BiPv 2-11 Mounting Instructions

Transcription

1 BiPv 2-11 Mounting Instructions In-roof system for unframed modules General information The in-roof BiPv 2-11 system was designed for frameless modules and can be applied as a defi ned section of an existing roof or as a complete roof covering of a new building. Modules are integrated into the existing roof surface and can be combined with conventional roofi ng tiles. Systems are custom-built and module sizes are compiled to customer specifi cations. A complete roof covering can be planned in advance with an architect. The system can also be applied to large roofs and can be mounted to industrial roofs with the additional deployment of a water-stream plate. Linear thermal expansion is counteracted by spring elements placed between the individual modules. This mounting instruction: This document offers information relating to the mounting of solar energy plants with the BiPv 2-11 system. Activities outlined in this instruction should be carried out exclusively by specialist personnel. Please read the instruction carefully and take note of all recommendations. Schletter GmbH accepts no liability for damage caused through failure to observe these instructions. Please also reference instructions relating to other components which make up the overall system. CONTENTS PAGE 1. Overview Preparing the roof surface Eaves-side cladding Mounting the base profi le Module mounting Verge-side cladding Ridge-side cladding Eaves ventilation / optional 22 1 / 22

2 Safety instructions The planning, mounting and commissioning of a solar energy plant must be undertaken, exclusively, by qualifi ed personnel. An unprofessional execution of the project can lead to damage to the plant and place people in danger. Please work professionally and accurately! Untidy work can compromise system impermeability and damage the modules. Do not stand on the profi les! Damage to components can compromise system impermeability and can lead to malfunction of the modules. Do not damage rubber seals! Soiled or damaged rubber seals can compromise system impermeability. Risk of electric shock! The mounting and maintenance of solar modules must be carried out exclusively by qualified specialists. Please observe the manufacturer safety regulations! 2 / 22

3 Components - Cover profiles Cover profi le Item no with seal Item no and end cap lower Art.-Nr and end cap upper Art.-Nr Ejot Screws - SUPER SAPHIR Drilling screw JT Item no. JT x50-E16/2 Approval Z Z Würth Panhead AW drive Item no Würth Panhead AW drive Item no Approval Z ETA 10/0184 Ejot Screws - SUPER SAPHIR Drilling screw JT Item no. JT x50-E16/2 Item no. Schletter: Würth Pan head AW drive Item no Item no. Schletter: Würth Pan head AW drive Item no Item no. Schletter: / 22

4 Components - Frame structure Conical plug-on profi le Item no with seal Item no Cross profi le Item no with seals Item no Item no Eaves cross profi le Item no with seal Item no Base profi le max. Item no Base profi le Item no Mounting claw BiPv 2-11 Item no with plastic inlay Item no Fastening lug Item no Module end-stop with molded rubber piece Item no Inlay batten, Aluminium or PE Item no Metal sheet mounting profi le Item no / 22

5 Flashing (available as option) Eaves apron fl ashing right Item no Eaves apron fl ashing left Item no Eaves apron fl ashing central Item no Joint connector eaves-side Item no Sealing tape Item no Side fl ashing right Item no Side fl ashing left Item no Side fl ashing eaves-side right Item no Side fl ashing eaves-side left Item no Edge fl ashing verge-side right Item no Edge fl ashing verge-side left Item no Edge fl ashing eaves-side right Item no Edge fl ashing eaves-side right Item no Hooked fastening bracket Item no Roofi ng nail Item no Ridge corner sheet Item no Ridge corner sheet left Item no Ridge sheet central: no sculpted corners Item no Joint connector ridge-side right Item no Joint connector ridge-side left Item no Joint connector ridge-side central Art.-Nr Self adhesive foam wedge Item no Eaves ventilation plate Item no / 22

6 Section view Roof breadth: Module width Module width Distance between axes = module breadth + 24 mm Distance between axes = module breadth + 24 mm Total breadth of system Detail A Detail A Basic profi le Side cladding Total system breadth Side cladding + (support distance x no. modules) + side cladding 215 mm + ((module breadth + 24 mm) x no. modules) mm 6 / 22

