HORIZONTAL INSTALLATION

A1410 1 12/2014

THERMO/SOLAR Žiar s.r.o.

MANUAL FOR INSTALLATION

PV SUPPORTING FRAMES

HORIZONTAL INSTALLATION

CONTENT

ORD.NO.

PAGE

Mounting information

3

Mounting, flat roof — A-frame

S7348

4 - 18

Connecting of supporting sections

9

Mounting of safety angle brackets

12

Mounting of side and centre fixtures

14 - 16

Mounting of additional bracing strut

17 - 18

Mounting, sloping roof - basic roof hook

S3014

19 - 31

Mounting, sloping roof - stainless steel roof hook

S3758

32 - 35

Mounting, sloping roof - aluminium straight roof hook

S3895

36 - 40

Mounting, sloping roof - stainless steel holder

S3011

41 - 42

Mounting, sloping roof - combi screw

S3244

43 - 48

A1410 3 12/2014 Mounting information

Follow the positions of the roof hooks according to this manual.

In areas with heavy snow loads it is strongly recommended use roof hooks on all of the rafters. In case of heavy snow load (snow load above ZONE 4) it is recommended to use replacement of standard tiles for metal tiles or kombi-screws.

Spacing the roof hooks (S3014) in this installation manual meets standards according to STN EN 1991-1-1 for the following:

Wind load

- dynamic pressure of gusty wind q(z) = 0,5 kN/m²

- equivalent for wind speed v = 105 km/h Snow load

- snow load on the ground sk = 1,5 kN/m²

- snow load 1,2 kN/m²

It is necessary to observe locally valid safety regulations for working at heights when working on the roof. Tools 10 13 ₆ Ø5 Ø8 Ø8,5 Bits for screwdriver

Torx Allen key Phillips 18

SUPPORTING FRAME FOR PV PANELS - FLAT ROOF

A-FRAME, HORIZONTAL INSTALLATION

A1410 5 12/2014

PV PANELS QUANTITY 1 2 3 4 5 6 7 8

A-FRAME QUANTITY 2 3 4 5 6 7 8 9

Panel’s layout

If the field of PV panels should be symmetrical it is necessary to keep the dimensions according to the picture below.

A

-fr

ame

2p

cs

A

-fr

ame

3p

cs

A

-fr

ame

4p

cs

A

-fr

ame

5p

cs

A

-fr

ame

6p

cs

A

-fr

ame

7p

cs

A-frame assembling

Screw the floor beam, ledger and post together using M8x20. The holes for roof fixing are already set in the floor beam. One piece of A-frame is needed for one PV panel. Two pieces of A-frame are needed if only single PV panel is used.

LEDGER

FLOOR BEAM POST

A1410 7 12/2014 Notice for mounting

To protect the panels from fall over by strong winds they have to be screwed tightly to the roof structure. If this is not possible, each panel must be attached to a minimum weight of 330 kg/panel.

Illustration of mounting A-frame to the concrete blocks using mechanical anchor to the concrete.

A1410 9 12/2014 Connecting of supporting sections

Depending on quantity of PV panels, supporting sections are multi-parted. Connection of supporting sections is shown in the picture below. If possible, connect the sections the way that connecting plate is facing to the bottom.

Ro

of d

irec

tio

n

Mounting of supporting sections to the A-frames

Push the carriage bolts M8x20mm into the section. It can be done from the side or through cut groove in the section. Subsequently push the supporting section with bolts into the A-frame and tighten through flange nuts.

A1410 11 12/2014 Illustration of mounted supporting frame for 2 pcs of PV panels. Condition: A=B!

A

Illustration of PV panel

Mounting of safety angle brackets

Mount safety angle brackets as shown in the picture. Use M6x16 bolt, M6 flange nut and . Montovať bezpečnostné uholníky podľa zob-razenia. Použiť skrutku M6x16, prírubovú maticu M6 and large washer.

A1410 13 12/2014 Mounting of PV panel to the supporting frame

Mounting of side fixtures

Mount the side fixtures as shown in the picture. Use M8x30 carriage bolt and M8 nut with inner Allen.

