Mounting System MCG 3.0 Membrane-Connected Glass System description
SUNOVA MCG 3.0 System Fields of application: Not suitable for: (please inquire for other SUNOVA systems) The SUNOVA MCG 3.0 system is a lightweight fixation system for lightweight contstruction flat roofs without penetration The crystalline photovoltaic modules are installed at an optimum inclination of 20 to the roof. Being preassembled to a large degree, they are quick and easy to install. Standards and regulations The applicable standards and regulations must be observed. Newly-built or newly re-roofed roofs Existing FPO or PVC roof membrane on flat roofs with mechanical fixation Flat roofs with 1 to 5 degrees inclination Lightweight roofs weight-loading 11 kg/m 2 Crystalline framed modules Requirements for mounting on flat roofs Shed roofs, sloping roofs roof slope > 5 Roof areas with water retention up to the connection boxes or connectors Existing roofs with bitumen, EPDM, Evalon or other flexible waterproofing membranes Fully adhered roof systems Glass glass PV laminates 2 Observe the manufacturer s technical documentation and mounting instructions. If this system description differs in certain points from the manufacturer s documentation, these deviations apply only to the SUNOVA system described in this documentation. The installer (roofer and electrician) and the planner are responsible for ensuring that the general acknowledged rules of technology and the applicable safety regulations are observed. Disclaimer regarding information about product and system All data in our product information is based on our current knowledge and experience. Because of the wide range of possible influencing factors in the use of our products, the user must thoroughly inspect the application and strictly observe the installation and usage instructions. The product information does not represent legally binding assurances of certain properties or the suitability for specific applications other than those described in our product-specific documentation. The recipient or user of our products is responsible for observing any industrial property rights and applicable laws and regulations relating to the product and its use. In addition, our General Terms of Sale and Delivery and our Warranty Conditions apply. Gehrlicher Solar Business GmbH MCG 3.0 EN 08/12 Wind uplift according to DIN 1055 and relevant national standards In the MCG 3.0 system the wind uplift forces are transmitted to the synthetic roof membrane, which channels these forces through the mechanical fixation into the roof structure. The mechanical fixation and the synthetic membrane must be laid out according to DIN 1055. Snow load according to DIN 1055 and relevant national standards Snow loads must be reliably absorbed by the weight-bearing substructure. To ensure transmission of the load, the thermal insulation must be sufficiently stable under load. Synthetic membrane The synthetic membrane is an integral component of the system. The selected product must be of sufficient quality and durability. Roof membrane New Existing Supporting Str uctural verification according to DIN 1055, taking into consideration: substructure + 11 kg/m 2 mounting system MCG 3.0 Vapor barrier Design according to building construction; no change through the MCG 3.0 system Thermal insulation Tread-proof Compressive load at F p > 650 N (DIN EN 12430) 5 mm compression Synthetic Sarnafil TS 77-20 FPO or PVC membrane (recommended) Other waterproofing membranes are not suitable! Expected lifespan > 20 yrs. Fixation method Sika line-fixaton Point, seam or line fixation Synthetic (recommended) membrane Design and execution according to DIN 1055 only mechanical fixation permissible. Do not use fully adhered systems. Inclination range flat roof PV-modules 1 (recommended) 5 2% 9% Crystalline modules with frame Only SUNOVA-approved products
Snow load zones Structural design Snow loads The structural layout of the mounting system is determined to a large extent by the wind and snow loads acting on the installation. These outside influences on building components are defined by the DIN 1055 standard. The applied forces must be individually determined for each project and for the layout of the mounting system. For details, refer to the DIN 1055 standard. Please use the relevant standards for snow load and wind uplift in your country. The following factors affect the calculation of snow loads: Snow load zone Height above sea level Roof shape and inclination Position (special roof shapes) The snow load zones for Germany according to DIN are shown in the chart on the right. The snow load zone for flat roofs also depends on the installation s height above sea level. Important: For other roof shapes or inclinations the specifications according to DIN apply. Wind load The following factors affect the wind forces on the installation: Wind zone Height above sea level Roof shape and inclination Position (center/edge of roof) Terrain category (surrounding buildings) Height of parapet Wind load zones On request we can support you with specific calculations for the wind suction and thrust forces for your project. Based on this design analysis, the required number of rail fasteners is determined. Gehrlicher Solar Business GmbH MCG 3.0 EN 08/12 3
