00MK-MA0190-EN00. Mounting System ASSEMBLY INSTRUCTIONS. Universal Light system with locking brackets, for sloped roof

00MK-MA0190-EN00

Mounting System

Universal Light system with locking

brackets, for sloped roof

November 2014

Rev.02

1

Table of contents

General instructions 2

General safety instructions 3

Universal Light system with locking brackets,

for sloped roof 4

Regulations 5 Components required 6 Tools required 8 Assembly instructions 9 Notes 12 Table of contents

2 General instructions

General instructions

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 [email protected].

All personnel on work site must have a copy of the assem-bly instructions.

2.The 12-year warranty is assured by our warranty certifi-cate subject to compliance with assembly instructions, general instructions and general safety prescriptions pro-vided 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

beco-ming dirty, so remove all the deposits during the routine maintenance.

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.

3 General safety instructions

General safety instructions

car-ried 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 re-gulations, and provisions relating to the environment. 4.Observe all regulations and national laws and local

regula-tions regarding health and safety, accident prevention and the requirements of professional associations.

In particular, it is necessary:

• Wear personal protective equipment: safety helmet, sa-fety gloves , sa• Wear personal protective equipment: safety helmet, sa-fety shoes, etc.

• If the system is to be fitted on an elevated surface com-ply 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 The-san 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 af-fected 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.

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.

4

Universal Light system

with locking brackets,

for sloped roof

Universal Light system with locking brackets, for sloped roof

The Universal Light system with locking brackets, for sloped roof, is 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.

FEATURES OF THE SYSTEM

• 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 modules, 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

tel. 0039 011 19870791

e-mail [email protected]

For any need or clarification you may required, please contact our customer service:

5

Regulations

BGV A1 Accident prevention regulations – General rules

BGV A3 Power system and equipment

BGV C22 Construction work

DIN EN 62305 Lighting protection

DIN VDE 0185 Lighting protection Components

DIN VDE 0100 part 410 Grounding

DIN VDE 0100 part 712 Electrical installations of buildings

DIN VDE 0105 Operation of electrical installation

DIN VDE 0298 Application of cables and cords in power installations

DIN 18338 Roofing work

DIN 18451 Scaffolding work

DIN 4102 Fire behavior of building materials and building components

DIN 18015 Electrical installations in residential buildings

DIN 18531 Waterproofing of roofs

VDS 2023 Electrical installations in structural works with mainly flammable materials

Eurocode 1 Wind loads

Eurocode 1 Snow loads

Eurocode 3 Design of steel structures

Eurocode 9 Design of aluminum structures

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.

6

Universal Light

Material: Aluminium

Locking bracket with slot Material: Aluminium

Alternatives available: SO-AYP13L3-0000 (3,1 m) SO-AYP13L6-0000 (6,2 m)

Self-drilling wood screw or Self-drilling screw or Concrete screw anchor

Depending on the type of module, refer to general catalogue.

Adhesive and structural tape SOST-V501-003M (25mmx33m)

Clamp sets

for frameless modules Material: Aluminium

Depending on the type of module, refer to general catalogue.

Clamp sets

for modules with frame Material: Aluminium

Depending on the type of module, refer to general catalogue. SO-AY036-0001 Components Required

Components Required

7 Components required

Clamps

for modules with frame Material: Aluminium

Depending on the type of module, refer to general catalogue.

Hammer head screw, M8 Material: Stainless steel

Nut with safety fit, M8, (DIN 6923)

Material: Stainless steel 0042-80500-0000

Other accessories available on request. Consult the general catalogue. Alternatives available: SOST-V209-00TH (M8X30mm) SOST-V206-00TH (M8X36mm) SOST-V210-00TH (M8X42mm) CLAMPS OPTIONAL

8 Tools Required

Tools Required

Wireless screwdriver

Torque wrench

Insert n°8, n°10 and n°13 for screwdriver

Mark line cord

Bubble level

9

Assembly instructions

Assembly instructions

Step 1

Preliminary checks

a Use the line marker cord to trace the positions where to apply the adhesive and structural tape.

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 2

Alignment

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.

Step 3

Applying the adhesive and structural tapes

the system is to be fitted.

b. Provide a minimum distance of the rails from the edge of the roof of 500 mm.

This system is highly versatile, hence it is ideal for in-stallation on different types of roofs and surfaces,

such as:

- Corrugated sheet metal roofs; - Wooden porch roofs;

- Metal porch roofs;

10 Assembly instructions

Step 4

Positioning the Universal Light mounting rails

Step 5

Positioning and fi xing the photovoltaic modules

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 specifi c 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.

If the clamps you are using are not preassembled, in-sert the hammer head screw in the specifi c 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 fi t.

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 por-trait, 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 fi t 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 fi nal clamps for PV module with frame

Pre-assembled middle and fi nal clamps for PV module with frame Module Rail Module Rail Upper side Bottom side a.

Remove the protective fi lm from the upper side of struc-tural adhesive tape, previously applied on the corrugated metal sheet.

b. Position the Universal Light mounting rail aligned with the tape, taking into account the trace previously made with the line marker cord in order to ensure correct ali-gnment of the rails.

c. Place a couple of brackets, one on the left side and one on the right side of the rail, close to the previously ap-plied tapes.

d. Fasten the brackets to the support surface. Use suitable fasteners depending on the support surface:

- Wood surfaces use stainless steel torx drive self- dril-ling screws, fl at head

- Metal surface use galvanized steel hex head self- dril-ling screws

- Concrete surfaces use concrete wall plugs

The type of fastener will be determined by Thesan Tech-nical Dept. (or Thesan confi gurator software) depending on the specifi c project to be carried out.

e. Space each profi le from the next by at least 1 cm in order to allow a safety margin in the case of thermalexpansion.

11

Step 6

Grounding system

Assembly instructions

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.

12 Notes

13

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