7 Roof length: System total length Basic profile length = ((module length - 1 mm) x number of modules) + 42 mm System total length Eaves dimensions + basic profi le length + ridge dimensions 270 mm + ((module length - 1 mm) x number of modules) mm Module length - 1 mm Module length - 1 mm Reference edging Support width acc. to struct. analysis Support width acc. to struct. analysis Support width acc. to struct. analysis See 3) See 4) See 2) Reference edge See 1) Reference edge Reference edge Reference edging 1) Align underside of reference battens, to upper side of tile edge, with a projection of 270 mm.. 2) Existing roof battens can be used (min. 30 x 50 mm). Ensure the battens are suffi ciently secured. 3) In the event that auxiliary battens are deployed, the structural width must not exceed the support width specifi ed in the structural analysis. When using the existing battens, ensure these are suffi ciently secured. 4) Auxiliary battens (min. 30 x 50 mm) required for formation of an expansion fi xed point Number according to structural regulations. 7 / 22

8 2. Preparing the roof surface Opening the roof Please open the covering to the existing roof. The breadth of opening required can be referenced in the accompanying mounting plan and relates to the module width + rail width + fl ashing Check that the roof battens are secure! It may be necessary, according to the mounting plan, to check and tighten the roofi ng battens. The application of a permeable underlay is recommended to mitigate the risk of damage due to moisture from dew and condensation. Please refer to the existing insulation design! Checking batten distances and set reference points If batten distances are too great, please add additional battens in accordance with the mounting plan. In new constructions: Batten distances in accordance with work plan. Reference point on eaves-side reference batten: Distance from the upper edge of the last covered roofi ng tile to the reference batten: 270 mm. See page 5, Covering length. Reference batten First exposed batten Last roofi ng tile 8 / 22

9 Establish the ridge-side fix-point The ridge-side fi x-point is determined from the base profile length and / or from the mounting plan. Arrange additional roofi ng battens for the length expansion fi x-point. These must be of the same thickness as the existing roofi ng battens. For greater roof inclines, please reference the supplied mounting plan to establish the fi x-point Fix-point Dividing up the roof Measure out and plot the central axis for the base profi le on the roof battens. We recommend using snap-lines for precision. Module width + spacing in accordance with the mounting plan The parallelism and perpendicularity of the opening must be maintained! Diagonal measurements should be taken for verifi cation. Mark points 30 mm to both the left and right of the central axis identifi ed with snap-lines. These points will mark the exterior edges of the base profi le on the roofi ng battens. Measure up dimensions for side cladding Establish an exterior positioning point for the cladding by measuring distances, according to the mounting plan, from the central axis outwards at both verge-sides. Distance: Distance to the exterior edge of the side cladding: 215 mm See Side View, Cover Width, Detail A. Laying connection cables (according to electrical plan) Lay connection cables to the inverter and feed these through the roof substructure. Cables must be laid tension-free. Ensure that cables are not crushed. 9 / 22

10 3. Eaves-side cladding Arrange the eaves apron cladding The aluminium pleated tape attached to the apron cladding is fragile and is therefore folded to the back for transport purposes. Do not open out to the front until shortly before mounting. Reference batten Hang the eaves apron cladding with the vertical edge to the reference batten. Do not adjoin the alu-pleated tape yet. Alu pleated tape Fastening the apron cladding Fasten the apron cladding in stages. Leave a space of approx. 20 mm between individual panels. Close the joins with joint connectors by sliding the connector upwards into the side seams of the apron cladding. Fix the self-adhesive sealing strip fl ush along the entire upper edge of the apron cladding and across the joint connectors to create a wind brake. Applying alu pleated tape Remove the protective strip from the self-adhesive alu pleated tape. Apply the self-adhesive alu pleated tape. 10 / 22

11 4. Mounting the base profile Positioning the base profile Align the base profi le to the edge of reference and according to the previous elevation. The lower edge of all base profi les must be exactly aligned to the eaves-side edge of reference of the apron cladding. Reference edging Preparing mounting claws Insert plastic inlays into mounting claws as shown. Fastening base profiles Fasten base profi les to the roofi ng battens with mounting claws, using drilling screws. Please refer to the mounting plan for arrangement and number of mounting claws. Position the eaves-side holding claw approx. 1 cm higher than the edge of reference. Eavesß-side, claws should not be applied due to the side cladding. Reference edging Potential equalization Where required, the potential equalization cable with ring-eyelet, is attached, eaves-side, to the base profi le using a drilling screw. Potential equalization Attach base profile to ridge-side fix-point Fastening the plant to the ridge-side fix-point prevents the plant from sliding. Fasten the base profi le to the fi x-point with additional drilling screws from the sides. Additional screws Refer to fastening plan for number of additional drilling screws required 11 / 22

