bipv 2-11 mounting instructions - schletter · this document offers information relating to the...

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BiPv 2-11 Mounting Instructions

© Schletter GmbH • Gewerbegebiet an der B15 • Alustraße 1 • 83527 Kirchdorf/Haag i. OB • Germany • Phone: +49 8072 9191-200Fax: +49 8072 9191-9200 • E-mail: [email protected] • www.schletter.eu • Updated 01/2012 • Subject to change without noticeYour contact in the UK: Schletter UK Limited, Phone: +44 1296 461 800, Fax: +44 1296 461 801, E-mail: [email protected]

BiPv 2-11Mounting Instructions

In-roof system for unframed modules

General information

The in-roof BiPv 2-11 system was designed for frameless modules and can be applied as a defi ned sec-tion of an existing roof or as a complete roof covering of a new building. Modules are integrated into the existing roof surface and can be combined with conventional roofi ng tiles. Systems are custom-built and module sizes are compiled to customer specifi cations. A complete roof covering can be planned in ad-vance with an architect. The system can also be applied to large roofs and can be mounted to industrial roofs with the additional deployment of a water-stream plate. Linear thermal expansion is counteracted by spring elements placed between the individual modules.

CONTENTS PAGE

1. Overview 032. Preparing the roof surface 083. Eaves-side cladding 104. Mounting the base profi le 115. Module mounting 146. Verge-side cladding 187. Ridge-side cladding 208. Eaves ventilation / optional 22

This mounting instruction:

This document offers information relating to the mounting of solar energy plants with the BiPv 2-11 sys-tem. Activities outlined in this instruction should be carried out exclusively by specialist personnel. Please read the instruction carefully and take note of all recommendations. Schletter GmbH accepts no liability for damage caused through failure to observe these instructions. Please also reference instructions relating to other components which make up the overall system.

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The planning, mounting and commissioning of a solar energy plant must be undertaken, exclusively, by qualifi ed personnel. An unprofessional execution of the project can lead to damage to the plant and place people in danger.

Please work professionally and accurately! Untidy work can compromise system impermeability and damage the modules.

Do not stand on the profi les! Damage to components can compromise system impermeability and can lead to malfunction of the modules.

Do not damage rubber seals! Soiled or damaged rubber seals can compromise system impermeability.

Risk of electric shock!The mounting and maintenance of solar modules must be carried out exclusively by qualifi ed specialists. Please observe the manufacturer safety regulations!

Safety instructions

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Components - Cover profi les

Cover profi le Item no. 122005-006with sealItem no. 129032-002and end cap lowerArt.-Nr. 973000-463and end cap upperArt.-Nr. 943000-469

Ejot Screws - SUPER SAPHIRDrilling screw JT3-2-6.5Item no. JT3-2-6.5x50-E16/2Approval Z-14.1-4 Z-14.4-407

Würth Panhead AW driveItem no.0127 755 55Würth Panhead AW driveItem no. 0206 148 13Approval Z-14.1-4ETA 10/0184

Ejot Screws - SUPER SAPHIRDrilling screw JT3-2-6.5Item no. JT3-2-6.5x50-E16/2Item no. Schletter: 943000-515

Würth Pan head AW driveItem no. 0127 755 55Item no. Schletter: 943000-516Würth Pan head AW driveItem no. 0206 148 13Item no. Schletter: 943000-517

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Components - Frame structure

Inlay batten, Aluminium or PEItem no. 129225-009

Base profi le max.Item no. 122007-012

Eaves cross profi leItem no. 122003-006with sealItem no. 129032-002

Conical plug-on profi leItem no. 122006-006with sealItem no. 129032-001

Cross profi leItem no. 122004-006with sealsItem no. 129032-002Item no. 129032-003

Module end-stopwith molded rubber pieceItem no. 139012-000

Fastening lugItem no. 139011-000

Metal sheet mounting profi leItem no. 129215-001

Base profi leItem no. 122008-012

Mounting claw BiPv 2-11Item no. 139010-000with plastic inlayItem no. 973000-464

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Flashing (available as option)

Side fl ashing right Item no. 129225-011Side fl ashing leftItem no. 129225-012Side fl ashing eaves-side rightItem no. 129225-013Side fl ashing eaves-side leftItem no. 129225-014

