energy for a better world INSTALLATION INSTRUCTIONS TRI-STAND East-West Mounting system for PV systems with east-west orientation on flat roofs Quick and easy installation Aerodynamically optimized No penetration of roofing cover Insertion or clipping
Contents 1. Basics 1.1 Notes 4 1.2 Load effect 4 1.3 Statics 4 1.4 Roof condition 5 1.5 TRI-DESIGN dimensioning software 5 2. Installation 2.1 Insertion system 6 2.1.1 Tools 6 2.1.2 Setup 6 2.2 Clip system 2.2.1 Tools 11 2.2.2 Setup 11
4_Basics 1. BASICS 1.1 Notes For the installation of the TRI-STAND East-West mounting system only products from the range of the TRI-STAND East-West mounting system must be used. Using third-party components can result in adverse effects on the system s stability and in major damages. The system may only be installed by trained and skilled personnel. We do not assume any liability for damages arising from the use of third-party components or from incorrect installation. These installation instructions describe the proper installation procedure for the TRI-STAND East-West flat roof system. In some situations, it is advisable, however, to have a specialist (e.g. roofer or joiner) check the special featrues of the roof. 1.2 Load effect In addition to the dead weight of the photovoltaic system, mainly wind and snow loads affect the system components and the substructure. For this reason, each system must be calculated and planned for your individual requirements and external influences, taking into consideration DIN EN 1991* (Actions on Structures). The stresses by wind loads depend mainly on the wind zone (according to DIN EN 1991-1-4*), the building s height, the shape and slope of the roof and the position of the roof s centre. Weight stresses through snow load are dependent on the snow zone (according to DIN EN 1991-1-3*), the building s height, the shape and slope of the roof and the position of the roof s centre. For each location the wind and snow load zone can be determined, which will determine the design of the system. 1.3 Statics On principle, the structural calculations of all roofs must be checked by authorised experts. The main question to be answered is whether the roof can take the additional stresses caused by the solar system. Since the load bearing capacity of a roof and the load effect of a photovoltaic system are determined by many factors, structural calculations must be made for each roof individually. * German standard: DIN EN 1991, DIN EN 1991-1-3, DIN EN 1991-1-4 Swiss standard: SIA 261 Austrian standard: ÖNORM EN 1991-1-3, B 1991-1-3 Eurocode 1 part 1-3 and part 1-4
Basics_5 1.4 Roof condition The current condition of the roof must be such, that renovation will not become necessary for a period of at least 20 years. In case of doubt, it is advisable to have the roof checked by an expert. The TRI-STAND East-West mounting system has been optimised for flat roofs with plane surfaces. If the roof is uneven due to aging or other reasons, it is advisable to consult a qualified specialist. 1.5 TRI-DESIGN dimensioning software The TRI-DESIGN dimensioning software calculates and designs the TRI-STAND East-West mounting system according to the standards of DIN EN 1991 (EC)*. The relevant directives are DIN EN 1991-1-4* for wind loads and DIN EN 1991-1-3* for snow and ice loads, which affect the photovoltaic system and its substructure. The dimensioning software calculates all sizes and distances relevant for the installation. In addition, the dimensioning software allows us to design the system optimally for the individual roof and thus to select the best version of the mounting system. Under the warranty terms and conditions, all TRI-STAND East-West systems must have been dimensioned using the TRI-DESIGN dimensioning software.
