energy for a better world

INSTALLATION INSTRUCTIONS TRI-VENT

The photovoltaic mounting systemfor trapezoidal sheet roofs• Quick and easy installation• Riveting instead of glueing• Securing without screws• Cost-effective alternative• Certificated for wind and snow loads• Tested for statics

Table of Contents

The Basics

Liability 4

Load Effect 4

Statics 4

TRI-DESIGN Dimensioning Software 5

Upright Installation

Tools 6

Installation of the Mounting System 6

Horizontal Installation

Tools 10

Installation of the Mounting System 10

4_The Basics

LiabilityFor the installation of the TRI-VENT Mounting System only products of the range of the TRI-VENT Mounting System must be used. Using third-party com-ponents can affect the system’s stability and result in significant damage.The installation of the system must only be carried out by trained and com-petent personnel. We do not accept liability for damages arising from the use of third-party components or incorrect installation.

Load EffectIn addition to the photovoltaic system’s own weight, the system’s compo-nents and substructure are mainly exposed to wind and snow loads. There-fore, each system must be calculated and designed specifically for its require-ments and external conditions, taking into consideration DIN 1055* (Effects on supporting structures).

The exposure to wind loads is mostly dependent on the wind zone (according to DIN 1055-4*), the building’s height, the position of the roof’s centre as well as the roof shape and slope. Weight loads due to snow are dependent on the snow zone (according to DIN 1055-5*), the building’s height, the position of the roof’s centre, the roof shape and slope.The wind and snow zone, on which the design of the system is based, can be determined for each location. Information and advice on the statics of the Mounting System are attached to these mounting instructions.

StaticsThe statics of each roof must be checked by authorised experts to determine whether it can tolerate the additional loads resulting from the solar system. The load capacity of roofs and the load effect of photovoltaic systems are dependent on numerous factors. For this reason, an individual statics calcu-lation must be performed for each roof. The advice and statics certificate of the TRI-VENT Mounting System must be observed without fail.Additionally, the current condition of the roof must be such that the roof will not be in need of repairs for a period of at least 20 years.

*European standard: EN 1991-1-3

Roof equipped with carrier profiles and module anchors

The Basics_5

TRI-DESIGN Dimensioning SoftwareThe TRI-DESIGN dimensioning software calculates and designs the TRI-STANDmounting system according to the standards of DIN 1055*. The relevant direc-tives are DIN 1055-4* for wind loads and DIN 1055-5* for snow and ice loads, which affect the photovoltaic system and its substructure.In addition to the number of roof hooks to be used, the dimensioning soft-ware also calculates the distances of the guide rails and the maximum span width of the various profiles. The dimensioning software allows us to design the system optimally for the individual roof and thus to select the best ver-sion of the mounting system.

Under the warranty terms and conditions, all TRI-VENT systems must have been dimensioned using the TRI-DESIGN dimensioning software.

System dimensioning using TRI-DESIGN

6_Upright Installation

DIFFERENT TYPES OF INSTALLATIONDepending on the system design, the TRI-VENT mounting system must be planned and installed in different ways. Horizontal or upright installation must be selected for the respective roof area. One of the two types of instal-lation must be determined for each roof individually.

UPRIGHT INSTALLATION

ToolsThe upright installation of the modules requires the following tools:• Cordless electric drill with a 6.5 mm drill• TRI-VENT riveting machine• TRI-VENT drilling gauge• TRI-VENT bending tool

Installation of the Mounting SystemThe upright installation is divided into three steps: 1. Attaching the horizontal carrier profiles2. Placing and attaching the modules using the TRI-VENT central module

anchors3. Securing the edge modules using the TRI-VENT end module anchors

1. Attaching the horizontal carrier profiles After the substructure of the roof has been checked for its point bearing ca-pacity, the holes for the attaching of the carrier profiles are drilled. Here spe-cial attention must be paid to the fact that all holes are placed in such a way that the carrier profiles are aligned straight to each other vertically and hori-zontally and at the correct intervals. To optimally position the holes, start with one of the bottom edge modules and use the TRI-VENT drilling gauge vertically and a piece of string horizontally.

Assembling the drilling gaugeTo position the holes using the drilling gauge, the gauge must be assembled first and then adjusted to the respective roof. Both profiles are attached to the angle piece using the supplied screws. Please make sure that at this point the first variable drilling guide has already been inserted into the profile.

