00MK-MA0160-EN00 Mounting System ASSEMBLY INSTRUCTIONS Little Plan and Little Plan Light systems, for corrugated sheet metal roof Rev.02 November 2014
Table of contents General instructions 2 General safety instructions 3 Little Plan and Little Plan Light systems, for corrugated sheet metal roof 4 Regulations 5 Components required 6 Tools required 8 Assembly instructions 9 Notes 12 Table of contents 1
General instructions Ensure you observe the general fitting and maintenance prescriptions. If you need any clarifications, please call immediately our customer service at number +39 011 19870791. 1.Thesan Mounting System is constantly evolving and may therefore be subject to changes; before starting, check the version of the assembly instructions in your possession and, if it is not up to date, send a request for an updated version to info@thesan.com. All personnel on work site must have a copy of the assembly instructions. 2.The 12-year warranty is assured by our warranty certificate subject to compliance with assembly instructions, general instructions and general safety prescriptions provided by Thesan S.p.A. 3.In case of non-compliance with the assembly instructions, or are not used the parts listed, the warranty is void and Thesan declines all liability. 4.To disassemble the system, perform the assembly steps in reverse sequence. 5.Follow the instructions of the manufacturer of PV modules and the manufacturer of inverters. 6.Is necessary to provide routine maintenance on all parts of the plant, on a regular basis (maximum each 6 months). Visual inspections: Atmospheric events damages Dirt, musk and other deposits Corrosion of metal parts Stability of the structure Sealing of the roof cover Mechanical inspections: Check the tightness of nuts and, if necessary, retighten the nuts to the torque given in the assembly instructions The areas under the modules are more prone to becoming dirty, so remove all the deposits during the routine maintenance. General instructions 2
General safety instructions Ensure you observe the general safety fitting and maintenance prescriptions. If you need any clarifications, please call immediately our customer service at number +39 011 19870791. 1.Fitting and commissioning of the systems must be carried out exclusively by skilled personnel who, thanks to their specific training or professional experience, are able to ensure that the work is performed correctly and to high standards. 2.The existing structures on which the system is to be fitted must be checked to ensure that the loading capacity of the building/structures is adequate. 3.Observe all regulations and local and national building regulations, and provisions relating to the environment. 4.Observe all regulations and national laws and local regulations regarding health and safety, accident prevention and the requirements of professional associations. In particular, it is necessary: Wear personal protective equipment: safety helmet, safety gloves, safety shoes, etc. If the system is to be fitted on an elevated surface comply with safety regulations for work at heights by using safety harnesses, falling objects signs, etc. At least two people must be on the work site during the fitting procedures, so that one person can provide first aid or call emergency services in case of accident. 5.Efficient grounding system is essential. If necessary, use the lightening protection devices. 6.You can not cut the mounting rails. In the event that Thesan S.p.a. Technical Dept. requires to cut the profiles, depending on the specific project to be carried out, you must make sure to remove the burrson the surfaces affected by the cut in order to eliminateany possible risk of injury. Also you need to make surethat the cutted rails are not curvy. 7.The electrical installation must be carried out exclusively by skilled personnel who, thanks to their specific training or professional experience, are able to ensure that the work is performed correctly and to high standards. The wiring of the photovoltaic modules must be made to avoid the possible creation of loops. General safety instructions 3
Little Plan and Little Plan Light systems, for corrugated sheet metal roof FEATURES OF THE SYSTEM Reduction of the amount of aluminium on the cover and reduction of weight on the roof. Easier, faster and cheaper transport and handling. Faster assembly. Thanks to the significant reduction in the number of components, Thesan Mounting System allows a reduction of approximately 57% in the amount of time required to fit the photovoltaic panels, compared to similar mounting systems of key competitors. Robustness, practicality, and reliability over time are key characteristics of the system. Suitable for photovoltaic modules with and without frame. Thesan is leader in guaranteeing, on request, a reliable and efficient after-sales service, which is at customers disposal for any requirements. All Thesan Mounting System documents are available at: www.thesan.com For any need or clarification you may required, please contact our customer service: tel. 0039 011 19870791 e-mail ufficio.tecnico@thesan.com Little Plan and Little Plan Light systems, for corrugated sheet metal roof, are a not pre-assembled mounting system for photovoltaic modules. In order to ensure safe and proper fitting of the system, each step described in these instructions must be carefully and accurately followed. At each step, necessary materials and equipment are listed. For any inconvenience or misunderstandings please call immediately our customer service. Little Plan and Little Plan Light system, for corrugated sheet metal roof 4
Regulations The installation of the system have to be performed in accordance to the following regulations, or similar standards which are being used in the region of installation. The quality level of the standards need to be equal or higher as the standards which are mentioned. BGV A1 BGV A3 BGV C22 DIN EN 62305 DIN VDE 0185 DIN VDE 0100 part 410 DIN VDE 0100 part 712 DIN VDE 0105 DIN VDE 0298 DIN 18338 DIN 18451 DIN 4102 DIN 18015 DIN 18531 VDS 2023 Eurocode 1 Eurocode 1 Eurocode 3 Eurocode 9 Accident prevention regulations General rules Power system and equipment Construction work Lighting protection Lighting protection Components Grounding Electrical installations of buildings Operation of electrical installation Application of cables and cords in power installations Roofing work Scaffolding work Fire behavior of building materials and building components Electrical installations in residential buildings Waterproofing of roofs Electrical installations in structural works with mainly flammable materials Wind loads Snow loads Design of steel structures Design of aluminum structures Regulations 5