Edge fl ashing verge-side rightItem no. 129225-005Edge fl ashing verge-side leftItem no. 129225-006Edge fl ashing eaves-side rightItem no.. 129225-007Edge fl ashing eaves-side rightItem no. 129225-008

Ridge corner sheetItem no. 192910-014Ridge corner sheet leftItem no. 192910-016Ridge sheet central: no sculpted cornersItem no. 129215-002

Eaves apron fl ashing rightItem no. 129235-002Eaves apron fl ashing leftItem no. 129235-003Eaves apron fl ashing centralItem no. 129235-001

Joint connector eaves-sideItem no. 129230-007

Eaves ventilation plateItem no. 129235-018

Joint connector ridge-side rightItem no. 129210-005Joint connector ridge-side leftItem no. 129210-0037Joint connector ridge-side centralArt.-Nr. 129210-003

Self adhesive foam wedgeItem no. 129200.003

Hooked fastening bracketItem no. 129200-001

Sealing tapeItem no. 129200-002

Roofi ng nailItem no. 129200-000

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Section view

Mod

ule

wid

thM

odul

e w

idth

Dis

tanc

e be

twee

n ax

es =

mod

ule

brea

dth

+ 24

mm

Dis

tanc

e be

twee

n ax

es =

m

odul

e br

eadt

h +

24 m

m

Tota

l bre

adth

of s

yste

mD

etai

l A

Det

ail A

Bas

ic p

rofi l

e

Sid

e cl

addi

ng

Roof breadth:

Tota

l sys

tem

bre

adth

Sid

e cl

addi

ng +

(

supp

ort d

ista

nce

x no

. mod

ules

)

+ s

ide

clad

ding

215

mm

+

((m

odul

e br

eadt

h +

24 m

m) x

no.

mod

ules

) +

2

15 m

m

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Sys

tem

tota

l len

gth

Eav

es d

imen

sion

s +

bas

ic p

rofi l

e le

ngth

+

ridge

dim

ensi

ons

270

mm

+

((m

odul

e le

ngth

- 1

mm

) x n

umbe

r of m

odul

es)

+

330

mm

Ref

eren

ce e

dgin

g

Syst

em to

tal l

engt

h

Basi

c pr

ofi le

leng

th =

((m

odul

e le

ngth

- 1

mm

) x n

umbe

r of m

odul

es) +

42

mm

Mod

ule

leng

th -

1 m

m

Mod

ule

leng

th -

1 m

m

Supp

ort w

idth

acc

. to

stru

ct. a

nalys

is

Supp

ort w

idth

acc

. to

stru

ct. a

nalys

is

Supp

ort w

idth

acc

. to

stru

ct. a

nalys

is

Ref

eren

ce e

dge

Ref

eren

ce e

dge

Ref

eren

ce e

dge

Ref

eren

ce e

dgin

g

See

1)

See

2)

See

3)

See

4)

1) A

lign

unde

rsid

e of

refe

renc

e ba

ttens

, to

uppe

r sid

e of

tile

edg

e, w

ith a

pro

ject

ion

of

270

mm

..2)

Exi

stin

g ro

of b

atte

ns c

an b

e us

ed (m

in. 3

0 x

50 m

m).

Ens

ure

the

batte

ns a

re s

uffi c

ient

ly s

ecur

ed.

3) I

n th

e ev

ent t

hat a

uxili

ary

batte

ns a

re d

eplo

yed,

the

stru

ctur

al w

idth

mus

t not

ex

ceed

the

supp

ort w

idth

spe

cifi e

d in

the

stru

ctur

al a

naly

sis.

W

hen

usin

g th

e ex

istin

g ba

ttens

, ens

ure

thes

e ar

e su

ffi ci

ently

sec

ured

.4)

Aux

iliar

y ba

ttens

(min

. 30

x 50

mm

) req

uire

d fo

r for

mat

ion

of a

n ex

pans

ion

fi xed

po

int N

umbe

r acc

ordi

ng to

stru

ctur

al re

gula

tions

.

Roof length:

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2. Preparing the roof surface

• Opening the roofPlease open the covering to the existing roof. The breadth of opening required can be referenced in the accompanying mounting plan and relates to the module width + rail width + fl ashing

Check that the roof battens are secure! It may be necessary, according to the mounting plan, to check and tighten the roofi ng battens.