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TRI-VENT upright installation

Assembly of the TRI-VENT drilling gauge using 6 screws

Marking of the raised beads to be drilled

Upright Installation_7

Adjusting the support pins Then the two support pins on the angle piece are adjusted in such a way that the drilled hole is in the centre of the raised bead and the distance between drilling gauge and raised bead is between 2 and 4 mm. For this, the pins are screwed symmetrically to the drill hole and adjusted for the right distance using washers. Now the drilling gauge is attached to the raised bead and can-not slip in the area of the angle piece.

Adjusting the hole distance Now the drilling gauge is set to the desired hole interval, which must be aligned with the raised bead distance and the pre-drilled holes in the carrier profile. For this, a carrier profile is fixed with its pin in the first drill hole. Then the drilling guide is set below the corresponding hole in the profile and fixed with the two screws, so that a hole can be drilled in the correct place of the drilling gauge profile. Using the drilling gauge, now both holes are in the centre of the raised beads, the one with the fixed and the one with the variable drilling guide. Now the drilling gauge is set for the correct hole distance in horizontal direction. Using this setting, the bottom horizontal row is drilled following the previous-ly made markings.

Optimal roof protection To protect the roof and drilling gauge from scratches and damages during installation, cable ties can be attached to the drilling gauge. These must be placed on the drilling gauge in such a way that they do not impede the drill-ing of the holes.

Adjusting the support pins

Adjusting the hole distance to the profile and the raised beads

Optimal roof protection

Measuring and marking of the bottom row

Drilling of the bottom row using the drilling gauge

Drilling of the second row

Distances of attachment rows

8_Upright Installation

Measuring and marking the first row Now the drilling gauge is prepared for drilling the bottom row. The row is marked using a piece of string. For this, the string is drawn from one end of the roof to the other at the correct distance from the lower edge of the roof. Please make sure that the lowest row of profiles is at the height of the bot-tom mounting holes of the modules, i.e. that the mounted module projects beyond the bottom attachment row.The raised beads, to which the drilling gauge and later the profiles will be attached, are marked with a tape measure.

Drilling the first row Using the set drilling gauge, now the holes of the bottom profile row are drilled. For this, the gauge with the support pins is positioned on the respec-tive raised bead. First drill the hole of the fixed drilling guide using a 6.5 mm drill. Then the drilling gauge is fixed to the raised bead using the pin, so that the second hole of the set variable drilling guide can be drilled. This proce-dure saves time and ensures a high level of accuracy.

Setting up and drilling the second row Having drilled the bottom row, the vertical distance to the next row is set. For this insert the last drilling gauge into the long profile of the drilling gauge. Using the tape measure, the distance (B) can be read, before the drill-ing guide is fixed to the profile by tightening its two screws. This distance corresponds to the distance of the mounting holes of the solar module. With this setting and based on the bottom row, the second row is drilled. For this the drilling gauge is fixed with its pin in one of the two holes of the bottom row and positioned higher vertically to the roof. Drilling the two holes in the drilling guides gives these holes the correct distance and ensures that they are parallel to the holes of the bottom row.

Measuring and drilling additional rowsAfter completion of the second row, the TRI-VENT drilling gauge is set for the last time. The vertical distance (A) is set in such a way that it corresponds to the distance of the bottom row to the third row. Since the rule is two attach-ment rows per module, this is the distance from the bottom attachment row of the first module row to the bottom attachment row of the second module row. It is comprised of the module height plus two centimetres distance, which has to be adhered to between the modules. With this setting and based on the bottom row, the third row is drilled. With the same settings and based on the second row, now the fourth row is drilled. Based on the third row the fifth and based on the fourth row the sixth row can be drilled etc. The drilling gauge must no longer be adjusted until the last row.

Riveting the carrier profiles

Attaching the TRI-VENT retaining ring

Fixing of the module using the TRI-VENT module anchor

Securing the edge module using the TRI-VENT bending tool

Laying and attaching the cables

Upright Installation_9

Riveting the carrier profiles When all holes are drilled, the TRI-VENT carrier profiles are riveted to the roof. By means of insertion of the sealing rubbers, the sealing rivets enable the easy and water-tight attachment of the profiles.

