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Solar Energy Systems 01.09.2009

Page

Mounting Directions for In-Roof Photovoltaic Systems

Ernst Schweizer AG, Metallbau, CH-8908 Hedingen, T41 44 763 61 11, T41 44 763 61 19, www.schweizer-metallbau.ch

Image 3-2: Framed photovoltaic modules (front and backside)

1 Photovoltaic

module

Socket

2 Solrif

-XL profile frames

Connecting cable with patch plug

3.3 Substructure

The substructure is the basis for the in-roof mounting of the modules. It consists of battens and mounting boards
fastened directly to the roof. It is constructed by means of a grid plan (cf. chapter 4.2.2, p. 26).

3.4 Mounting

Clamps

Modules framed with Solrif

XL profile frames are braced to the substructure with mounting clamps. Three different

types of clamps can be used:

Number

Designation

Article Number

Mounting clamp “profile” and “frame”

respectively

13318

1.1

Mounting clamp “profile”, black

06497

Mounting clamp “glass” and “module”

respectively

13319

2.1

Mounting clamp “glass”, black

06500

Mounting clamp “top”, long, for flat

sheet-metal seams

33954

Table 3-2: Overview of mounting clamp types

Summary of Contents for Solrif D

Page 1: ...8908 Hedingen Telefon 41 44 763 61 11 Telefax 41 44 763 61 19 www schweizer metallbau ch Solar Energy Systems of Schweizer Installation Manual Solrif XL D September 2009 Solrif XL D Mounting Directions for In Roof Photovoltaic Systems ...

Page 2: ...he Roof 7 3 Instructions 7 3 1 Overview 8 3 2 Solrif framed Photovoltaic Modules 8 3 3 Substructure 9 3 5 Required Components for In Roof Mounting Flashing 12 3 5 1 Flashing profiles 13 3 5 2 Flashings 15 3 5 3 Eaves Skirting Sealing Tape for Seams and Clamps for the Lower Seam 18 4 Mounting 20 4 1 Tools Auxiliary Material 20 4 2 Preliminary Steps 21 4 2 1 Structure Statics in Accordance with DIN ...

Page 3: ...ed all other applicable documents 1 1 Revisions Date Version What s new 12 Feb 2009 1 complete update 20 April 2009 1 1 potential equalization supplement Table 1 1 Revisions 1 2 Validity This manual is valid exclusively for the installation of Ernst Schweizer AG photovoltaic modules Solrif XL and Solrif D 1 3 Target Group This manual is intended for installers of photovoltaic systems as well as fo...

Page 4: ...lation manual symbols and displays are used to facilitate comprehension Symbol Meaning Prerequisite to this specific stage of installation Installation stage with one or more steps the order of which is not important 1 2 3 Installation stage with several steps the order of which is relevant and therefore listed Listing at the first level Listing at the second level including stage instructions cf ...

Page 5: ...ecially as pertaining to the installation of electrical appliances and systems to working with direct current and to the regulations of the local power company applicable to parallel operation of solar power system Regulations of the construction employers liability insurance association Regulations concerning accident prevention 2 3 Personnel Qualifications The operator and the installer are resp...

Page 6: ...ected or insulated Voltage Higher than Safety Extra Low Voltage SELV Injury to persons due to summation of voltage during series connection Observe proper safety and security measures Dampness During Electrical Installation Injury to persons damage to the system Carry out work on the system only on a dry undersurface During installation see that photovoltaic modules wiring etc are dry 2 5 2 Workin...

Page 7: ...nstructions 3 1 Overview Image 3 1 Exploded drawing of the photovoltaic system 1 Eaves side skirting and sealing tape 8 Batten for roof tiles 2 Sheet grips 9 Side flashing upper left 3 Mounting clamp 10 Ridge side flashing left corner 4 Cylinder head screw 5 x 35 11 Solrif framed photovoltaic module 5 Flashing left side 12 Join capping piece 6 Flashing profile left 13 Flashing ridge middle 7 Mount...

Page 8: ...s of an additional rubber lip By roof slopes 10 the rainproof integration of the modules into the roofing is thereby possible in accordance with guidelines set by the German Roofers Association ZVDH Ready to mount Solrif framed photovoltaic modules for in roof installation can be obtained by various means Solrif frame kit with framing from Schweizer Module manufacturers wholesalers or partners of ...

