INTM Installation Tiled Roof

STATICS. STABILITY. SAFETY.

TILED ROOFInstallation instructions

Manufacturing and distribution: Donauer Solartechnik Vertriebs GmbH. Subject to errors and technical modifications.Version: 02/2009; contact: [email protected] // www.donauer.eu

TOOLSYou require the following tools:

• 13mm,15mmand17mmring/open-endedwrenches(open-endedspanners) • Electricscrewdriver • 6mmhexagonalsocketwrench(Allenkey)

TILED ROOF

Pleasereadthesafetyinstructionscarefullybeforebeginning installation work. You must always an-chortheroofhooksinthesupportingroofstructure.The substructure is usually a rafter roof. In suchcases, youmust install roofhooksonevery rafter.Onpurlin roofs, youhave toproceeddifferently,asthetiles‘displacementusuallydoesnotcorrespondto thespacingof thepurlins.Thismeans that youcannot install thehooksonthepurlins.Withotherroofstructures, it isusuallypossibletoanchortheroof hooks.

If you have any additional questions, use INTERSOL‘s professional and comprehensive consultation ser-vice. Our competent construction engineers and technicians are happy to help you.

You can choose between roof hooks with thick-nessesof5mm,6mmand8mm.Theseareavaila-bleas„fixedoradjustable“boltedroofhooks(itemno.10301-180to-185)oras„normalorlow“weldedroofhooks (itemno. 10301-201/2 to -206).Forex-tremeloads,youcanusethe40x10roofhook(spe-cialarticle).

On tiled roofs, modules are usually installed verti-cally. For this purpose, you must install 2 cross gir-ders. If wind and snow loads are high, a third cross girder may be necessary.

PleaseuseonlytheM10boltsandnutsprovidedondeliveryforfasteningtheframe,andtheM8boltsand nuts for fastening the modules to the frame.

The following torques are to be adhered to:

• M8 (A2-70 / A4-70): 20 Nm • M10 (A2-70 / A4-70): 45 Nm

Please note: use a torque wrench to ensure ad-herence to these torques. Align the frame or mo-dules before tightening the bolts.

InSTaLLaTIOn InSTrucTIOnS

Tiled roof

BOLTS


Removetilesfromtheroofcoveringandpositiontheroofhookonthe rafter in such a manner as to enable anchoring to the substruc-turewithatleast2bolts,andsothatanexitpointcanbeprovidedfortheroofhookatthetile.Youmayneedtocutanotchoutthetilesintheareaoftheroofhook.Upondelivery,50%oftheboltedroofhookshavealeft-sidedarrester,and50%havearight-sidedarrester.Ifitisnecessarytoadjustthearresterdirection,youcanrotatethebaseplatebylooseningthetwohexagonalnutsonthebaseplate‘spress-fittedM8bolts,andbymovingtheroofhook.Inordertosetthecorrectinstallationheightabovetherafter,positi-onthehookinsuchamannerthatthesidepiecehasaminimumclearanceof3-5mmfromthetile(Fig. 1 and 2).Forthispurpose,youmayneed to underlay the hook.With bolted roof hooks, youcanadd3to10mmofheightbetweenthebaseplateandtheroofhookbymeansof3mmsteelshim(itemno.10301-186)and5mmsteelshim(itemno.10301-187).Inordertoinsertthesteelshim,loosenthetwoM8nutsabovethesidepiece.Youcanthenraisethesidepiecefarenoughtomakeitpossibletoslideinthesteelshimlaterally(Fig. 2).Withweldedroofhooks,ifitisnecessarytoadjusttheheightontherafter,dosobyunderlayingtheweldedroofhookswithhardwoodorMDFpanelsbetweenrafterandbaseplate.Onroofswithanunevensurface,theadjustableroofhooksareused.Theseallow you to increase thedistancebetween thesidepieceandtheroofcoveringfurther,byupto40mm(Fig. 3).

Thefasteningtothesubstructure(rafters)isthenrealisedwithatleast2screwsper roofhook.Here, youcanchoosebetweenfiathead screws (itemno. 10301-420100, -420120),which canbe in-stalled without pre-drilling, and wood screws (item no. 10301-42/100, /120, /200), which require pre-drilling into the woodenstructure. For roofs with insulation on the outside of the roof struc-ture,AssyIsotopbolts(specialarticle)areusedinordertofastentheroofhooks,soastoachievethedesiredanchoringinthesup-portstructure(Fig. 4).

