energy for a better world

INSTALLATION INSTRUCTIONS TRI-FLAT SOUTH

Ballast- and transport-optimized flat roof installation system for PV systems with a southern exposure • Installation with few tools• Fast and easy module clipping using a click system • Easy warehousing, fast and economical transport

Contents

1. Basics

1.1 Notes 4

1.2 Load effect 4

1.3 Statics 4

1.4 Roof condition 5

1.5 TRI-DESIGN dimensioning software 5

2. Installation

2.1 Tools 6

2.2 Setup 6

2.2.1 Pre-mounting of the substructure 6

2.2.2 Preparation of the roof and setup of the substructure 11

2.2.3 Mounting the rear wall panel 13

2.2.4 Mounting the cable holders 14

2.2.5 Ballasting the system 15

2.2.6 Insertion of earthing plates 15

2.2.7 Insertion and fixation of solar modules 16

3. Product Specification

3.1 Product Details 18

3.2 Dimensions 19

3.3 Roof layout 20

3.4 Further information 20

3.5 Ballasting and snow pressure 21

4_Basics

1. BASICS

1.1 Notes

For the installation of the TRI-FLAT South mounting system only products from the range of the TRI-FLAT South mounting system must be used. Using third-party components can result in adverse effects on the system’s stability and in major damages. The system may only be installed by trained and skil-led personnel. We do not assume any liability for damages arising from the use of third-party components or from incorrect installation.

These installation instructions describe the proper installation procedure for the TRI-FLAT South flat roof system. In some situations, it is advisable, ho-wever, to have a specialist (e.g. roofer or joiner) check the special featrues of the roof.

1.2 Load effect

In addition to the dead weight of the photovoltaic system, mainly wind and snow loads affect the system components and the substructure. For this rea- son, each system must be calculated and planned for your individual require- ments and external influences, taking into consideration DIN EN 1991* (Actions on Structures).

The stresses by wind loads depend mainly on the wind zone (according to DIN EN 1991-1-4*), the building’s height, the shape and slope of the roof and the position of the roof’s centre. Weight stresses through snow load are depen- dent on the snow zone (according to DIN EN 1991-1-3*), the building’s height, the shape and slope of the roof and the position of the roof’s centre.For each location the wind and snow load zone can be determined, which will determine the design of the system.

1.3 Statics

On principle, the structural calculations of all roofs must be checked by autho- rised experts. The main question to be answered is whether the roof can take the additional stresses caused by the solar system. Since the load bearing capacity of a roof and the load effect of a photovol-taic system are determined by many factors, structural calculations must be made for each roof individually.

* German standard: DIN EN 1991, DIN EN 1991-1-3, DIN EN 1991-1-4 Swiss standard: SIA 261 Austrian standard: ÖNORM EN 1991-1-3, B 1991-1-3 Eurocode 1 part 1-3 and part 1-4

Basics_5

1.4 Roof condition

The current condition of the roof must be such, that renovation will not be- come necessary for a period of at least 20 years. In case of doubt, it is advis- able to have the roof checked by an expert. The TRI-FLAT South mounting system has been optimised for flat roofs with plane surfaces. If the roof is un-even due to aging or other reasons, it is advisable to consult a qualified specialist.

1.5 TRI-DESIGN dimensioning software

The TRI-DESIGN dimensioning software calculates and designs the TRI-FLAT South mounting system according to the standards of DIN EN 1991 (EC)*. The relevant directives are DIN EN 1991-1-4* for wind loads and DIN EN 1991-1-3* for snow and ice loads, which affect the photovoltaic system and its substructure.The dimensioning software calculates all sizes and distances relevant for the installation. In addition, the dimensioning software allows us to design the system optimally for the individual roof and thus to select the best version of the mounting system.Under the warranty terms and conditions, all TRI-FLAT South systems must have been dimensioned using the TRI-DESIGN dimensioning software.

6_Installation

2. INSTALLATION

2.1 Tools

The following tool is required for the installation of TRI-FLAT South:

• TRI-FLAT bending tool• cordless screwdriver with screw attachment 8 mm

2.2 Setup

Mounting is provided in seven steps:

1. Pre-mounting of the substructure2. Preparation of the roof and setup of substructure3. Mounting the rear wall panel4. Mounting the cable holders5. Ballasting the system6. Insertion of earthing plates7. Insertion and fixation of solar modules

2.2.1 Pre-mounting of the substructure

1. Mounting the lower module holder

TRI-FLAT South 10° support

TRI-FLAT South 15° support

Pre-mounting can be done on a table.