12 Fasten the eaves cross-profile to the base profile Position the lower edge of the eaves cross beam fl ush with the front - eaves-side - of the base profi le. fl ush alignment! Base profi le Rubber Eaves cross-profi le These surfaces at the same level! Use drilling screws to secure the eaves crossprofi le with fastening lugs to the base profi le. Mount module end-stops Module end-stops prevent the fi rst module row from sliding. Clearance Assemble by inserting end-stops one after the other, left and right, into the eaves cross-profi le. Module end-stops are not required at the verges. Module end-stops must only be mounted in the fi rst horizontal row. Please ensure the ultimate precision when working! Once the base profi les are mounted with the respective spacing (module length + 24 mm), a clearance of 2 mm is added between the cross profi le and the base profi le. Mount rubber moulds Mount rubber moulds on the end-stops to protect module edges. 12 / 22

13 Insert conical plug-on profile Position the conically formed plug-on profi le centrally on the base profi le, in the fi rst horizontal module row. The conical plug-on profi les should be positioned against the eaves cross-profi le such that the higher ends of the double-track face to the eaves. The conical plug-on profi les are delivered with an inlaid rubber seal. The rubber seals are found on both sides of the seal and have a projection of approx. 20 mm Please leave this projection! Insert the cross profile Position each cross profi les against the upper ends of the conical plug-on profi les. Position the cross beams such that the track with the premounted rubber seal faces the eaves. Cross profi le Once the cross-profile with pre-assembled rubber seal has been positioned, leave clearance at each end of the base profile of 2 mm. Please ensure the ultimate precision! Last opportunity to fine-tune alignments! The lower seals on the cross profi les are pre-assembled at production. The upper seals are added as the modules are mounted. Repeat the two previous steps (insertion of the plug-on profi les and alignment of cross-profi les) upwards, in horizontal rows, for the entire system. Ridge-side boundary At the ridge-side boundary, the cross-profi le is fastened with holding claws using drilling screws as at the eaves. 13 / 22

14 5. Module mounting Please ensure the correct working orientation: Mounting of the modules themselves begins at the eaves edge and is effected in horizontal rows. Lay the first row of modules Align the fi rst horizontal row of modules with the lower edges to the module end-stops. Please ensure that no cables are trapped or crushed when mounting modules. Cables must be laid tension-free. Similarly while laying electric cables, these must be protected from mechanical tension. Bind cables together with wires where necessary. Connect modules to the grid Connect modules to the string cables and network the modules themselves together. Plug connections must always be fully locked. The polarity of the solar modules must be taken into account. An incorrect polarity can result in damage to the modules. Never remove or insert plugs under load current. 14 / 22

15 approx. 2 mm clearance Align the upper edge of the module to the crossprofi le. Leave approx. 2 mm clearance at the upper edge for the application of cross-profi le rubber capping Apply upper cross profile rubber capping Uncut lengths of capping rubber are applied to the upper cross profi les. If a joint is necessary, this must be effected to the centre of the base profi le. Repeat this process until the fi rst module row is complete. 15 / 22

16 Cover profiles Cover profi les are delivered complete with upper and lower end caps and seals. Holes are bored into the cover strip in preparation for the drilling screws. Upper end cap Lower end cap Buffer Correct arrangement of cover profiles. Position cover profiles against the upper conical plug-on profiles and align centrally on the lower conical plug-on profiles. The upper end-cap bridge is the end-stop for the next plugon profi le. The upper cover profi le end caps serve as an end-stop to the next module row and prevent panels from slipping. There is also a defi ned overlap of the cover profi les. Secure cover profiles Fasten cover profi les with drilling screws. A notch for the screw-tip is made in the profi le to allow for precise centering of the drill-hole. Drilling screws: TORX T25 Tightening torque: maximal 5 Nm The cover profi le must be pressed down forcefully while screwing to avoid the profi le lifting momentarily as the screw is inserted. Do not apply cover profi les to the verges yet. These are only then applied when fastening the fi nal cladding. In the event of interruption to the mounting process, the cover strips should be mounted temporarily to the verges for safety. 16 / 22