A1410 15 12/2014 Mounting of centre fixtures

Mount the centre fixtures as shown in the picture. Use M8x30 carriage bolt and M8 nut with inner Allen.

Picture of required fixing points for 4 pcs of PV panels A - Joint between panels

B - Joint on the side of panel

A

A1410 17 12/2014 Mounting of additional bracing strut

It is highly recommended to use additional bracing strut in case of frame instability and in-creased adverse weather conditions (snow, wind).

Mount the additional bracing strut as shown in the picture. Drill 8,5mm holes on the lower part of the post and attach the bracing strut to the posts. Use M8x20 bolt, M8 nut and 8,4 washer to the attachment.

A1410 19 12/2014

SUPPORTING FRAME FOR PV PANELS - SLOPING ROOF

BASIC ROOF HOOK, HORIZONTAL INSTALLATION

FIXING HOOKS QUANTITY RAFTERS SPACING 800 mm ROOF INCLINATION ≥ 30° Panel‘s layout PANELS QUANTITY 1 2 3 4 5 6 7 8 HOOKS QUANTITY 4 6 8 10 12 14 16 18 H oo ks q u an tit y 4pc s H oo ks q u an tit y 6pc s H oo ks q u an tit y 8pc s H oo ks q u an tit y 10pc s H oo ks q 12pc s H oo ks q u an tit y

A1410 21 12/2014 FIXING HOOKS QUANTITY

RAFTERS SPACING 900 mm ROOF INCLINATION ≥ 30° PANELS QUANTITY 1 2 3 4 5 6 7 8 HOOKS QUANTITY 4 8 12 16 20 22 26 30 Panel‘s layout Hook s q ua n tit y 4pcs Hook s q ua n tit y 8pcs Hook s q ua n tit y 12 pc s Hook s q ua n tit y 16 pc s Hook s q ua n tit y 20 pcs Hook s q ua n tit y 22 pc s

FIXING HOOKS QUANTITY RAFTERS SPACING 1000 mm ROOF INCLINATION ≥ 30° PANELS QUANTITY 1 2 3 4 5 6 7 8 HOOKS QUANTITY 4 8 10 14 18 20 24 28 Panel‘s layout H oo ks q u an tit y 4pc s H oo ks q u an tit y 8pc s H oo ks q u an tit y 10pc s H oo ks q u an tit y 14pc s H oo ks q u 18pc s H oo ks q u an tit y 20pc

A1410 23 12/2014 It is necessary to keep the hooks spacing because of static strength of whole construction. Keeping the hooks spacing and following assembly instructions ensures the tile protection against breaking. It prevents to get water through the roof casing into the roof itself.

Mounting preparation

Discover the location of rafters beneath the roof tiles.

Pull or take roof tiles out placed above the rafters.

RA

FTERS

SPACI

NG

68

0 t

o 8

45

mm

A1410 25 12/2014 Remove the lock from relevant roof tile in the area where to hook is going to be set.

Strengthen the correctly-placed hook as shown in the picture. Use wood screw with min. of length 80 mm. Use wood screws with ordering no. F1486 (F1488). If the hooks are being un-derlaid, it is necessary to use wood screws with min. of length 120 mm, ordering no. F1487 (F1489). Pre-drill hole with ø5 drill to 2/3 of the total screw length. Grease the screws with solid lubricant before the mounting.

When installing the hook, rule of minimum space between hook and roof tile needs to be kept. It is necessary to keep the distance of 5 mm. See picture below.

5 m

A1410 27 12/2014 Using of underlay beneath the hook

If the space between roof tile and hook is smaller than 5 mm, the underlay needs to be used! See picture below.

If the certain hook cannot be fixed correctly to the rafter, it is necessary to take measures according to following picture!

Rafter is located between the roof tiles. It is necessary to mount additional support because of impossibility to fix the hook reliably.

A1410 29 12/2014

Mounting of additional support. Choose dimension of support according to the rafter size. Minimum length of the support is 600 mm. Use the screws with appropriate length or screwed joint for fixing the support.