Push clip over lower module holder and hook in.

Click module carrier centrically into lower module holder.

Click lower module holder into bottom profile.

Click second clip into bottom profile.

Push clip over link of the lower module holder.

Notes for mounting a 15° support:

Click together bracket and intermediate bracket. Set bracket centrically onto intermediate bracket.

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8_Installation

Bend off intermediate bracket toward the outside with bending tool flush with bracket, once per side (crosswise).

Note: The bend must be torn out.

2. Mounting the upper module holderClick together upper module holder and module carrier. Set module holder in position in the centre of the module carrier.

Push module holder into bracket up to the stop.

Fasten the holder for the rear wall panel with a self-forming screw on one side.

Installation_9

The holder must rest against the bracket with the shapings.

The pre-mounted bracket (for 15° support with intermediate bracket) is cli-cked into the bottom profile and pushed away 80 mm when using a module with width of 800 mm (30 mm when using a module with witdth of 1000 mm)from the edge of the bottom profile. Provide once bend flush with the bra-cket (for 15° support to intermediate bracket).

Note: The bend must be torn out.

3. Mounting the series connectorOverlap series connector approx. 10 mm with the bottom profile and click in.

Push series connector at least 80 mm into bottom profile.

Use the bending tool to bend off bottom profile and series connector on both sides toward the outside. Another possibility is to bend off twice on the same side, spaced apart by 20 mm.

Note: The ballast plans show which series connectors (680 mm or 980 mm) must be screwed. Another possibility exists in bending off 2 times on the same side with a 20 mm distance.

80 mm

30 – 80 mm

Note: The bend must be torn out.

4. Determine module spacePlace gauge with the corresponding module width flush onto the module carrier of the lower module holder.Push lower module holder so far that the gauge fits without any gap bet-ween the two module carriers.

Use the bending tool to bend off the bottom profile twice flush with the clip toward the outside. Make sure that the lower module holder and the clip rest up to the stop of the bend-off.

Note:If the substructure is assembled without pre-mounting, this bend may be done later in chapter 2.2.2 with inserted series connector.

Note: The bend must be torn out.

10_Installation

2.2.2 Preparation of the roof and setup of the substructure

Mark grid according to layout plan.

Cut protective bottom mat approx. 20 mm longer than the bottom profile and lay out according to plan.

Lay out pre-mounted elements on grid. Start with the very last row (north). Always take care that the bracket and not the bottom profile is aligned on the grid.

Laying out is possible simultaneously in southern and east/west direction. In southern direction, the series connectors are connected with the prior bot-tom profiles.

For connection of the elements, click series connectors into bottom profile.

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12_Installation

Push prepared substructure element to the designated place.

Subsequently, the series connector and the bottom profile must be edge-bent with the bending tool 4 x per series connector.

Note: The bend must be torn out.

Each series connector must be edge-bent with the bending tool 4 x. There are two possible bending places:

1. On facing edges of the module carrier.

2. On facing edgesin front of the module carrier.

Note: Keep a space of at least 20 mm between the bottom profiles.

Note: The bend may be combined with the fastening bend for the lower mo-dule holder (see 2.2.1).

min. 12 mm

Installation_13

2.2.3 Mounting the rear wall panel

1. Mounting the lower rear wall panelPlace spacer plate behind the bracket in the series connector.

Position rear wall panel.

Overlap neighbouring rear wall panel.

At a distance of 35 mm (equivalent to the width of a 2-m folding rule), screw the rear wall panel on the bottom onto the series connector with a self-for-ming screw. The spacer plate is located between rear wall panel and series connector.

Attention: It is absolutely necessary to position the self-forming screw as clo-se as possible to the panel wall.

2. Fastening the rear wall panel to the holderNote: The rear wall panel must possibly be reinforced according to the bal-lasting plan.

Press rear wall panel to holder and position flush.

35 mm

14_Installation

Fix in place the rear wall panel to the holder with a self-forming screw and a washer in the hole provided for it.

3. Measure for heat expansion in mounting the rear wall panelTo ensure heat expansion of the rear wall panel, with every sixth panel joint, tighten the 2 self-forming screws top and bottom only to a gap of 0.5 mm between the panel and the rubber of the self-forming screws.