The application of a permeable underlay is rec-ommended to mitigate the risk of damage due to moisture from dew and condensation. Please refer to the existing insulation design!

• Checking batten distances and set reference pointsIf batten distances are too great, please add ad-ditional battens in accordance with the mounting plan. In new constructions: Batten distances in accordance with work plan.

Reference point on eaves-side reference batten: Distance from the upper edge of the last covered roofi ng tile to the reference batten: 270 mm. See page 5, Covering length.

Reference batten

First exposed batten

Last roofi ngtile

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• Establish the ridge-side fi x-point

The ridge-side fi x-point is determined from the base profi le length and / or from the mounting plan.

Arrange additional roofi ng battens for the length expansion fi x-point. These must be of the same thickness as the existing roofi ng battens. For greater roof inclines, please reference the supplied mounting plan to establish the fi x-point Fix-point

• Dividing up the roofMeasure out and plot the central axis for the base profi le on the roof battens. We recommend using snap-lines for precision. Module width + spacing in accordance with the mounting plan

The parallelism and perpendicularity of the opening must be maintained!Diagonal measurements should be taken for verifi cation.

Mark points 30 mm to both the left and right of the central axis identifi ed with snap-lines. These points will mark the exterior edges of the base profi le on the roofi ng battens.

• Measure up dimensions for side claddingEstablish an exterior positioning point for the cladding by measuring distances, according to the mounting plan, from the central axis outwards at both verge-sides. Distance: Distance to the exterior edge of the side cladding: 215 mm See Side View, Cover Width, Detail A.

• Laying connection cables(according to electrical plan)

• Lay connection cables to the inverter and feed these through the roof substructure.

Cables must be laid tension-free. Ensure that cables are not crushed.

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3. Eaves-side cladding

• Fastening the apron claddingFasten the apron cladding in stages. Leave a space of approx. 20 mm between individual pan-els. Close the joins with joint connectors by slid-ing the connector upwards into the side seams of the apron cladding.

• Arrange the eaves apron cladding

The aluminium pleated tape attached to the apron cladding is fragile and is therefore folded to the back for transport purposes. Do not open out to the front until shortly before mounting.

Hang the eaves apron cladding with the verticaledge to the reference batten.Do not adjoin the alu-pleated tape yet.

Alu pleated tape

• Applying alu pleated tapeRemove the protective strip from the self-adhe-sive alu pleated tape. Apply the self-adhesive alu pleated tape.

Reference batten

Fix the self-adhesive sealing strip fl ush along the entire upper edge of the apron cladding and across the joint connectors to create a wind brake.

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4. Mounting the base profi le

• Positioning the base profi leAlign the base profi le to the edge of reference and according to the previous elevation.

The lower edge of all base profi les must be ex-actly aligned to the eaves-side edge of reference of the apron cladding.

• Attach base profi le to ridge-side fi x-point

Fastening the plant to the ridge-side fi x-point prevents the plant from sliding. Fasten the base profi le to the fi x-point with ad-ditional drilling screws from the sides.

Refer to fastening plan for number of additional drilling screws required

• Preparing mounting clawsInsert plastic inlays into mounting claws as shown.

• Fastening base profi lesFasten base profi les to the roofi ng battens with mounting claws, using drilling screws.

Please refer to the mounting plan for arrangement and number of mounting claws.Position the eaves-side holding claw approx. 1 cm higher than the edge of reference.Eavesß-side, claws should not be applied due to the side cladding.

Reference edging

Reference edging

Additional screws

• Potential equalization

Where required, the potential equalization cable with ring-eyelet, is attached, eaves-side, to the base profi le using a drilling screw.

Potential equalization

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• Fasten the eaves cross-profi le to the base profi lePosition the lower edge of the eaves cross beam fl ush with the front - eaves-side - of the base profi le.

• Mount module end-stops

Module end-stops prevent the fi rst module row from sliding.

Assemble by inserting end-stops one after the other, left and right, into the eaves cross-profi le. Module end-stops are not required at the verges.

Module end-stops must only be mounted in the fi rst horizontal row.