RA

FTERS

SPA

CING

68

0 t

o 8

45

mm

After mounting of hooks, the supporting sections can be mounted. Strengthen the supporting sections according to the picture. Use M8x20 carriage bolts and M8 flange nuts. Push the bolts into the sections from the side or through cut groove in the section.

A1410 31 12/2014

B

A

Check the diagonals! Condition A=B !

For mounting of PV panels follow the instructions in section „Mounting of PV panel to the supporting frame“, pages 12-18.

SUPPORTING FRAME FOR PV PANELS - SLOPING ROOF

STAINLESS STEEL HOOK, HORIZONTAL INSTALLATION

A1410 33 12/2014 Panel’s layout

If the field of PV panels should be symmetrical it is necessary to keep the dimensions according to the picture below.

PANELS QUANTITY 1 2 3 4 5 6 7 8 HOOKS QUANTITY 4 6 8 10 12 14 16 18 Hook s q ua n tit y 4pcs Hook s q ua n tit y 6pcs Hook s q ua n tit y 8pcs Hook s q ua n tit y 10 pc s Hook s q ua n tit y 12 pc s Hook s q ua n tit y 14 pc s

Mounting preparation

Pull the roof tiles out depending on hooks position

Check the existing battens for stability. The battens must not show any signs of deteriora-tions. Rotten battens needs to be replaced. If the battens to be used are smaller then 50 x 30 mm give them additional strength by fixing additional wood screws (ø5 x 60 mm — not

sup-Place the roof hooks in the correct position using 2 wood screws (ø5x30 - F1406). Fix the sliding blade under the lower roof batten and bolt together using screws. The sliding blade holds the hook in its correct position. In case of roof tiles with high thickness: Bend the blade of the tile, in order to fit under the batten and not just under the roof tile. If necessary, grind the roof tiles so that the hook has full contact to the tile!

A1410 35 12/2014 Stainless steel hook is height adjustable. This can be used if the une-venness situated on the roof needs to be compensated.

For mounting of supporing section and PV panels follow the instructions on pages 31 and 32!

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Spaci

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scheme o

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e 33

68

0 t

o 8

45

mm

For mounting of supporting frames (supporting sections) to the stainless steel hooks follow the instructions for the basic roof hook. See page 30, below.

For mounting of PV panels follow the instructions in section „Mounting of PV panel to the supporting frame“, pages 12-18.

SUPPORTING FRAME FOR PV PANELS - SLOPING ROOF

ALUMINIUM STRAIGHT ROOF HOOK, HORIZONTAL INSTALLATION

A1410 37 12/2014 Panel‘s layout

The straight roof hook can be fixed as follows: into the rafter

It is necessary to keep the hooks spacing according to the basic roof hook S3014, see pages 20 - 22. Use the wood screws ø8x120. Depending on type of roof tile, grind the roof tiles so that the hook has full contact to the tile!

(When fixing to the rafter, it is necessary to underlay the hook. See picture below. The underlay of hook is quite demanding for precision and therefore we recommend to use different fixing elements.

into the shingle roof, tin roof, or into the different underlay

It is necessary to keep the hooks spacing according to the hook S3758, see page 33.

Illustration of underlaying of hook when fixing to the rafter

Illustration of alternative underlaying of hook when fixing to the rafter.

Use mininum of 4 screws when fixing the hook to the shingle roof, tin roof or into the different underlay. Use screws ø6, length according to

A1410 39 12/2014 Mount the angle bracket S3843 to the straight roof hook. The angle bracket is needed for fi-xing of supporting section.

Mounting of supporting section to the hook

Push the carriage bolts M8x20mm into the section. This can be done from the side or through cut groove in the section. Subsequently put the supporting section with bolts on the angle bracket and tighten through flange nuts.

A1410 41 12/2014

SUPPORTING FRAME FOR PV PANELS - SLOPING ROOF

STAINLESS STEEL HOLDER, HORIZONTAL INSTALLATION

When mounting on tin roofs, it is necessary to prefer mounting on the inner construction of roof, i.e. to use kombi screws (threaded bars). If this is not possible, we recommend to use stainless steel holder.

The trapezodial sheets has to be sufficiently fixed to the roof construction!