Components for fitting the substructure Fitting the substructure SUNOVA rail fastener FPH-FPO PPH-PVC Tools: Important: MCG 3.0 900 Triangular frames, transverse profiles and back panel MCG 3.0 1400 Triangular frames, transverse profiles and back panel Chalk line Tape measure Allen key 6mm Try square Hand hot-air welder Cleaning kit Installation: To achieve an optimum southerly alignment of the panels, the MCG 3.0 frames can be laid either at right angles to or parallel with the inclination of the flat roof. When welding the rail fasteners onto existing synthetic waterproof sheeting, clean the sheeting according to manufacturer s instructions. Caution: Operations 1 and 2 must always be performed together. If the frames are transported or stored without back panel, they can become damaged. Before installing the frames, draw the position of the frames onto the roof with a chalk line. Caution: Operations 1 and 2 must always be performed together. If the frames are transported or stored without back panel, they can become damaged. 1. Fit the screws for the back panels into the prefitted nuts on the triangular frames and engage the back panels. 2. Fit the predrilled transverse profiles to the triangular frames with hexagon socket screws and using the nuts prefitted to the frames. 3. Position on the roof and align with a try square. 4. Weld the profile retainers onto the waterproofing sheeting with hot air. Especially when preparing the seams of the waterproofing sheeting for welding, observe the manufacturer s instructions. 4 Gehrlicher Solar Business GmbH MCG 3.0 EN 08/12
Fitting the modules Components for fitting the modules Tools: Important: Cable clips UV- and temperatureresistant Allen key, 6 mm Crimping tool Double-check that all connectors are correctly and firmly seated. Installation: 1. Insert the profile retainers into the transverse profiles and prefit the end clamps to the lower transverse profile. 2. Fit the lower row of modules. 3. Lay and connect the DC cables according to the cabling diagram, making sure that the plugs are connected correctly. Secure the plugs to the frame and subframe with cable ties. 4. Fit the center clamps and position the upper row of modules. 5. Lay and connect the DC cables according to the cabling diagram, making sure that the plugs are connected correctly. Secure the plugs to the frame and subframe with cable ties. 6. Fit the end clamps to the upper transverse profile and tighten all screws. SUNOVA center clamp SUNOVA end clamp Aluminum sliding block M8 Hexagon socket screw M8 V4A Gehrlicher Solar Business GmbH MCG 3.0 EN 08/12 5
Installing the inverters Tools: Allen key 6mm Installation: 1. Fit two transverse profiles to the back of the subframes. 2. Secure the inverter to the transverse profiles and connect the DC and AC cables. 3. Fit the weather protection. MCG 3.0-900 MCG 3.0-1400 No. of modules 4 6 Width m 3.30 5.01 Heigh m 1.07 1.07 Depth m 2.69 2.69 Weight kg 114 172 Module 20 20 inclination 6 Gehrlicher Solar Business GmbH MCG 3.0 EN 08/12
Components for DC cabling DC cabling Tools: Important: SUNOVA cable tray fastener FKH-FPO PKH-PVC Hand hot-air welder Cleaning kit Allen key, size 6 Bolt cutters Crimping tool Make sure that the plugs are connected correctly, observing the manufacturer s instructions. The connectors must be positioned at least 4 cm above the roof membrane. Cable tray Montage: Option 1: Thoroughly clean the old waterproofing sheeting and weld on the cable duct retainers at a spacing of 1.5 m. Screwfit the cable duct onto the cable duct retainers. Option 2: Screw-fit the cable duct onto the profile retainers on the reverse side of the subframe. Cable tray cover Cable clips UV- and temperatureresistant Lay the DC cables in the cable duct and connect them according to the string wiring diagram. If necessary, secure them with cable clips. Finally fit the cover and secure it with cable ties. Roof penetration Cables are fed through the flat roof through a goose neck at the roof s center. Fire protection Observe the applicable fire protection regulations. specially when routing cables through several fire-containment sections. Gehrlicher Solar Business GmbH MCG 3.0 EN 08/12 7
Maintenance and operational management Accessibility Where possible, the photovoltaic system should be easily accessible for maintenance and operational management. Provide suitable protection against falling, such as safeguards. Cleaning the generator If dirt accumulates on the generator, it may have to be cleaned. We recommend an inspection at least once every year. Clean the system only with fresh water. Do not use chemical cleaning agents and avoid the use of hard or sharp tools on the glass surfaces, as this will cause damage. Operational management of the solar installation To ensure a reliable, high yield of solar power over many years, remote management of the solar power installation is strongly recommended. SUNOVA or one of its partner companies will be pleased to provide this service. Maintaining the roof waterproofing The roof should be inspected at least once a year. To ensure a reliable function of the waterproofing, remove any accumulations of dirt in corners and drains. SUNOVA or one of its partner companies will be pleased to provide this service. SUNOVA s services at a glance First-class lightweight roof waterproofing technology Site survey (building structure survey, thermal insulation, roof slope, mechanical fixation, drainage) Waterproofing design using long-lasting flat roof components Highest quality components and installation Waterproofing guaranteed for 20 years in combination with regular maintenance (maintenance contract) Innovative lightweight roof solar technology Determination of key data (shade analysis, determination of local solar irradiation, building electrical installation, coordination with electricity provider) Planning of optimal mounting and module components for the specific roof construction Layout drawings for efficient roof area usage Profitibilty study Perfect installation Services (on-site maintenance, remote maintenance and production insurance) Solar module performance guaranteed for 20 years SUNOVA lightweight solar power roof as complete solution backed by an exceptional international partner network first-class system components in-house and third party quality control attractive rate of return environmentally friendly Gehrlicher Solar Business GmbH Feldkirchener Straße 2 85540 Haar Germany Tel.: +49(0) 89 420792200 Fax: +49(0) 89 4207928800 sunova@gehrlicher.com www.sunova.eu