1 ROOF FASTENING

2

3

3 - 5 mm

≥2,4 cm

TILED ROOF

Please note: the screws for fastening the roof hooks must be at least 2.4 cm from the edge. As the screws are to be guided into the wooden structure in a straight line, the rafter must be at least 6 cm wide if the base plate is used. We recommend 8 cm as the minimum anchoring length.

Makesure that a support point is alwaysprovidedintheareaofthesidepiecebeneaththebaseplate.This, for instance,canberealisedbyusinganad-ditionalbattenbeneaththeroofhook.Ifyoucannotinstall theroofhook‘ssidepiece intheareaoftherafter,anauxiliaryraftermustbeaddedtothesideof the rafter (Fig. 5). If lateral reinforcement is not possible,ourteamwillbehappytohelpyoufindasuitable solution.

4 5


With the cross girder types Standard type 2 (itemno. 10301-03/1 to /7) and Light type 2 (item no.10301-04/16to/20),thelowerslotservestoaccom-modate theM10T-headboltsandM10mushroomheadsquareneckedbolts.TheupperT-shapedslotisonlysuitableforfasteningthemodules,becauseonlyM8squarenuts (itemno.10301-41/M)canbeinsertedhere.TheFutura40x40crossgirder (itemno.10301-04/310,/311,/32)canaccommodateM10boltsandnutsinbothslots.Thus,thecrossgirder‘sapplication options are highly flexible. The upperT-shapedslotalsoservestoaccommodatetheM8hammerhead nut (10301-41/E) for fastening mo-duleswithM8Allenboltswithinterlocking(itemno.10301-411to-419).All3typesofcrossgirderscanbeconnectedquicklyandeasilywith theassemblyangle (item no. 10301-073). With the cross girderStandard type 2 and Futura 40x40, attach the as-semblyangleinsuchamannerthatthesidepiece

withthe2drilledholesservesasalateralarrester(Fig.6).With thecrossgirderStandard type2, thearrester is not to be situated on the side of the cable channel.WiththecrossgirderLighttype2,thesidepiecewiththe3drilledholesisthelateralarrester(Fig.7).Everyassemblyangle is fastenedwith twoM10T-headorM10mushroomheadsquareneckedboltsandM10hexagonnutwith interlocking (itemno. 10301-40/M). Make sure that the connectingjointisnotsituateddirectlyatafasteningpoint.

Please note: the maximum transverse rail length should not exceed 15.0 m. After 15.0 m, install an expansion joint of at least 5 cm.

Endcapscanbeappliedtothecrossgirdersasopti-calfinishing.Asuitableendcapisavailableforeverytypeofcrossgirder.ForcrossgirdersStandardtype2,youneedtheendcapwithitemno.10301-083,for

Standard type 2

CROSS GIRDERS

Light type 2

6 7 M8↙

↗ M10

M8↙

↗ M10

TILED ROOF

crossgirdersLighttype2theendcapwithitemno.10301-082,andforcrossgirdersFutura40x40, theendcapwith itemno.10301-081.TheendcapsareaffixedontheundersidewithanM10/16he-xagonbolt(itemno.10301-40/A)andaserratedM10hexagonnutwithoutinterlocking(itemno.10301-41).

Installingmodulesportrait:ifinstallingmodulesportrait,fastenthecross girder to the roof hooks. You can use the cross girder Stan-dardtype2,Lighttype2,orFutura40x40.Thecrossgirdersarefa-stenedtotheuppersidepieceofeachroofhookwithanM10T-headorM10mushroomheadsquareneckedboltsandanM10hexagonnutwithoutinterlocking.YoucaninserttheT-headboltanywhereinthelowerslotofthecrossgirder.InserttheM10mushroomheadsquareneckedbolts intotheslotat theendof therail,andslidethemtothedesiredposition(Fig. 8 and 9).

IfthecrossgirderStandardtype2isselected,youmustensurethatthecablechannelisuppermost,sothatthecablescannotfalloutofthechannel.Thecrossgirdersshouldnotprotrudemorethan300mmbeyondthelastroofhook.

