Play it safe. Mounting instructions incell system. Premium incell XM, L Mounting system for roof-integrated photovoltaic systems

Transcription

1 Play it safe Mounting instructions incell system Premium incell XM, L Mounting system for roof-integrated photovoltaic systems

2 DIN EN ISO 9001 Quality Management System DIN EN ISO Environmental Management System BS OHSAS Occupational Safety and Health Management System Subject to technical modifications and changes to the product design. The technical information valid at the time of the product being manufactured apply. Solar-Fabrik, Freiburg, 2014 Status: / Document No.: 1408TU TU0713 incell XM, L

3 I Table of contents Introduction and overview On these mounting instructions 4 Safety instructions 5 Application limits 7 Transportation and storage 7 Tools, aids 8 Before mounting 8 System incell Overview 9 PV modules Mounting dimensions 16 Module field Position on the roof and dimensions 17 Module field Layer / bottom section 18 Module field Dimensions and material list 20 Electrical connection Overview 21 Earthing Overview 21 Mounting Mounting process Overview 22 Preparing the module field on the roof 24 Mounting the layer / bottom section (planks) 25 Mounting the bottom flashings 26 Mounting the underlay sarking membrane 28 Mounting the bottom mounting brackets and battens 29 Mounting the bottom ventilation panels 31 Mounting Module 1 32 Mounting Module 2 34 Mounting Module 3 36 Mounting Module 4 (centre) 38 Mounting Module 4 (top) 40 Mounting the left side flashing and side connection profiles 42 Mounting the top flashings 44 Bonding on the foam sealing wedges and mounting the sheet staples 49 overing the roof 51 incell XM, L 1408TU0713 3

4 On these mounting instructions These mounting instructions describe rapid and safe in-roof mounting of the photovoltaic system. Read these mounting instructions attentively before mounting. Keep these mounting instructions for the operating period of the photovoltaic system. Ensure that these mounting instructions are available for the owner-operator at all times. Pass these mounting instructions on to each subsequent owner or user of the photovoltaic system. Insert every supplement received from the manufacturer. Observe the further applicable documents. Read these mounting instructions and all the further applicable documents attentively before carrying out mounting. Read and observe the safety instructions in these mounting instructions and all the further applicable documents. Further applicable documents These mounting instructions are valid only in combination with the following technical information. Document type, title "Instructions for installation and operation of Premium incell modules" Data sheet for earthing screw Solfil SFP41916 Technical information for the inverter, junction box and cabling "incellplan" planning programme Revisions Version Date Version Remark First issue Modifications Modifications Modifications Modifications Validity current version as to delivery specification current version. Download: These mounting instructions are valid solely for the mounting of the SF incell photovoltaic modules of Solar-Fabrik AG. the mounting, operation and maintenance of photovoltaic systems. These mounting instructions are intended for specialist users who are familiar with the requirements for the mounting of solar systems on roofs and with the locally applicable regulations and standards on occupational safety and mounting and who dispose of sufficient qualification to carry out all mounting steps on their own responsibility. Warnings In these instructions warnings are used in order to avoid injuries or material damage. Always read and observe these warnings. These warnings are identified by the following symbols and signal words: Warning symbol Symbol Warning word DANGER WARNING AUTION AUTION Meaning Symbols and markings Imminent danger. Non-observance results in death or extremely serious injuries. Threatening danger. Non-observance can result in death or extremely serious injuries. Dangerous situation. Non-observance can result in minor injuries. ritical situation. Non-observance can result in material damage. Description Prerequisite that has to be fulfilled before an action begins. Action with one or more steps Enumeration of first level Enumeration of second level Ensure when executing an action, check the result of an action Observe when carrying out an action Impermissible execution of an action Target group These mounting instructions are intended for installers of photovoltaic systems and trained specialist personnel who are familiar with TU0713 incell XM, L