17 Add further module rows Once the fi rst horizontal row has been mounted, repeat the previous steps for each further horizontal row. When mounting the modules, please ensure that each panel is placed with the lower edge against the lower cover profi le capping of the previous row. This capping serves as a buffer and prevent the modules arranged above from slipping. Arrange cover profiles to overlap. Mounting as outlined in previous steps. No module end-stops are required at the verges. These are only then applied when fastening the fi nal side-cladding. In the event of interruption to the mounting process, the cover strips should be mounted temporarily to the verges for safety. Position top cover profile An end-stop is not mounted with the topmost cover profi le. The top module row must nevertheless overlap the cover profi les at the lower end, in the same way as with previous rows. Ridge-side termination Sheet metal mounting rails For verge-side cladding, arrange the sheet metal mounting rails between the cover profi les and align with the profi le fi n here (see image). The rail is hereby pressed against the rubber seal of the topmost cross profi le. Sheet metal mounting rails are delivered predrilled and are screwed to the topmost cross profi le, through the seal, with drilling screws. Align the sheet metal mounting rail fi n here. Screw here 17 / 22

18 6. Verge-side cladding Position side cladding In order to ensure outfl ow of water, you must work from bottom to top. The fi rst cladding piece is custom-assembled. All further side cladding sheets are delivered to a standard length. The topmost side cladding sheet is angled verge-side. folded side Slide the side cladding, eaves-side, under the folded edge of the eaves apron cladding and fasten. Projection 35 mm Secure side cladding using adhesives and roofi ng nails. 18 / 22

19 Overlapping All further side sheets must be mounted with an overlap of at least 15 cm. Secure the side sheets using adhesives and roof nails at distances of approx. 1 m. Mounting of the overhang flashing Mount the right-angled inlay battens on the rubber seals of the plug-on profi le. Inlay battens Mount edge fl ashing on the inlay battens. Edge fl ashing Mount cover profi le and secure with drilling screws as outlined above. The edge fl ashing is now secure. Be aware of the upper end-cap piece. 19 / 22

20 7. Ridge-side cladding Begin with the ridge corner sheet Slide the ridge corner sheet under the folded edge of the side cladding. In so doing, the upper edge of the sheet must be positioned on the roof batten. The roof battens may need to be extended. Upper edge Folded side Slide ridge corner sheet and ridge sheet upwards and under the metal sheet mounting rails as far as the end-stop. The hollow seam of the ridge- and ridge corner sheets must be slide under the sheet hanging rails. Position the remaining ridge sheets and feed these into the hanging rails. In doing so, centre the distances (approx. 20 mm) between the ridge fl ashing sheets along the length of the cover profi les. Close the remaining joins with the joint connectors. 20 / 22

21 Fasten ridge sheets and joint connectors using adhesives and roofi ng nails. As a precaution, pull the ridge sheet upwards once again, to the end-stop. Fix ridge-side ventilation sheet to the upper edge using adhesives to prevent slipping. Fix self-adhesive foam wedges (Meterware) ridge and verge-side to the edge fl ashing as a wind-brake. Position foam wedge in the cavity area beneath the tiles. 21 / 22

22 8. Eaves ventilation / optional Mount eaves ventilator Begin with the left-hand eaves ventilation plate. Slide the eaves ventilation plate from below into the eaves cross profi le. Slide the remaining ventilation plates similarly from below into the eaves cross profi le, slotting each, respectively, into the existing ventilation plate. slot slide Align each eaves ventilation plate with its respective designated drill-hole and use drilling screws to secure each to the eaves cross profi le. Finally, relay the roof covering from the exposed area as far as the module fi eld. Smooth out standing seams if required, however, please ensure that water-fl ow is not affected in so doing. Rework individual roofing tiles as required. For further information relating to our systems, please refer to our website: under Downloads in the Solar section. Schletter GmbH, 2012, I400200DE, V3 22 / 22