Components Required ALTERNATIVE RAILS Little Plan Material: Aluminium Little Plan Light Material: Aluminium SO-AYP14L05-0000 (0,5 m) SO-AYP10L040-0000 (0,4 m) ALTERNATIVE TAPES ALTERNATIVE FASTENERS Self-drilling screw with seal Material: Stainless Steel Watertight rivet Material: Stainless Steel Adhesive and structural tape Adhesive EPDM tape Alternatives available: 0042-31400-0000 (5,5x25mm) 0042-31401-0000 (5,5x35mm) Alternatives available: SOST-V228-00SP (4,8x10 mm) SOST-V229-00SP (4,8x16 mm) SOST-V230-00SP (6,4x20 mm) SOST-V501-003M (25mmx33m) SOST-V502-003M (30mmx30m) Components Required 6
CLAMP SETS Clamp sets for frameless modules Material: Aluminium Clamp sets for modules with frame Material: Aluminium Depending on the type of module, refer to the general catalogue. Depending on the type of module, refer to the general catalogue. Clamps for modules with frame Material: Aluminium Depending on the type of module, refer to the general catalogue. CLAMPS Hammer head screw, M8 Material: Stainless steel Alternatives available: SOST-V209-00TH (M8X30mm) SOST-V206-00TH (M8X36mm) SOST-V210-00TH (M8X42mm) Nut with safety fit, M8, (DIN 6923) Material: Stainless steel 0042-80500-0000 OPTIONAL Other accessories available on request. Consult the general catalogue. For the possible use of alternative components contact Thesan S.p.a. technical department at ufficio.tecnico@thesan.com Components required 7
Tools Required Wireless screwdriver Insert n 8 and n 13 for screwdriver Riveter for diameters 4,8 and 6,4 Torque wrench Mark line cord Metric tape measure Level Tools Required 8
Assembly instructions Step 1 Preliminary checks a. Check the design measurements on the roof on which the system is to be fitted. b. Provide a minimum distance of the rails from the edge of the roof of 500 mm. Step 2 Alignment a. Use the line marker cord to trace the positions where to apply the tape. You can use two different kind of tape: - adhesive and structural tape - adhesive EPDM tape The kind of tape and the distance will be determined by Thesan Technical Dept. (or Thesan configurator software) depending on the specific project to be carried out. In case of different assembly solutions the warranty is void. Step 3 Applying the adhesive tape a. Make sure that the metal surface where the tapes are to be applied is clean. If there are traces of dirt, remove any residual particles with a rag soaked in an oil-free cleaner. b. Cut the tape into lengths of approx. 10 cm. c. Remove the protective film from the tape and apply the latter, with a slight pressure, to the support surface at the distance indicated by Thesan Technical Dept. Assembly instructions 9
Step 4 Positioning the Little Plan or the Little Plan Light mounting rails You can use two different kind of rail: - Little Plan - Little Plan Light The kind of rail will be determined by Thesan Technica Dept. (or Thesan configurator software) depending on the specific project to be carried out. a. Position the mounting rail aligned with the tape, taking into account the trace previously made with the line marker cord in order to ensure correct alignment of the rails. b. Place the self-drilling screws with seal, one on the left side and one on the right side of the rail, close to the previously applied tapes. Fasten it to a maximum torque of 4 Nm. c. We recommend the installation of this system on corrugated metal sheets with a thickness exceeding 0,5mm. In the case of corrugated metal sheets with a thickness of less 0,5 mm use watertight rivets instead of self-drilling screws with seal, with the same criterion described above. The type and the numbers of fasteners, and the related application distance will be determined by Thesan Technical Dept. (or Thesan configurator software) depending on the specific project to be carried out. In case of different assembly solutions the warranty is void. Step 5 Positioning and fixing the photovoltaic modules If the clamps you are using are not preassembled, insert the hammer head screw in the specific opening in the upper side of the mounting rail, turn the screw of 90 clockwise, position the clamp and partially tighten the nut with safety fit. Upper side Bottom side Attention: Follow the instructions of the manufacturer of the PV modules a. If pre-assembled clamp sets are used, insert the hammer head screw into the specific opening in the upper side of the mounting rail, press the clamp gently to turn the screw of 90 clockwise. Make sure that hammer head screw is in an orthogonal position respect to the rail, and that the spring of the clamp makes completely adhere the hammer head screw to the rail. b. If the PV module is mounted landscape, the long side of the clamp must be in longitudinal position respect the mounting rail, if instead the PV module is mounted portrait, the long side of the clamp must be in orthogonal position respect the mounting rail. c. Position the photovoltaic module and fully tighten the nut with safety fit to a torque of 14Nm. d. Ensure the correct position of the clamp compared to the frame of PV module. The vertical walls of the clamp must adhere perfectly to the frame of the module: Middle and final clamps for PV module with frame Pre-assembled middle and final clamps for PV module with frame Module Rail Module Rail Assembly instructions 10
Step 6 Grounding system a. Efficient grounding system is essential. b. Fastened with a screw the ground wire at any point on the aluminium rail, using only stainless steel fasteners and components. c. Tighten the screw securely. Assembly instructions 11
Notes Notes 12
www.thesan.com Thesan S.p.A. - Via Torino 25-10050 Chiusa di San Michele (TO) Italy - tel. +39 011 19870791 - info@thesan.com 13