Please note: the tiles‘ dimensions form a pattern for the spacing of the roof hooks / cross girders. The permissible mounting areas are described in the data sheet, or in the installation instructions, of your selected module.

Installingmodules landscape: if installing landscape, you shouldcheckwhetherthemanufacturer‘sspecificationspermitfasteningofmodulesontheshortside.Ifthisoptionispossible,proceedasforportraitinstallation.However,ifthefasteningpointsaresituatedonlyonthelongsidesofthemodule,acrossrailsystemisnecessa-ry.Formoredetailedinformationinthisregard,refertothespecificinstallationinstructions„Crossrailsystem“.

8

9


10 11

Installingmodulesportraitor landscape:nowpre-paretheendclamps(itemno.10301-1532to-1551)/endclampsforframelessmodules2-parts(itemno.10301-98)andcentralclamps(itemno.1030114and-141)/centralclampforframelessmodules2-parts(itemno.10301-97)forfasteningthemodulestothemodule rails.

Please note: the mounting areas prescribed by the manufacturer of your module can be found in the module data sheet.

ForthecrossgirdersStandardtype2andLighttype2,theclampsareprovidedwithM8serratedAllenbolts

with interlockingandM8squarenuts.Slide there-quirednumberofclamps into theupperslotof thecrossgirders.WiththecrossgirderFutura40x40,anM8hammerheadnutisusedinsteadoftheM8squarenut.Here,theclampscanbeinserteddirectlyintotheslotofthecrossgirderatanylocation.Nowplacethefirstmoduleonthecrossgirder,withatleast30mmclearancefromtheedge.Slidetheendclampsontothemodule‘s frame,and tighten thebolts (Fig. 10). Tofastenthemoduleontheotherside,placeanothermodule,andfastenbothtothecentralclamps(Fig. 11). Continue in thismanner, and lock off the finalmodulewithendclamps (Fig. 12).

MODULE FASTENING

TILED ROOF

Inordertosecurethemodulesagainsttheft,youcaninsertastar-shapedanti-theftdevice(itemno.10301-80) intotheM8Allenboltand fasten itwitha centrepunch.Thismeans that thehexagonalsocketwrenchcannolongerbeinserted,andtheAllenboltcannotbe loosened.

L


PRODUCT LIAbILITy:

the technical documentation constitutes part of the product. Donauer Solartechnik Vertriebs GmbH is not liable for damages caused by failure to observe the installation instructions, particularly the safety instructions, or caused by inappropriate use of the products.

We recommend that you read the following information carefully, as it is of great importance when handling the product. Please also inform yourself of the safety regulations which pertain to the other system components.

•oushouldadhere to these instructionsprecisely,wheneverworkingonthePVsystem.Installation,commissioning,maintenanceandre-pairsmayonlybeperformedbyappropriatelyqualifiedandauthorisedpersons.

•Pleaseobservetheapplicableregulationsandsafetyinstructions.

you must observe the following accident prevention regulations:

•BGVA1–Generalregulations

•BGVA2–Electricalsystemsandequipment

•BGVC22–Constructionwork(personalfallprotectionequipment)

•Thetradeassociationhealthandsafetyatworkrules(BGR203–Wor-kingonroofs)andDINEN516„Equipmentforaccessingroofs“

•Thetradeassociationregulationsregardingworkclothingandworksafety

you must adhere to the following DIN standards:

•DIN18299–Generalrulesforallkindsofbuildingworks

•DIN18338–Roofcoveringandroofsealingworks

•DIN18360–Metalconstructionandlocksmithworks

•DIN4102–Firebehaviourofbuildingmaterialsandbuildingcompo-nents

Only authorised personnel may carry out work on Donauer Solartech-nik Vertriebs GmbH systems. The operator of the system has the fol-lowing safety-related obligations:

• Performanceofregularannualmaintenancework,e.g.inspectionofcabling,boltconnections,andtheroofskin.

• Theframemayonlybeinstalledbypersonswithsuitablequalifica-tions, technicalskills,andknowledgeof the fundamentalsofme-chanics.