PANELS QUANTITY 1 2 3 4 5 6 7 8 HOLDERS QUANTITY 4 6 8 10 12 14 16 18 Panel’s layout Holders quantity 4pcs Holders quantity 8pcs Holders quantity 12pcs Holders quantity 14pcs Holders quantity 10pcs Holders quantity 6pcs

Use only bolts packaged with the holder Bolts cannot be slipping during the mounting

Roof must be able to bear addtional load of PV panels Fixing of hook

A1410 43 12/2014 Use only bolts packaged with the holder

Bolts cannot be slipping during the mounting

Roof must be able to bear addtional load of PV panels

SUPPORTING FRAME FOR PV PANELS - SLOPING ROOF

COMBI SCREW , HORIZONTAL INSTALLATION

FIXING SCREWS QUANTITY RAFTERS SPACING 800 mm PANELS QUANTITY 1 2 3 4 5 6 7 8 SCREWS QUANTITY 4 6 8 10 12 14 16 18 Panel’s layout H oo ks q u an tit y 4pc s H oo ks q u an tit y 6pc s H oo ks q u an tit y 8pc s H oo ks q u an tit y 10pc s H oo ks q u an tit y 12pc H oo ks q u an tit y 14pc

A1410 45 12/2014 FIXING SCREWS QUANTITY

RAFTERS SPACING 900 mm

PANELS QUANTITY 1 2 3 4 5 6 7 8

SCREWS QUANTITY 4 8 12 16 20 22 26 30

FIXING SCREWS QUANTITY

RAFTERS SPACING 1000 mm PANELS QUANTITY 1 2 3 4 5 6 7 8 SCREWS QUANTITY 4 8 10 14 18 20 24 28 Screws quantity 4pcs Screws quantity 8pcs Screws quantity 12pcs Screws quantity 16pcs Screws quantity 20pcs Screws quantity 22pcs Screws quantity 4pcs Screws quantity 8pcs Screws quantity 10pcs Screws quantity 14pcs Screws quantity 18pcs Screws quantity 20pcs

Mounting preparation

Discover the location of rafters beneath the roof tiles.

Pull or take roof tiles out placed above the rafters.

RA

FTERS

SPACI

NG

68

0 t

o 8

45

mm

A1410 47 12/2014 Drill a holes with ø25mm core drill through

the tiles with a high quality masonry bit. Do not apply too much pressure to the drill as this may cause the tile to break, do not penetrate beyond the tile. After the holes have been drilled in the tiles use an 8mm wood bit to drill through the rafters.

NOTE: The angle from the rafter to the drill must be 90°!

Screw the combi screw into the pre-drilled holes in the rafters. In order to avoid potential leaks, the boreholes can be filled with roof sealant before the combi screw gets screwed in possition.

Mount the angle bracket S3843 to the combi screw. The angle bracket is needed for fixing of supporting section.

Fix the angle bracket to the combi screw. See picture below.

Mount the supporting section to the combi screw as shown below. Push the carriage bolts M8x20mm into the section. This can be done from the side or through cut groove in the section. Subsequently put the supporting section with bolts on the angle bracket and tighten through flange nuts.

A1410 49 12/2014

SUPPORTING FRAME FOR PV PANELS

MOUNTING ON FACADE, HORIZONTAL INSTALLATION

Mounting of A-frame on the facade

The same A-frame is used as when mounting on flat roof. Fixing points can be seen on the post. Choose fixing points in a distance of 100 mm from the edge of the post. Holes need to be drilled manually using drill and bit with proper diameter. Use proper type of fixing elements according to material of the facade. If threaded bars are used, we recommend to use threaded bar with diameter ø12mm.

Life danger caused by falling panel as a result of improper use!

Fixing points

When mounting on facade, follow the instructions for mounting A-frame on the flat roof (page 4).

Mounting of supporting frame with 60° angle (supporting frame on flat roof rotated by 90°)

If the supporting frame is not stable enough, we recommend to use additional bracing struts. See picture below.

A1410 51 12/2014 Mounting on facade (parallel with facade)

For mounting on facade follow the instructions for combi screws (see page 43). According to the material of facade, combi screws can be changed for different fixing elements. The result can be straight mounting on the wall (facade).