Page 9: ...unting of the modules It consists of battens and mounting boards fastened directly to the roof It is constructed by means of a grid plan cf chapter 4 2 2 p 26 3 4 Mounting Clamps Modules framed with Solrif XL profile frames are braced to the substructure with mounting clamps Three different types of clamps can be used Number Designation Article Number 1 Mounting clamp profile and frame respectivel...

Page 10: ...s Image 3 3 Mounting clamp profile Mounting Clamp Glass In order to meet the demands of statics a module can be additionally fastened in the glass area by means of the mounting clamp glass The necessary number of clamps per module edge is to be determined on the basis of the grid plan in accordance with the static demands To protect the glass the front side of the clamp has been coated with weathe...

Page 11: ...es from the top This clamp is only necessary when flat sheet metal seams other than those provided by Ernst Schweizer AG are used If sheet metal seams are to be laid from the top mounting clamps frame should be used The necessary number of clamps per module edge is to be determined on the basis of the grid plan in accordance with the static demands Clamp width 16 5 mm Material gauge 2 0 mm Materia...

Page 12: ...es does not correspond exactly with the measurements of the roof itself In this case the rest of the roof surface must be integrated into the system by means of flashing profiles and flashings which can be delivered 3 5 1 Flashing profiles For in roof mounting special profiles for flashings on the right and left sides of the system are available as an option They compose a uniform transition to th...

Page 13: ... Photovoltaic Systems Ernst Schweizer AG Metallbau CH 8908 Hedingen Telefon 41 44 763 61 11 Telefax 41 44 763 61 19 www schweizer metallbau ch Flashing profile left 3 2 1 3 7 Flashing profile left 1 Flashing seam left side 3 Photovoltaic module 2 Flashing profile left side ...

Page 14: ...les The following flashings are available Flashing side left right Flashing side top left right Flashing ridge middle left right 1 1 2 7 7 6 3 4 8 5 Image 3 8 Mounting of the flashings No Designation Lamination size L x W 1 Flashing side left W 110 x 121 mm 2 Flashing side top left 281 x 121 mm 3 Flashing ridge left W 54 x 281 mm 4 Flashing ridge middle W 29 x 281 mm 5 Flashing ridge right W 54 x ...

Page 15: ...ttached to the flashing profiles and fastened to the mounting board by means of sheet grips and nails The flashings are laid upon the modules mounting boards and are thus at the same height Flashing right side 2 1 3 Image 3 9 Flashing side right 1 Flashing right side 3 Flashing profile right side 2 Sheet grips with nails TIP Fasten the sheets with as many sheet grips as deemed necessary but at lea...

Page 16: ... upper right left side The ridge flashings are laid upon the upper side flashings right left They have the same width as the side flashings These flashings can be used with all types of modules Flashing upper right side 1 2 4 6 5 3 Image 3 11 Flashing side top left 1 Sheet grips with nails 4 Flashing ridge left 2 Flashing left side 5 Photovoltaic module 3 Flashing upper left side 6 Flashing profil...

Page 17: ... 3 12 Flashing side top left 1 Sheet grips with nails 4 Flashing ridge left 2 Flashing left side 5 Photovoltaic module 3 Flashing upper left side 6 Flashing profile left side Flashing Ridge The upper seam consists of individual sheets each of which is assigned to a module in the upper row There are three types of flashings for the upper seam Flashing ridge middle Flashing ridge left side Flashing ...

Page 18: ...the lower array edge to the tiles it is normal to use eaves skirting as for other in roof fixtures such as dormer windows rolled lead sheet 150 mm or Mage flex aluminum roll black 280 mm available as accessories The sealing strips valley sealing strips are mounted on the eaves skirting in order to close off the roof hollows for small animals and insects TIP It is advisable to lay a 17 mm spacing b...

Page 19: ...sts maximum clamp load and load effect in accordance with DIN 1055 WLZ 2 This method is appropriate for normal wind and snow conditions For higher wind conditions and snow loads the dimensioning must be carried out in accordance with DIN 1055 4 2 2 General Planning TIP The particular design of the generator field should conform with local factors and with the demands of the project Size of the Gri...