6_Installation 2. INSTALLATION 2.1 Insertion system It is particularly easy and fast to mount the insertion variant, and it ensures a uniform appearance of the system. Moreover, loads are evenly distributed due to the insertion of the modules. The permissible load of the module can be utilized up to 5400 N/m² in accordance with the manufacturer s information. During maintenance work, the replacement of modules is facilitated, and system extensions are easy to realize by means of TS-C and UP-C rail connectors. 2.1.1 Tools The following tools are required for the installation of the TRI-STAND East- West insertion variant: 15 3 5 15 mm open-end wrench 3 mm Allen wrench 5 mm Allen wrench TS bending tool 2.1.2 Setup The installation is carried out in six steps: 1. Measuring the module field and laying the UP-L bottom profiles 2. Preliminary mounting of SafeClicks on UP-L transverse profiles 3. Mounting the angles, UP-L transverse profiles and the OW-h support 4. Clicking in the TS insertion profiles 5. Weighing down the system 6. Laying the cables and insertion of the modules 1. Measuring the module field and laying the UP-L bottom profiles The size of the module field results from the number of modules to be installed. The exact size of the field results from the TRI-DESIGN dimensioning. After measuring the module field on the roof area, the UP-L profiles are laid which serve as the sub-structure. While laying them out, care must be taken that the profiles are aligned as described in the dimensioning plan. Axis centre distance of the UP-L profiles in the last module strip on the south and north side: Module length 45 mm Axis centre distance of the UP-L bottom profiles on the inside fields: Module length + 2mm Attention: The module field must have at least 0.50 m clearance to the outer edges of the roof!
Installation_7 The joints of the continuous UP-L bottom rails are effected with the UP-C connector. In this respect, it is to be ensured that the entire bottom rail length does not exceed 12m to minimize stresses as a result of thermal expansions. For the setup on a gravelled flat roof, the sub-structure of UP-L profiles can be directly applied. For the installation on a non-gravelled membrane roof, protective strips can be glued onto the UP-L profiles. They protect the roof against mechanical influences. They are each cut to size to half the module width and glued under the low and high points of the supports. The protective strips may not be glued on continuously to still enable the flow of water transversely to the UP-L profiles. For both installation variants, it is not necessary to provide a screw connection with the roof. The roof membrane thus remains undamaged.
8_Installation 2. Preliminary mounting of SafeClicks on UP-L transverse profiles Already in advance, the SafeClicks can be screwed onto the UP-L transverse profiles with a 5mm Allen wrench. To be able to mount the SafeClicks fast and dimensionally accurately, a gauge may be cut to size for the clearance between SafeClicks. The clearance is equivalent to the module width in mm 57.5 mm. This dimension can also be taken from the TRI-DESIGN dimensioning plan. 3. Mounting the angles, UP-L transverse profiles and the OW-h support The installation of a 10 support is carried out in four steps: 1. Mount the OW end angles with an M15 open-end wrench at the end of the UP-L bottom profiles. 2. Stick the UP-L transverse profile up to the stop into the OW end angle. 3. Prepare another UP-L transverse profile with two counter-inserted OW angles and stick it into the transversely mounted UP-L profile.
Installation_9 4. Lead the OW-h support from the top through the opening of the OW 10 angle, stand it up in the groove of the UP-L bottom rail and turn by 90. For a 20 installation, the support is mounted, as needed, with the UP-L support profile, the TRI-STAND 90 and TRI-STAND 110 angle by means of hammer head screws M10x20 A2 and self-locking nuts A2. With minor snow and wind loads, the support may be omitted. 4. Clicking in the TS insertion profiles At the corresponding places, the TS profiles are set onto the SafeClicks in parallel and clicked in. Care must be taken that the longer leg of the upper TS flange is facing towards the bottom. The TS profiles must each be bevelled by means of the TS bending tool left and right of a SafeClick lying in the middle of the TS rail. This measure limits the wandering of profiles as a result of temperature changes. For systems wider than 12m, the TS-C connector may only be tightened on one side. The grub screws must here face towards the bottom so that the embossing of the TS-C connector does not abut the TS profile. The following profile is inserted with a space of at least 3mm to the one before to keep the stresses in the profiles low which result from temperature influences.
10_Installation To finish the TS profiles, the TS end angles TS-E are installed. They are pushed in at the module field ends of the TS profile and fastened with the grub screws (3mm Allen wrench). For ease of installation, the TS end angles can be mounted already before clicking in the TS profiles. 5. Weighing down the system The ballast plates are placed onto the UP-L bottom profiles according to the ballast plan from the TRI-DESIGN dimensioning plan. Subsequently, they are weighed down with paving stones or flagstones according to the required weights. 6. Laying the cables and insertion of the modules Basically, all cables are laid in parallel with the mounted rails. Fastening on the universal profiles UP-L is effected by means of cross cable clip blocks which are pushed into the profile and fixed in place by a 90 turn. The cables can now be directly fixed to the profiles by means of cable ties. The cables are fastened to the TS profiles with TRI-STAND edge clips TS-EC. These are directly clipped to the TS profile. The cables can now be fixed to the rails by means of the cable ties. For connecting the cables, the modules are set onto the lower TS profiles; they can thus be wired without any problems. After the string lines have been completely laid, insertion of the solar modules can be started. First, the modules are pushed into the upper TS profile and then put down on the lower profile. Thereafter, the solar modules are pushed into the lower profile. They are now positioned by the force of gravity and need not be fixed in place by screws.