• Itmustbeensuredthattheassignedpersonscanassesstheworkallocatedtothem,andcanidentifypossibledangers.

• The installation instructions are part of the product, andmust beavailableduringinstallation.

• Itmustbeguaranteedthattheinstallationinstructions,andparticu-larlythesafetyinstructions,havebeenreadandunderstoodbytheassignedpersonnelbeforeinstallation.

• Thetradeassociationregulations,thelocalworksafetyregulations,and the technical regulations must be adhered to.

• Suitablehoistingequipmentandladdersaretobeusedfortheins-tallationwork.Noleaningladdersmaybeused.

• Itisnecessarytoarrangeforaqualifiedconstructionengineertoas-sessthebuilding‘sexistingstaticloadingcharacteristicswithregardtotheadditionalloadsofaPVsystem.

• Anygeneral loadreductionmeasuresspecifiedbyDonauerSolar-technikVertriebsGmbH(e.g.theneedtoclearsnow,soastolimitthesnowload)aretobeobserved.

PrODucT LIaBILITY / cOMMErcIaL GuaranTEE (LIaBILITY EXcLuSIOn IF aPPLIcaBLE)

• Thedimensioninginformationincludedintheseinstructionsmerelyrepresentsinformationgatheredinpractice.Bindingstaticloadingcharacteristicsformountingframescanbecompileduponrequest.

• Astheinstallationcompany,youareresponsibleforcorrectexecuti-on of installation work.

• DonauerSolartechnikVertriebsGmbHisnotliableforthedimensi-oninginformationincludedincommercialsystemproposals.

• Astheinstallationcompany,youareresponsibleforthemechanicalstabilityoftheinstalledinterfaceconnectionsatthebuildingenvelo-pe,andinparticularfortheirleak-tightness.ThecomponentsfromDonauerSolartechnikVertriebsGmbHaredesignedforthispurpo-se,accordingtotheexpectedloadsandthecurrentstateoftechno-logy.Tothisend,withinthescopeofthequery/order,youmustpro-videDonauerSolartechnikVertriebsGmbHwithwrittennotificationof all general technical framework conditions on the project datacollectionsheet (detailsof thesupport structure, snow loadzone,buildingheights,windloadsetc.).

• Donauer Solartechnik Vertriebs GmbH is not liable for incorrecthandlingoftheinstalledparts.

• Useinthevicinityoftheseaisprohibited,duetoriskofcorrosion.

• DonauerSolartechnikVertriebsGmbHgrantsa2-yearproductgu-arantee on the service life and stability of themounting systems,subject to correct handling, dimensioning in accordance with thestaticloadingconditions,normalenvironmentalconditions,andnor-malambientconditions.Thisapplieswithinthegenerallyprevalentweatherconditionsandenvironmentalconditions.

• Material andworkmanship guarantee: Donauer Solartechnik Ver-triebsGmbHgrantsa12-yearmaterialandworkmanshipguaranteeonthematerialsused.Consultthespecificguaranteeconditionsformore detailed information.

STANDARDS AND GUIDELINES

All standards and guidelines listed are issued for Germany, and are to be applied for Germany, in the respective valid version. Outside Germany, you must also observe the relevant national standards and guidelines.

nOTES On ELEcTrIcaL InSTaLLaTIOn WOrK

Only if you are a qualified electrician, may you perform any electrical work. The applicable DIN standards, VDE regulations, VDEW guideli-nes, VDN guidelines, accident prevention regulations and the regulati-ons of the local utility company are authoritative in this regard.

• DINVDE0100(Installationofhighvoltagesystemswithnominalvol-tagesupto1000V)

• VDEWguidelineforparalleloperationofdomesticpower-generationsystemswiththelowvoltagegridoftheutilitycompany

• VDI6012sheet2,guidelinefordecentralisedenergysystemsinbuil-dings:Photovoltaics

• LeafletforVDEWguideline„Domesticpower-generationsystemsonthelowvoltagegrid“

• VDNguideline„Domesticpower-generationsystemsonthelowvol-tagegrid“

• DIN/VDEregulations,DIN/VDE0100„Installinghighvoltagesystemswithgridvoltagesupto1000V“, inparticularVDE0100,Part410,„Protectionagainstdirectandindirectcontact(Directcurrent>120V,<1000Vdirectcurrent)“andthe„Accidentpreventionregulationsofthecommercialtradeassociations“VBG4„Electricalsystemsandequipment“

