spacer (item 6) sideways into each end clamp (item 5). 18 Position the module clamp (items 4, 5 and 6) on the ALUVER rail (item 2) and press into place until the slot nut latches into place in the slot with an audible click. click Slide the module (end clamp) or both modules (middle clamp) right up to the clamp so that no gap exists between the clamp and module, then align accordingly. Tighten the module clamp (items 4, 5 and 6) using an electric screwdriver (item E) and AW 30 bit (item F) to a maximum torque of 15 Nm. Take note of the instructions provided by the module manufacturer with regard to the clamping position.

19 installing THE MODULES Fit the end clamps (items 5 and 6) to the outermost ALUVER rails. Ensure that the clamps latch correctly into the rails (spring mechanism). Position the first module on the ALUVER rails (item 2). The module must lie flat on the surface of the rails. Fasten the end clamps. Fit the middle clamps (item 4) to each ALUVER rail (item 2). Ensure that the clamps latch correctly into the rails. 19 Fit and fasten the remaining modules step by step in the same manner. Then refasten the end clamps to the last module in each row.

20 Installing the TOP AVS Terminate the connected rails using the optional cover caps (item 7), if required. Finished installation. 20

21 21

22 22

23 MAINTENANCE The following maintenance requirements must be adhered to: Have the photovoltaic system checked annually by a specialist photovoltaic company to confirm the full functionality and mechanical stability of the system. In addition to a visual inspection of the mounting system, especially the tightness of the screwed connections and the watertightness of the roof cladding are to be checked. The safety instructions and all other specifications in these installation instructions must be adhered to for all work on the mounting system and the DC cabling. The installation instructions also apply in principle to any removal work, in the reverse sequence where applicable. Especially the DC electrical connections must never be disconnected while under load (danger of arcing) and the current must always first be switched off via the circuit breaker in or on the generator junction box or inverter. 21 In particular on roofs with a bitumen roofing, it is necessary to ensure the proper and safe condition of the DC side wiring due to the risk of fire caused by arcs. In particular, hazards include defective plug connectors and damaged insulation, and any circumstances that favour the occurrence of such damages.

24 Ma HANGER BOLT Art.-Nr Stand Creotecc GmbH Bebelstraße Freiburg Tel.: Fax: info@creotecc.com