Installation_11 2.2 Clip system The clip system makes do with little material used since the modules are clipped on the short side. In this respect, the manufacturer s information is to be taken into account. TRI-STAND East-West is used in the clip variant in regions where the PV system is exposed to relatively low snow and wind loads. 15 6 2.2.1 Tools The following tools are required for the installation of the TRI-STAND East- West clip variant: 15 mm open-end wrench 6 mm Allen wrench 2.2.2 Setup The installation is carried out in four steps: 1. Measuring the module field and laying the UP-L bottom profiles 2. Mounting the angles, UP-L transverse profiles and the OW-h support 3. Laying the cables 4. Weighing down the system and clipping the modules 1. Measuring the module field and laying the UP-L bottom profiles The size of the module field results from the number of modules to be installed and from the TRI-DESIGN dimensioning. After measuring the module field on the roof area, the UP-L profiles are laid which serve as the sub-structure. While laying them out, care must be taken that the profiles are aligned as described in the dimensioning plan. Spacings of the UP-L bottom profiles Module length + 20 mm A new module field must begin after 12m. Attention: The module field must have at least 0.50 m clearance to the outer edges of the roof! The joints of the continuous UP-L bottom rails are provided with the UP-C connector. In this respect, it is to be ensured that the entire bottom rail length does not exceed 12m to minimize stresses as a result of thermal expansions.
12_Installation For the setup on a gravelled flat roof, the sub-structure of UP-L profiles can be directly applied. For the installation on a non-gravelled membrane roof, protective strips can be glued onto the UP-L profiles. They protect the roof against mechanical influences. They are each cut to size to half the module width and glued under the low and high points of the supports. The protective strips may not be glued on continuously to still enable the flow of water transversely to the UP-L profiles. For both installation variants, it is not necessary to provide a screw connection with the roof. The roof membrane thus remains undamaged. 2. Mounting the angles, UP-L transverse profiles and the OW-h support The installation of a 10 support is carried out in four steps: 1. Mount the OW end angles with an M15 open-end wrench at the end of the UP-L bottom profiles. 2. Stick the UP-S transverse profile up to the stop into the OW end angle. 3. Prepare another UP-S transverse profile with two counter-inserted OW angles and stick it into the transversely mounted UP-L profile.
Installation_13 4. Insert EW-h support and turn by 90, push in another UP-S transverse profile and mount the next OW angle. For a 20 installation, the support is mounted, as needed, with the UP-L support profile, the TRI-STAND 90 and TRI-STAND 110 angle by means of hammer head screws M10x20 A2 and self-locking nuts A2. With minor snow and wind loads, the support may be omitted. 3. Laying the cables Basically, all cables are laid in parallel with the mounted rails. Fastening on the universal profiles UP-L and UP-S is effected by means of cross cable clip blocks which are pushed into the profile and fixed in place by a 90 turn. The cables can now be directly and securely fixed to the profiles by means of cable ties. After the string lines have been completely laid, clipping of the solar modules can be started. 4. Clipping the modules and weighing down the system The modules are laid onto the transverse UP-S profiles, aligned and fastened with middle and end clips. On the end clips, the end clip insert must be premounted prior to the insertion.
14_Installation After one side of an East West support has been provided with modules and clipped, weighing down can be started. The ballast plates are placed onto the UP-L bottom profiles according to the ballast plan from the TRI-DESIGN dimensioning. Subsequently, they are weighed down with paving stones or flagstones according to the required weights. TRITEC s Terms and Conditions apply. Made in Switzerland Version 1.0 Subject to technical changes. info@tritec-energy.com
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