• DINVDE0100-540Selectionandinstallation–Earthing,protectiveconductorsandequipotentialbondingconductors

• DIN57185VDE0185InstallationofalightningprotectionsystemandVDS2010

IMPOrTanT WarnInGS

Solar modules generate electricity as soon as they are exposed to light. There is always a voltage present. The fully insulated plug con-tacts provide a level of contact protection but when dealing with solar modules, the following points must be observed:

• Donotinsertelectricallyconductivepartsintotheplugsorsockets.

• Donotinstallsolarmodulesandwiringusingwetplugsorsockets.

• Exerciseutmostcautionduringallworkonthewiring.

• Donotcarryoutanyelectricalinstallationworkindampconditions.

• Alsowith low lighting, connectingsolarmodules in series causesveryhighDCvoltagestooccur,whichcanbelife-threateninguponcontact.Inparticular,notethepossibilityofsecondarydamageintheeventofelectricshocks.

The inverter can produce high touch voltages, even when not connec-ted:

• Exerciseutmostcautionwhenworkingonthewiringandinverter.

• After switching off the inverter, it is essential towait for the timeintervalspecifiedbythemanufacturerbeforebeginninganyfurtherwork.Thisallowsthehighvoltagecomponentstimetodischarge.

• Pleasealsoobservetheinvertermanufacturer‘sinstallationregula-tions.

When breaking a connected string of modules (e.g. when disconnec-ting the DC line from the inverter under load), a lethally strong electric arc can occur:

• Neverdisconnectthesolargeneratorfromtheinverterwhilethein-verterisconnectedtothemainsgrid.

nOTES On THE InSTaLLaTIOn OF MOunTInG FraMES

For installation in roof areas, you must observe the currently appli-cable construction engineering regulations, especially the require-ments formulated in the DIN standards and in the „Regulations of the German Roofing Industry“ („Regelwerk des Deutschen Dachdecker-handwerks“).

• Checkwhetherallboltconnectionsaretight.

• Adheretothespecifiedtorques.

• Regardlessofverifiablestatic loadingconditions,youmustensurethat theproductcomplieswith thestatic loadingrequirementsonsite,asperDIN1055,beforeeveryinstallation.

• DINstandard1055„Actionsonstructures“

Part 1:Densitiesandweightsofbuildingmaterials,structuralele-ments and stored materials

Part 4:Windloads

Part 5: Snow load and ice load

Part 100:Basisofstructuraldesign–Safetyconceptanddesignrules

• Themounting frame isdimensionedasperDIN4113 „Aluminiumconstructions under predominantly static loading“ and DIN 18800„Structuralsteelwork;dimensioningandconstruction“ortherele-vantEurocodeEC1,EC3,EC9.

• Makesurethatthesubstructureisappropriatewithregardtoloadcapacity(dimensioning,stateofmaintenance,appropriatematerialspecifications),supportingstructure,andanyotherlayerswhich itaffects(e.g.insulationlayer).

• Makesurethattherainwaterrunoffisnotimpeded.

• Payattentiontothephysicalconstructionaspects(e.g.possiblecon-densationproblemscausedbypenetrationofinsulatinglayers).

SAFETY INSTRUCTIONS AND WARNINGS

TILED ROOF

Stan

d02

/09

STATICS. STABILITY. SAFETY.

STILL HaVE QuESTIOnS?We will be happy to provide you with more information.

Distributed by

Donauer Solartechnik Vertriebs GmbH Zeppelinstr.10 82205Gilching Germany Telephone +49(0)8105/7725-0 Fax +49(0)8105/7725-100

[email protected] // www.donauer.eu

you can also visit us online at:

www.intersol.eu

Ifyoustillhaveunansweredquestionsorsuggestions,youarewelcometo call us. You can reachour competent consultants,whowill answerall your questions regarding products, planning and installation, at +49(0)8105/7725-0.Here,youcanalsoobtaininformationonthein-stallationsystemsforallotherrooftypes.

Just get in contact with us!

INTM Installation Tiled Roof

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