Page 20: ...r of mounting clamps in accordance with DIN 1055 Damage to the roof structure and to the entire photovoltaic system Calculate so that the required number of mounting clamps in direct relationship to the given snow load and wind zone are used Image 4 1 Distance between the mounting clamps If the demands of the structural design require it set the mounting clamps glass in center between the framing ...

Page 21: ...e fasteners directly on to the roof 2 Align the substructure with the position of the mounting clamps for the photovoltaic modules cf grid plan 3 Close off the open cross cut between the eaves side battens with a protective screen against birds etc 4 If possible convert the roof ridge into an aeration ridge in order to divert the warmth 5 Use eaves side skirting lead roll or Mage flex strip for th...

Page 22: ...ircuits TIP Only high voltage cables and ultraviolet and heat resistant solar cables are permissible for wiring photovoltaic systems e g Solarflex 1 x 2 5 mm or 1 x 4 mm 1 Connect the inverter cable to the first module or to the lowest module of the circuit 2 Connect the modules in horizontal circuits with circuit connecting cables and plugs 3 Connect the module circuits by means of the circuit co...

Page 23: ...individual photovoltaic modules has been plotted Safety regulations are adhered to Inverting cable has been laid and the photovoltaic modules have been set up with module and circuit cables 4 4 1 Installing the Photovoltaic Modules CAUTION Neglecting Structural Demands Use only high grade construction quality 30x100 mm mounting boards for the substructure With lesser boards the effective strength ...

Page 24: ...mounting board using two cylinder head screws 5x35 per clamp Image 4 5 Fastening mounting clamp frame 3 Line up the two mounting clamps with the chalk line and fasten it 4 Align the other lowest row mounting clamps according to the grid plan and fasten them 5 Test the clamps for stability 6 Inlay the modules In Preparation for Mounting on the Tiles CAUTION Drainage at the Eaves Skirting Water dama...

Page 25: ...d screws 5x35 per clamp 3 Line up the two mounting clamps with the chalk line and fasten it 4 Align the other lowest row mounting clamps according to the grid plan and fasten them 5 Test the clamps for stability 6 Apply the channel sealing tape 4 7 Inlay the modules 4 4 1 1 Mounting the Modules CAUTION Wrong Screws Using the wrong screws can damage the mounting clamps and will not ensure the neces...

Page 26: ...ed before installing the modules Lead the module circuit connecting cable to the left before laying the module for contact access to the following module 1 In the lowest row of the first column to the right inlay the first photovoltaic module in the mounting clamp Thereby mind that the drainage channels of the frame profile are on the left and the open lamination edge on the bottom 2 Inlay flashin...

Page 27: ... flashings should be installed with their respective row of modules 3 Make sure that the mounting clamp frame is fit exactly into the slots of the frame profile fixed point Image 4 9 Position of the mounting clamp 4 Take another module and take the plug from the first module and put it into the connecting socket of the next module 5 Slide the frame profile of the next module into that of the first...

Page 28: ...ules cf image 4 11 When removing slide the modules upwards until they are free of the lower clamps Image 4 11 Spacing the module clamp to the module 1 Position of reference 3 Module frame 2 Mounting clamp 4 Space X 12 15 mm 7 Fasten the second row of mounting clamps to the rafter and test for stability TIP The system measurement R space between the mounting clamps cf image 4 1 is crucial for the c...

Page 29: ...ps in the second row to the right Mind that the notches of the frame profile which are facing upwards are on the left side 9 Take another module and take the plug from the first module and put it into the connecting socket of the next module 10 Slide the frame profile of the next module into that of the first one Image 4 13 Mounting modules 11 Mount further rows of mounting clamps and photovoltaic...

Page 30: ...en Telefon 41 44 763 61 11 Telefax 41 44 763 61 19 www schweizer metallbau ch Image 4 14 Mounting flashing profile and flashing on the left side 13 Fasten the top row of the modules Using mounting clamp top long for sheet metal seams for connecting directly to the roof ridge or Using mounting clamp profile if flashing ridge is required ...