2. Placing and attaching the modules using the TRI-VENT central module anchorsTo insert the modules into the system securely, first the slip protection is at-tached to the module. Attach the two TRI-VENT retaining rings to the holes in the solar module; they prevent the slipping of the module during installa-tion and exposure to wind and snow loads. The retaining rings rest against the profiles and thus ensure the secure hold of the modules.

Inserting and fixing the modules The TRI-VENT module anchors can be inserted into the anchor rail at two dif-ferent heights each. One module anchor can thus provide anchoring for two module frame heights. Six types of anchors are currently available: 31 / 42, 34 / 45, 35 / 46, 36 / 45, 38 / 48 and 40 / 50 mm.The modules equipped with the TRI-VENT retaining rings are now placed in the desired position and fixed with the module anchors. Please make sure to use the thicker end module anchors at the end of rows and the central module anchors between the modules.

Laying and attaching the cables When the modules are placed, the cables can be laid and attached to the carrier profiles using the Edge Clip TV-EC. This prevents the cables lying open and unprotected and reduces the risk of damages to the cables and connec-tors.

3. Securing the edge modules using the TRI-VENT end module anchorsTo secure the edge modules and ensure the stability of the entire system, TRI-VENT end module anchors are attached to the end of each module row. The anchor’s firm connection to the carrier profile secure the rows. They are fixed by bending the carrier profile using the TRI-VENT bending tool. This en-sures a firm connection of the anchor and saves time. After the installation and with a module field width of more than five modules, the anchor rail is bent slightly upwardly using the TRI-VENT bending tool between every fifth module. This additionally secures the modules against horizontal displace-ment.

By means of the module anchors and gravity the modules are now positioned and must not be secured by screws.

10_Horizontal Installation

HORIZONTAL INSTALLATION

ToolsThe horizontal installation of the modules requires the following tools:• Cordless electric drill with a 6.5 mm drill• TRI-VENT riveting machine• TRI-VENT drilling gauge• TRI-VENT bending tool

Installation of the Mounting SystemThe horizontal installation is divided into three steps: 1. Attaching the vertical and horizontal carrier profiles2. Placing and attaching the modules using the TRI-VENT central module

anchors3. Securing the edge modules using the TRI-VENT end module anchors

1. Attaching the vertical and horizontal carrier profiles After the substructure of the roof has been checked for its point beating ca-pacity, the holes for the attaching of the carrier profiles are drilled. Here spe-cial attention must be paid to the fact that all holes are placed in such a way that the carrier profiles are aligned straight to each other vertically and hori-zontally and at the correct intervals. To optimally position the holes, start with one of the bottom edge modules and use the TRI-VENT drilling gauge vertically and a piece of string horizontally.The edge profiles are attached to the outer profiles of each row in the centre of each module.In general, it is recommended to use a laser or piece of string to measure the drilling hole positions before drilling.

Assembling the drilling gaugeTo position the holes using the TRI-VENT drilling gauge, the gauge must be assembled first and then adjusted to the respective roof. Both profiles are attached to the angle piece using the supplied screws. Please make sure that at this point the first variable drilling guide has already been inserted into the profile.

Horizontal installation of modules

Assembly of the TRI-VENT drilling gauge using 6 screws

Marking of the raised beads to be drilled

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Adjusting the support pins

Optimal roof protection

Horizontal Installation_11

Adjusting the support pins Then the two support pins on the angle piece are adjusted in such a way that the drilled hole is in the centre of the raised bead and the distance between drilling gauge and raised bead is between 2 and 4 mm. For this, the pins are screwed symmetrically to the drill hole and adjusted for the right distance using washers.

Adjusting the hole distance Now the drilling gauge can be set to the desired hole interval, which must be aligned with the raised bead distance and the pre-drilled holes in the carrier profile. For this, a carrier profile is fixed with its pin in the first drill hole. Then the drilling guide is set below the corresponding hole in the profile, fixed with the two screws, so that a hole can be drilled in the correct place of the drilling gauge profile. Using the drilling gauge, now both holes are in the centre of the raised beads, the one with the fixed and the one with the vari-able drilling guide. Now the drilling gauge is set for the correct hole distance in vertical direction.

Optimal roof protection To protect the roof and drilling gauge from scratches and damages during installation, cable ties can be attached to the drilling gauge. These must be placed on the drilling gauge in such a way that they do not impede the drill-ing of the holes.