Note: If the rear wall panel must be reinforced according to the ballasting plan, loosen only the middle one of the 3 self-forming screws.

Important: Always start counting the 6 panel joints from the field edge east and west. The outermost 6 panel joints at the east and west end of the field must always be screwed tightly. Depending on the length of the rows, in the centre of the field, every fifth panel joint may possibly be even mounted with a gap of 0.5 mm, as described above (in exceptional cases, even the fourth or, if absolutely necessary, the third panel joint).However, at least 5 rear wall panels must always be mounted next to each other and screwed tightly.

2.2.4 Mounting the cable holders

The cable holder is fastened on the rear wall panel in the middle of the PV module.

Position the cable holder in the centre of the panel and screw tightly with one self-forming screw and a washer.

Alternatively, mounting of the holder may also be done only after mounting the PV module.

Note:Depending on the type of module frame, the underside of the module is va-riable. Accordingly, the cable holder must first be positioned on the panel in the direction of the blue arrow.

2.2.5 Ballasting the system

Place ballast clip on bottom profile and click in.

The clip must be placed such that it supports the ballast stone at approx. 1/3.

Place ballasting according to ballast plan. If more than 50 kg ballast is neces-sary please contact TRITEC.

2.2.6 Insertion of earthing plates

The earthing plates are placed on the upper module holder.

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variabel

The distance of the earthing plates to the edge of the module carriers is 40 – 50 mm and corresponds with the placement of the module clamp (see 2.2.7).

Optionally, the earthing plates may be temporarily fixed with a thin adhesive strip. Adhesive is here to be placed at maximum half over the earthing plates.

It is to be ensured that the earthing plate bites into the module frame.

2.2.7. Insertion and fixation of solar modules

The PV module is placed flush onto the prepared substructure.

The module must placed flush and centrically in the lower and upper modu-le holder.

Placing the clamp suitable for the module thickness. Five clamps are required per module: one each per module corner and one on the cable holder.

16_Installation

40…50 mm

Distance of clamp to module edge is 210 – 220 mm. If necessary, comply with information by the module manufacturers. The clamps are positioned on the edge of the module carrier. The distance between the centre of the clamp and edge of the module carrier is 40 – 50 mm.

Fix in place cable holder and PV module by means of module clamp.

TRITEC‘s Terms and Conditions apply.

Made in Switzerland © Version 1.3Subject to technical changes.

info@tritec-energy.com

ca. 210 mm ca. 50 mm ca. 50 mm ca. 50 mm

Installation_17

18_Product Specification

3. PRoDucT SPEcIFIcaTIoN

3.1 Product details

PV module type Framed modules

PV module size Width approx. . 800 – 1‘015 mm, others upon request Length appr. 1‘550 – 1‘720, others upon request, Thickness of frame 35 / 38 / 40 / 45 / 46 / 50 mm, others upon request

Module inclination 10° or 15°, varies slightly depending on module width, details see table page 19

Module orientation Landscape format

Weight Dead weight mounting system starting at 1 kg/m2

Row division RD 1‘165 mm – 1‘965 mm

Bearing on roof 0.115 m2 per PV module (width of bottom profile 100 mm)

Total roof load As of 5 kg/m2 with object-specific wind load calculation

Max. roof inclination 5°

Material High-quality aluminium alloy; resistant to sea water specification and ammonia vapours, protective building mat UV-resistant, temperature- and weather-resistant

Compass direction Optional

Means of fastening Without roof penetration, substructure with positive- fit connection

Mounting aids Bending tool (connection of substructure), cordless drill

Types of roofs Membrane roofs, bitumen roofs, gravel roofs, sub- strate and green roofs

Special features Mostly ballast-free in central roof area; low ballasting in marginal area, Upon request, very high ballasting possible. Suitable for small and large module fields. Object-specific wind load calculation results in opti- mized ballast distribution according to DIN EN 1991-1-4

Earthing: As a standard, without earthing. Optionally earthing of module frames to substructure, analogous with VDE conformity test according to DIN VDE 0100 Part 712

Product Specification_19

3.2 Dimensions

Side view with dimensioning measures:

Clearance: The upper clearance of 60 mm must not be changed due to aero-dynamic reasons.