5 Safety instructions Proper use The photovoltaic system is designed exclusively for the generation of solar current. Mounting is carried out exclusively as in-roof variants in accordance with these mounting instructions. Any other use is regarded as improper. Mounting location and ambient conditions Observe the field of use and conditions of use as specified in the planning documents. These include the specifications for: Mounting location Specifications for operation in moderate climate Specifications for minimum and maximum operating temperatures Specifications for maximum snow and wind loads Specifications for the alignment and angles of inclination Safety regulations The owner-operator of the photovoltaic system is responsible for the observance of all the relevant statutory regulations and directives. ommission, operate and maintain the photovoltaic system only under observance of the following regulations and standards. Mounting instructions Warning and instruction signs at the photovoltaic module Further applicable documents System-specific provisions and requirements Valid country-specific laws, regulations and directives for the planning, mounting and operation of solar power systems and for working on roofs Valid international, national and regional regulations, in particular on the installation of electrical devices and systems, on working with direct current and the regulations of the responsible supply companies on the parallel operation of solar current systems. in Germany: Directives of the ZVDH in France: Règles DTU Regulations of the building and construction employers' liability insurance association Regulations on accident prevention Qualification of personnel The owner-operator and installer are responsible for ensuring that mounting, maintenance, servicing and repair and dismantling are carried out only by qualified and trained skilled workers. Keep children and unauthorised persons away from the photovoltaic system. Ensure that the personnel has understood these mounting instructions and can implement them. Ensure that the personnel knows and observes the relevant accident-prevention and safety regulations. Ensure that the personnel uses suitable protective clothing and equipment. Handling of the components of the photovoltaic system Protect all the components (modules, sheet metal parts. mounting material) against contact with objects with sharp edges, against damage, especially against impacting against edges, through bumping or falling down. Do not let any objects fall on the module. Protect the surface of the module against mechanical loads and stresses (tension compression, torsion). Do not step on the module or place your weight on it. Ensure that the modules do not stand or lie in water at any time and are not subject to humidity, moisture and rain. Keep tools clean and dry at all times during mounting. Observe the specifications for cleaning and care in the further applicable documents. Modifications and alterations Modifications and alterations to the mounting system can damage the photovoltaic module or impair functions. Do not carry out any modification or alterations to the mounting system with the exception of the actions described in these mounting instructions. Particular sources of danger The photovoltaic module (called the "module" below) is to be treated as a glass product. Wear suitable protective equipment (gloves, protective shoes). Do not place it on exposed edges. Do not step on it or place improper loads on it. incell XM, L 1408TU0713 5

6 Safety instructions Electrical installation Danger of injury through electric shock! The module can build up voltage which is present at the junction boxes during the mounting process. over the module with lightproof material during the entire mounting process in order to ensure a de-energized state. Take into account that even under low solar irradiation the total open circuit voltage can apply. Ensure that the electrical installation and commissioning are carried out by a concessionary electrician. Do not open the junction boxes. Do not insert electrically conductive parts into the connectors and junction boxes. Do not touch contacts and exposed terminals. Observe the smallest permissible bending radii at the junction boxes. Electric arcs Electric arcs at conductors carrying direct current! Fatal injury through simultaneous contact of both poles. Do not disconnect cable under load. onnect or insulate bare cable ends. Voltage Higher voltage than safety extra-low voltage! Injury to persons through addition of the voltage due to series connection. Take suitable safety and protective measures. Fire hazard Fire hazard when damaged modules or components are mounted! Mount only undamaged modules and components. Inspect modules and all components for damage before mounting. Replace damaged components. Working on the roof arry out mounting only during dry weather, not during strong wind or rain. Above a height of 3 m (eaves) a scaffold with arrester system is mandatory. If it is not possible to mount a scaffold or the roof is very steep: Wear a safety harness and fasten it to a building part able to take the weight. Use suitable fall protection devices when working on the roof. Provide suitable storage space for tools and material. Set up barriers to protect against falling objects. Observe the pertinent regulations for working on the roof. Moisture Moisture during the electrical installation! Injury to persons, damage to the system. arry out work on the system only on a dry surface. During mounting ensure that the photovoltaic modules, cables, etc. are dry TU0713 incell XM, L