Adjusting the hole distance to the profile and the raised beads

Measuring and marking of the bottom row

Drilling in the fixed drilling guide

Set drilling gauge with pin

12_Horizontal Installation

Measuring and marking the first row Now the drilling gauge is prepared for drilling the bottom row. The row is marked using a piece of string. For this, the string is drawn from one end of the roof to the other at the correct distance from the lower edge of the roof. The raised beads, to which the drilling gauge and later the profiles will be at-tached, are marked with a tape measure.

Drilling the first row Using the set drilling gauge, now the holes of the bottom profile row are drilled. For this the gauge with the support pins is positioned on the respec-tive raised bead. First drill the hole of the fixed drilling guide using a 6.5 mm drill. Then the drilling gauge is fixed to the raised bead using the pin, so that the second hole of the set variable drilling guide can be drilled. This proce-dure saves time and ensures a high level of accuracy.

Setting up and drilling the second row Having drilled the bottom row, the vertical distance to the next row is set. For this insert the last drilling guide into the long profile of the drilling gauge. Using the tape measure, the distance (A) can be read, before the drilling guide is fixed to the profile by tightening its two screws. This distance corre-sponds to the width of the solar module plus 2 cm distance between the mod-ules. With this setting and based on the bottom row, the second row is drilled. For this the drilling gauge is rotated by 180° and fixed in the bottom hole of the two pre-drilled holes of the bottom row using the pin. Drilling the two holes in the drilling guides gives these holes the correct distance and ensures that they are parallel to the holes of the bottom row.

Measuring and drilling additional rowsAfter completion of the second row the third row is drilled using the set drill-ing gauge. This is carried out in the same way as the drilling of the second row. Using the pin, the drilling gauge is fixed in the holes of the second row in such a way that the holes of the third row can be drilled in the drilling guides. The drilling gauge does not need any further re-setting.

Complete row with a horizontal carrier profileTo prevent the modules slipping sideways, each module row is completed with a horizontal carrier profile on the left and right. For this, holes are drilled into the roof at the distances of the holes pre-drilled in the carrier pro-files. These must be positioned in the centre of the module width and on two raised beads. The vertical distances are comprised of the distance (B) from the module width plus 2 cm.

Riveting the carrier profilesWhen all holes are drilled, the TRI-VENT carrier profiles are riveted to the roof. By means of insertion of the sealing rubbers, the sealing rivets enable the easy and water-tight attachment of the profiles.

Horizontal Installation_13

Distances of the TRI-VENT profiles

Riveting the carrier profiles

Installation of the edge profiles

Fixing of the module using the TRI-VENT module anchor

Laying and attaching the cables

Securing the edge modules using the TRI-VENT bending tool

Inserting the end module anchor

14_Horizontal Installation

2. Placing and attaching the modules using the TRI-VENT central module anchorsBeginning at the ridge, the modules are mounted horizontally and vertically and fixed with the module anchors. The TRI-VENT module anchors can be in-serted into the anchor rail at two different heights. One module anchor can thus anchor two module frame heights. Six types of anchors are currently available: 31 / 42, 34 / 45, 35 / 46, 36 / 45, 38 / 48 and 40 / 50 mm.Please make sure to use the thicker end module anchors at the edge of the rows and the central module anchors between the modules.

Fixing using the TRI-VENT end module anchorTo prevent modules from slipping off the roof, the TRI-VENT anchors are fixed, for each module, by bending the anchor rail using the TRI-VENT bend-ing tool. The broader TRI-VENT end module anchors are used in the topmost and the lowest row of anchors.

Laying and attaching the cables When the modules are placed, the cables can be laid and attached to the carrier profiles using the Edge Clip TV-EC. This prevents the cables lying open and unprotected and reduces the risk of damages to the cables and connec-tors.

3. Securing the edge modules using the TRI-VENT end module anchorsTo secure the edge modules and ensure the stability of the entire system, TRI-VENT end module anchors are attached to the end of each module row. The anchor’s firm connection to the carrier profile secure the rows. They are fixed by bending the carrier profile using the TRI-VENT bending tool. This en-sures a firm connection of the anchor, saves time and is therefore extremely efficient.By means of the module anchors and gravity the modules are now positioned and must not be secured by screws.

Horizontal Installation_15

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