Page 31: ... modules do not completely cover the roof Roof Seams left and right TIP Make sure that the inverter cables and the circuit connecting cable are installed before beginning with the mounting of the modules TIP Flashing profiles and flashings should be laid with each respective row of modules 1 Connect flashing profiles right and left to the frame profiles at the array edge 2 Connect flashings to the...

Page 32: ...ening flashing with sheet grips 1 Nail 2 Sheet grip 3 Fasten the outer upturn of the flashings with sheet grips and nails 4 Using the angle grinder with the diamond grinding wheel remove the right or as the case may be the left nib of the tile that is to lie upon the flashing 5 Cover the rest of the roof with tiles TIP Fasten the side sheets with sheet grips according to need but at least Flashing...

Page 33: ...t 1 Photovoltaic module 7 Tile batten 2 Solrif XL profile frame 8 Counter batten 3 Flashing profile right 9 Mounting board 100 x 30 mm 4 Flashing side right 10 Underlay 5 Roof tile 11 Roof 6 Sheet grip 12 Rafter Roof Seam Top Flashing Seams TIP Normally mounting clamps profile are suitable for ridge flashings as a flashing has no glass surface 1 Fasten flashing side top right 2 Fasten the uppermos...

Page 34: ...Image 4 19 Flashing ridge right 3 Fit the flashings into the last row of mounting clamps Fasten flashing ridge left above the uppermost left module Make sure that the flashing overlaps flashing side top left Fasten flashing ridge right above the uppermost right module Make sure that the flashing overlaps flashing side top right Fasten flashing ridge middle above the center modules Image 4 20 Flash...

Page 35: ...Photovoltaic module 4 Roof tile 2 Mounting clamp profile 5 Tile batten 3 Flashing ridge 6 Mounting board TIP Warmth emitted from the photovoltaic modules lessens the system s output Sufficient ventilation of the modules minimizes the output loss High module temperatures lessen the system s output Ventilation in the counter batten area reduces module temperature and diverts the warmth up and away D...

Page 36: ...irectly with a ridge tile Image 4 23 Integration without flashings 1 Photovoltaic module 4 Ridge tile 2 Mounting clamp long for flat topside flashing 5 Mounting board 3 Sealing tape 6 Ventilation ridge TIP Warmth emitted by the photovoltaic modules lessens the system s output Sufficient ventilation of the modules minimizes this output loss High module temperatures lessen the system s output Ventil...

Page 37: ...ential Equalization TIP It is generally recommended to ground the photovoltaic generator and to link it to potential equalization Potential equalization is of the utmost importance in the following cases Non transformer inverter Existent lightning protection system with proper distancing Establish potential equalization in accordance with DIN VDE 0100 or with the corresponding national regulations...

Page 38: ...rvoltage protection Damage to the photovoltaic module array to the inverter and the building due to faulty exterior or interior lightning protection is possible Properly installed lightning protection in accordance with VDE 0185 305 DIN EN 62305 prevents damage due to overvoltage TIP Lightning or overvoltage protection may be necessary instead of potential equalization Neglected safety distance be...

Page 39: ...ty regulations and the corresponding operating guidelines of the inverter TIP Proper system configuration for optimal solar energy production from each module The system configuration has essential influence on the output capability of the photovoltaic system Follow the laying criteria for the inverters and the guidelines of the module manufacturer for an optimal combination with the inverters 6 D...

Page 40: ...lations when disposing of or recycling the photovoltaic system or its components Questions pertaining to the disposal of the photovoltaic system should be addressed to an authorized specialist 9 Parts List Designation Measurement Condition Article Number Mounting clamp profile 16 mm x 1 5 2 0 mm 13318 Mounting clamp profile black 16 mm x 1 5 2 0 mm 06497 Mounting clamp glass 16 mm x 1 5 2 0 mm 133...

Page 41: ...hing side top right left 06683 06684 Flashing ridge side right left Specific to the module Flashing ridge middle Specific to the module 9 2 Accessories Solrif D Designation Article Number Flashing profile right left 06435r Flashing side right left Specific to the module Flashing side top right left 06852 06853 Flashing ridge side right left Specific to the module Flashing ridge middle Specific to ...

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