7 Application limits Observe the application limits of the system. Parameter Value Roof pitch Snow load (max.) 1500 Pa (153 kg/m 2 ) Wind suction (max.) 930 Pa (95 kg/m 2 ) Height of module field (max.) 8 m Distance of module field roof 1.0 m ridge (max.) Pa 8 m 1500 Pa Ensure that the roof surface on which the system is mounted disposes of a rain-proof or rain-resistant sub-roof (depending on the roof pitch and structural requirements of the building). Transportation and storage Store the modules secured in cool and dry rooms. Take into account that the original packaging does not protect the components against weather conditions. Transport all the components in the original packaging until mounting. Use glass suction cups when removing and transporting a module. Hold and carry the module only at the edges. arry the module vertically as far as possible in case of longer transport distances. Under no circumstances may you hold or carry the module at the connecting cables or junction box. Do not stack modules. Do not place the module on the edges unprotected. incell XM, L 1408TU0713 7

8 Tools, aids Lay ready the following tools and aids for mounting: arpenter's pencil Line/chalk line Tape measure and folding yardstick Set of screwdrivers Nails for sheet staples Hammer for nails of the sheet staples Straight-edge or level Wood saw Sheet shears and pliers Knife ordless screwdriver with T25 bit Angle grinder with diamond disk for grinding off the tile nose Multimeter able ties resistant to ultraviolet rays Underlay sarking membrane Planks Screws Before mounting Prerequisites for mounting Bearing capacity of the roof structure checked. Grid size and grid plan drawn up for the photovoltaic system. Electrical connection diagram and earthing plan drawn up and connection prepared at customer. Safety regulations read, understood and observed. Rain-proof or rain-resistant sub-roof exists Application limits observed Preparatory activities Have ready the planning documents for the grid plan and grid sizes, structural engineering documents. Have ready the electrical connection diagram and earthing plan. Secure the mounting location suitably and protect against access by unauthorised persons. Preparing the material Unpack the supplied packages and check whether complete. Lay out ready all the components. Lay out the tools. Lay out ready additional mounting material (planks, battens, screws, nails, underlay sarking membrane). Lay out ready the electrical connecting material (cables, connectors, material for earthing). Secure or cordon off the mounting location (building site). heck whether the roof can be accessed and moved on and implement the required safeguards TU0713 incell XM, L

9 System incell Overview PV module (with junction box) 2 Wooden wedge (optional) 3 Head flashing (left) 4 Ventilation grille, top (left) 5 ap 6 Ventilation grille, top (centre) 7 Head flashing (centre) 8 Head flashing (right) 9 Ventilation grille, top (right) 10 Side connection profile, right 11 Side flashing (right) 12 Side flashing (right, bottom) 13 Retaining bracket (glass) 14 Mounting bracket (frame) 15 Mounting bracket (glass) 16 Bottom flashing, (right) (with pleated lead) (optional) 17 Ventilation panel, bottom (right) 18 Bottom flashing, (centre) (with pleated lead) (optional) 19 Ventilation panel, bottom (centre) 20 Bottom flashing, (left) (with pleated lead) (optional) 21 Ventilation panel, bottom (left) 22 Retaining bracket (frame) 23 Side flashing (left, bottom) 24 Sheet staples (bag with nails) 25 Side connection profile, left 26 Side flashing (left) 27 Foam sealing wedge Screws (HEO Topix) Metal screws Earthing screw (optional) 28 Batten incell XM, L 1408TU0713 9

10 System incell Overview Basic kit 2 2 Size Order No. XM mono black SBl L - - SBl mono black SBl omponent Piece Order No. XM mono black L L mono black Head flashing (left) 1 Bl L-10 Bl L-10 Head flashing (right) 1 Bl R-10 Bl R-10 Side flashing (right) 1 Bl R-10 Side flashing (right, bottom) 1 Bl RU-10 Side flashing (left) 1 Bl L-10 Side flashing (left, bottom) 1 Bl LU-10 Ventilation grille, top (left) 1 Bl L-00 Bl L-00 ap 1 Bl Sealing tape 2 Bl Metal screw 1 Bl Ventilation grille, top (right) 1 Bl R-00 Bl R-00 Side connection profile, right 2 Bl R-20 Bl R-00 Bl R-20 Side connection profile, left 2 Bl L-20 Bl L-00 Bl L-20 Retaining bracket (frame) 12 Bl Bl Bl Retaining bracket (glass) 6 Bl Bl Bl Mounting bracket (frame) 3 Bl Mounting bracket (glass) 6 Bl Ventilation panel, bottom (right) 1 Bl R-10 Bl R-10 Ventilation panel, bottom (left) 1 Bl L-10 Bl L-10 Sheet staples (bag with nails) 4 Bl Screws (HEO Topix) 63 Bl Foam sealing wedge, 1.0 m 9 Bl Batten, 1.7 m 2 Bl Optional Bottom flashing, (left) (with pleated lead) 1 Bl L-10 Bl L-10 Bottom flashing, (right) (with pleated lead) 1 Bl R-10 Bl R-10 Wooden wedge 4 Bl Earthing screw SOLFIL 4 Bl TU0713 incell XM, L