Nominal support angle:

Support angle α, nominal

Support angle � with module width Height h depending on thickness of frame

800 mm

850 mm

900 mm

950 mm

1000 mm

TRI-FLAT South 10°

11,4° 10,7° 10,1° 9,6° 9,1° 255 – 270 mm

TRI-FLAT South 15°

19,2° 18,2° 17,2° 16,4° 15,6° 333 – 345 mm

Recommended row division RD:For the optimum utilization of roof surfaces, TRITEC recommends a short row division which, up to a shadowing angle of 10°, does not produce any sha-dowing at CET 12:00 noon (Central European Time) on 21 December.

Recommended row division for TRI-FLAT South 10° with 40 mm module thickness:

Place shadowing angle on 21 December (CET 12:00)

module width 800 mm

module width 1000 mm

Hamburg 14° 1420 mm 1585 mm

Munich 18° 1275 mm 1480 mm

Rome 24° 1165 mm 1345 mm

Recommended row division for TRI-FLAT South 10° with 40 mm module thickness:

Place shadowing angle on 21 December (CET 12:00)

Modulbreite B 800 mm

Modulbreite B 1000 mm

Hamburg 14° 1780 mm 1965* mm

Munich 18° 1560 mm 1780 mm

Rome 24° 1400 mm 1580 mm

* 1‘995 mm would be ideal, limited 1‘965 due to the system

Module clippingModule clipping is effected without tools by means of the module clip. Width of the clip: 30 mm. Integrated theft protection: It is very easy to remove the clip, but possible only with a special tool.Clipping area: Clipping on longitudinal side of module, distance x = 220 mm

20_Product Specification

3.3 Roof layout

Roof layout for sample roof with 4 double rows in field width und 2 x 10 PV-modules in field length.

Planning recommendation: To be noted for planning: Required ballasting may be significantly influenced by selecting the distance to the edge of the roof R. To keep ballasting low, a distance to the edge of the roof is recommended of at least 1.2 m on all sides; for roofs at heights of over 8 m, better yet even 2 m or more. The necessary ballasting of marginal areas is individually calculated for every project to pre-vent any unnecessary or excessive burden of the roof.

For planning a system, the dimensions can be roughly calculated as follows:

Field length = number of modules per double row * (module length + 5 mm) + max. 160 mm

Field width = (number of double rows – 1) * RD + 2300 mm

Required roof length = field length + 2 * R

Required roof width = field width 1 + 2 * R

3.4 Further information

1. optimized aerodynamic propertiesTRI-FLAT South is a mounting system – optimized with wind tunnel tests – for the reduction of ballasting with excellent aerodynamic properties and ag-gressive rear ventilation. Accordingly, the system-integrated free cross-sec-tions for air circulation – such as on the bottom front and rear as well as bet-ween module and rear wall – must remain completely open and not be reduced during the mounting activities, e.g. by means of gravel, roof sub-strate, and the like.

2. Load compatibility With regard to wind loads, the mounting system meets the requirements of DIN EN 1991-1-4. Since TRITEC does not adequately know all building para-meters, wind forces on the mounting system are exclusively taken into ac-count. The required additional load compatibility (PV system, wind, snow, etc.) of the roof or the building is to be ensured by the builder / buyer.

Product Specification_21

3. chemical compatibilitySince TRITEC does not adequately know the condition of the roof membrane, the builder / buyer is to ensure the chemical compatibility between the pro-tective building mat delivered by TRITEC and the roof membrane of the buil-ding. The data sheet of the protective building mats used by TRITEC may be requested. If other protective building mats are used or an intermediate layer or from another surface, a friction value (wet) of at least 0.6 is to be maintained.

4. Module clippingModule clips are available for the thicknesses of frames used the most on the market. Modules are each clipped on the long side. It is to be checked by the builder whether the clipping area is complied with which had been specified by the module manufacturer. For more detailed information, please see Chapter 2 of these mounting instructions.

5. EarthingWith the additional earthing element, the module can be easily and swiftly connected at low ohms with the substructure. Earthing of the substructure is to be guaranteed on the part of the builder, as well as compliance with the regulations applicable in this respect at the plant location.

3.5 Ballasting and snow pressureBased on the information in the inquiry form with regard to wind suction and snow pressure, TRITEC subjects every single project to a feasibility test. High-er ballast values are to be expected for locations and buildings with higher wind loads.

Example ballasting plan:Location: ZurichHeight of building / wind pressure: q 7 m / 0.85 kN / m2Attic heights in m: N: 0.3 / E: 0.3 / S: 0.3 / W: 0.3Module dimensions 1650 mm x 990 mmNumber of modules: 121 / row division 1800 mm

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