11 System incell Overview Extension kit vertical Size Order No. XM mono black SBl L - - SBl mono black SBl omponent Piece Order No. XM mono black L L mono black Head flashing (centre) 1 Bl M-10 Bl M-10 ap 1 Bl Sealing tape 2 Bl Metal screw 1 Bl Ventilation grille, top (centre) 1 Bl M-00 Bl M-00 Retaining bracket (frame) 5 Bl Bl Bl Retaining bracket (glass) 3 Bl Bl Bl Mounting bracket (frame) 1 Bl Mounting bracket (glass) 3 Bl Ventilation panel, bottom (centre) 1 Bl M-10 Bl M-10 Sheet staples (bag with nails) 1 Bl Screws (HEO Topix) 28 Bl Foam sealing wedge, 1.0 m 2 Bl Batten, 1.7 m 1 Bl Optional Bottom flashing, (centre) 1 Bl M-10 Bl M-10 (with pleated lead) Wooden wedge 2 Bl Earthing screw SOLFIL 2 Bl incell XM, L 1408TU

12 System incell Overview Extension kit horizontal Size Order No. XM mono black SBl L - - SBl mono black SBl omponent Piece Order No. XM mono black L L mono black Side flashing (left) 1 Bl L-10 Side flashing (right) 1 Bl R-10 Side connection profile, right 1 Bl R-20 Bl R-00 Bl R-20 Side connection profile, left 1 Bl L-20 Bl L-00 Bl L-20 Retaining bracket (glass) 6 Bl Bl Bl Retaining bracket (frame) 3 Bl Bl Bl Sheet staples (bag with nails) 1 Bl Screws (HEO Topix) 18 Bl Foam sealing wedge, 1.0 m 2 Bl Optional Earthing screw SOLFIL 2 Bl TU0713 incell XM, L

13 System incell Overview Extension kit module central Size Order No. XM mono black SBl L - - SBl mono black SBl omponent Piece Order No. XM mono black L L mono black Retaining bracket (glass) 3 Bl Bl Bl Retaining bracket (frame) 1 Bl Bl Bl Screws (HEO Topix) 8 Bl Optional Earthing screw SOLFIL 1 Bl incell XM, L 1408TU

14 Individual components PV module 1 PV module 2 Junction box 3 Earthing screw 4 onnector 5 able 6 Socket Side flashings, side connection profiles Side flashing (left) 2 Side flashing (left, bottom) 3 Side connection profile, left 4 Side connection profile, right 5 Side flashing (right, top) 6 Side flashing (right, bottom) 7 Nail 8 Sheet staple 9 Foam sealing wedge TU0713 incell XM, L

15 Top flashings Sheet staples 2 Flashing (left) 3 ap 4 Sealing strips 5 Flashing (centre) 6 Screw 7 Flashing (right) 8 Nail 9 Ventilation grille (right) 10 Ventilation grille (centre) 11 Ventilation grille (left) 12 Foam sealing wedge Bottom flashings 1 Ventilation panel, bottom (left) 2 Ventilation panel, bottom (centre) 3 Ventilation panel, bottom (right) 4 Pleated lead 5 Butyl sealing strips (selfadhesive) 6 Flashing (right) 7 Flashing (centre) 8 Flashing (left) 9 Sheet staples 10 Nail 11 Batten (1.7 m) incell XM, L 1408TU

16 a PV modules Mounting dimensions PV module 1 PV module 2 Mounting bracket (glass) 3 Mounting bracket (frame) 4 Side flashing 5 Top flashing 6 Bottom flashing 7 Pleated lead 8 Side connection profile Module type Mounting dimensions Parameter incell XM incell L Mounting bracket [pc.] (per module) 4 4 A [mm] B [mm] [mm] D [mm] E [mm] F [mm] X1 D 5 X D X = n B + 27 cm Y = n A + 93 cm E X 1 = n B + 15 cm Y 1 = n A + 60 cm 1 B = 1377 mm XM A Y1 Y = 344,25 mm B = 1693 mm F L 6 7 B = 423,25 mm mm 10 mm B B 8 4 B B D X1 X D TU0713 incell XM, L

17 Module field Position on the roof and dimensions A B D E F Y X Z s r t Mounting dimensions Mounting height of a module row Mounting width of a module row Distance between the mounting brackets Mounting width of the side flashings Mounting height of the top flashing Mounting height of the bottom flashing Module field height Module field width (Approx.) distance between removed tile rows Distance between side flashing and right-hand tile row overing width tile Distance between bottom flashing and righthand tile row Module field 1 Module field 2 Rafters 3 Roof battens 4 Tile row, lies on the flashings after mounting 5 Tile row possibly to be removed (to fasten the planks on the rafters) 6 Pleated lead 7 Side flashing 8 Bottom flashing m 3 6 Z X Y r s mm s mm 55 mm t r 8 incell XM, L 1408TU

18 Module field Layer / bottom section D d c A B 6 G E F 8 A B 6 B Module field 1 Module field 2 Rafters, max. distance: 800 mm 3 Roof battens 4 Tile row, lies on the flashings after mounting 5 Tile row possibly to be removed (to fasten the planks on the rafters) 6 Module 7 Base: Planks, min. 27 (max. 30) x 100 mm 8 Base: Battens (for retaining bracket), min. 27 (max. 30) x 60 mm 9 Mounting bracket (frame) 10 Mounting bracket (glass) 11 Support plank, min. 27 (max. 30) x 100 mm 12 Wood screw, 80 x 6, 2 pc./rafter 13 Wood screw, 55 x 6, 1 pc./plank; 6 pc./support plank 14 Batten, 15 x 20 mm A B c d Mounting dimensions Mounting height module Mounting width module Max. projection of the planks at the rafters c = 300 mm Allowance for fastening to next rafter mm min. 27 / max. 30 mm 100 mm 60 mm 20 mm 80 x 6 mm R ax,k = 2,5 kn (50 mm) 55 x 6 mm R ax,k = 1,7 kn (25 mm) TU0713 incell XM, L

19 D c 7 A 8 B mm 25 mm 18 mm 18 mm 30 mm 5 mm 2 d F E 7 min. 20 mm G incell XM, L 1408TU

20 Module field Dimensions and material list Module field dimensions You can determine the required dimensions with the incell planning tool. Distance s between side flashing and right-hand tile row You can determine the required dimensions with the incell planning tool. Material list for base The calculation of the required meters of planks and batters can only supply an approximate value. Take sufficient allowances for cutting and adaptation to the respective roof situation into account when planning the required material. Take into account the maximum permissible projection of the planks at the rafters (Dimension c). If the projection exceeds the value (Dimension c), measure the length of the planks to the next rafter and add as an allowance (Dimension d). Planks The number of plank rows per module depends on the number of roof battens that are covered by a module during mounting. Allowances depending on the position of the rafters lying laterally next to the module field have to be taken into account depending on the roof situation. You can determine the required dimensions with the incell planning tool. Battens You can determine the required dimensions with the incell planning tool. Screws You can determine the required number of pieces with the incell planning tool TU0713 incell XM, L

21 Electrical connection Overview Electrical connection 1 PV module 2 Module cable (mounted) 3 onnector 4 Bundle cable ( ) (provided by customer) 5 Bundle cable (+) (provided by customer) 6 Inverter 7 Junction box 8 onnecting cable (provided by customer) 9 Socket = ~ Earthing Overview Earthing 1 Earthing screw 2 Earthing wire (provided by customer) (mm 3 PV module 4 Earthing wire (provided by customer) (mm 5 Earthing (provided by customer) We recommend already screwing the earthing screw on at all the modules before mounting the modules onto the roof. incell XM, L 1408TU

22 Mounting process Overview Module field Layer / bottom section Bottom flashings 4 Underlay sarking membrane 5 Bottom mounting brackets 6 Bottom ventilation panels 7 Module (1) 8 9 Module (2) Module (3) 10 At more than 2 rows: 1 further module (2) per row TU0713 incell XM, L

23 10 Module (4) centre 11 Module (4) top At > 2 rows: 1 further module (4) centre per row At > 2 columns: Further modules (3) At > 2 columns: Further modules (4) top and centre Side flashings and side connection profiles (left) Top flashings Foam sealing wedges and sheet staples 15 Roofing onnection to inverter. ommissioning. incell XM, L 1408TU

24 1 Preparing the module field on the roof Measuring the module field X, Y, Z: a Z X Y Removing the roof TU0713 incell XM, L

25 2 Mounting the layer / bottom section (planks) Mounting the planks E u u = >20 mm 80 x 6 mm 55 x 6 mm E H 2x 3x 80 x 6 mm H 2x 2x 2x Preparing the connections Lay the earthing line ( 16 mm 2 ) and bundle cable. Route in suitable manner through the roof and lay on the collector field in such a manner that the modules can be connected. = ~ incell XM, L 1408TU

26 3 Mounting the bottom flashings Mounting the first bottom flashing 1. s, t: t = s 55 mm s t t min. 15 cm min. 15 cm min.15 cm TU0713 incell XM, L

27 3 Mounting further bottom flashings 1. v v = 15 cm incell XM, L 1408TU

28 4 Mounting the underlay sarking membrane Drawing in the underlay sarking membrane ~5 cm x x = 20 cm TU0713 incell XM, L

29 5 Mounting the bottom mounting brackets and battens Mounting the bottom mounting brackets 1. B B B, : a 2. y y = 17 cm incell XM, L 1408TU

30 5 Mounting the battens 1. A A B 10 mm 25 mm B B 18 mm 18 mm 30 mm 5 mm 2. D D x 55 x 6 mm TU0713 incell XM, L

31 6 Mounting the bottom ventilation panels Mounting the ventilation panels incell XM, L 1408TU

32 7 Mounting Module 1 Mounting the side flashing and side connection profile onnecting the module TU0713 incell XM, L

33 7 Mounting the module Mounting the earthing We recommend already 1. screwing the earthing 2. screw on at all the modules before mounting the modules onto the roof. incell XM, L 1408TU

34 8 Mounting Module 2 Mounting the top retaining brackets 1. 0 mm 16 mm 2. : a Mounting the side flashing and side connection profile onnecting the module TU0713 incell XM, L

35 8 Mounting the module Mounting the earthing incell XM, L 1408TU

36 9 Mounting Module 3 onnecting the module Mounting the module TU0713 incell XM, L

37 9 Mounting the earthing incell XM, L 1408TU

38 10 Mounting Module 4 (centre) Mounting the top retaining brackets mm : a 2. onnecting the module TU0713 incell XM, L

39 10 Mounting the module (centre) Mounting the earthing incell XM, L 1408TU

40 11 Mounting Module 4 (top) Mounting the top retaining brackets mm : a 2. onnecting the module TU0713 incell XM, L

41 11 Mounting the module (top) Mounting the earthing incell XM, L 1408TU

42 12 Mounting the left side flashing and side connection profiles Mounting the earthing onnecting to the bundle cable to the inverter = ~ TU0713 incell XM, L

43 12 Mounting the side flashing and side connection profile (bottom) Mounting the side flashing and side connection profile (centre and top) incell XM, L 1408TU

44 13 Mounting the top flashings Mounting the top retaining brackets 1. 0 mm 16 mm 2. : a Mounting the ventilation grille TU0713 incell XM, L

45 13 utting the battens to size mm 30 mm Mounting additional planks incell XM, L 1408TU

46 13 Mounting the wooden wedges and support planks mm mm 20 mm 10 mm 180 mm TU0713 incell XM, L

47 13 Mounting the top flashings incell XM, L 1408TU

48 13 Mounting the caps TU0713 incell XM, L

49 14 Bonding on the foam sealing wedges and mounting the sheet staples incell XM, L 1408TU

50 14 Bending the corners at the bottom flashing Mounting the sheet staples TU0713 incell XM, L

51 15 overing the roof >15 cm incell XM, L 1408TU

52 Play it safe Solar-Fabrik AG Munzinger Str Freiburg Germany Phone +49 (0) Fax +49 (0) Status: / Doc. No.: 1408TU0713