Please ensure the ultimate precision when work-ing! Once the base profi les are mounted with the respective spacing (module length + 24 mm), a clearance of 2 mm is added between the cross profi le and the base profi le.

• Mount rubber mouldsMount rubber moulds on the end-stops to protect module edges.

Use drilling screws to secure the eaves cross-profi le with fastening lugs to the base profi le.

fl ush alignment!

Clearance

Base profi le

Rubber

Eaves cross-profi leThese surfaces at the same level!

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The conical plug-on profi les are delivered with an inlaid rubber seal. The rubber seals are found on both sides of the seal and have a projection of approx. 20 mm

Please leave this projection!

• Ridge-side boundaryAt the ridge-side boundary, the cross-profi le is fastened with holding claws using drilling screws as at the eaves.

• Insert the cross profi lePosition each cross profi les against the upper ends of the conical plug-on profi les. Position the cross beams such that the track with the pre-mounted rubber seal faces the eaves.

Once the cross-profi le with pre-assembled rubber seal has been positioned, leave clearance at each end of the base profi le of 2 mm. Please ensure the ultimate precision! Last opportunity to fi ne-tune alignments!

• Insert conical plug-on profi lePosition the conically formed plug-on profi le centrally on the base profi le, in the fi rst horizontal module row. The conical plug-on profi les should be positioned against the eaves cross-profi le such that the higher ends of the double-track face to the eaves.

The lower seals on the cross profi les arepre-assembled at production. The upper seals are added as the modules are mounted.

Repeat the two previous steps (insertion of the plug-on profi les and alignment of cross-profi les) upwards, in horizontal rows, for the entire system.

Cross profi le

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5. Module mounting

Please ensure the correct working orientation: Mounting of the modules themselves begins at the eaves edge and is effected in horizontal rows.

• Lay the fi rst row of modulesAlign the fi rst horizontal row of modules with the lower edges to the module end-stops.

Please ensure that no cables are trapped or crushed when mounting modules. Cables must be laid tension-free. Similarly while laying electric cables, these must be protected from mechanical tension.Bind cables together with wires wherenecessary.

• Connect modules to the grid

Connect modules to the string cables and net-work the modules themselves together.

Plug connections must always be fully locked.

The polarity of the solar modules must be taken into account. An incorrect polarity can result in damage to the modules.

Never remove or insert plugs under load current.

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Align the upper edge of the module to the cross-profi le. Leave approx. 2 mm clearance at the upper edge for the application of cross-profi le rubber capping

If a joint is necessary, this must be effected to the centre of the base profi le.

Repeat this process until the fi rst module row is complete.

• Apply upper cross profi le rubber cappingUncut lengths of capping rubber are applied to the upper cross profi les.

approx. 2 mm clearance

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Cover profi les

Cover profi les are delivered complete with upper and lower end caps and seals. Holes are bored into the cover strip in preparation for the drilling screws.

• Correct arrangement of cover profi les.Position cover profi les against the upper conical plug-on profi les and align centrally on the lower conical plug-on profi les. The upper end-cap bridge is the end-stop for the next plug-on profi le.

The upper cover profi le end caps serve as an end-stop to the next module row and prevent panels from slipping. There is also a defi ned overlap of the cover profi les.

• Secure cover profi lesFasten cover profi les with drilling screws. A notch for the screw-tip is made in the profi le to allow for precise centering of the drill-hole.

Drilling screws: TORX® T25

Tightening torque: maximal 5 Nm

The cover profi le must be pressed down force-fully while screwing to avoid the profi le lifting momentarily as the screw is inserted.

Do not apply cover profi les to the verges yet. These are only then applied when fastening the fi nal cladding. In the event of interruption to the mounting process, the cover strips should be mounted temporarily to the verges for safety.

Upper end cap Lower end cap

Buffer

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• Add further module rowsOnce the fi rst horizontal row has been mounted, repeat the previous steps for each further hori-zontal row.

• Arrange cover profi les to overlap.Mounting as outlined in previous steps.

No module end-stops are required at the verges. These are only then applied when fastening the fi nal side-cladding.

In the event of interruption to the mounting process, the cover strips should be mounted temporarily to the verges for safety.

• Position top cover profi leAn end-stop is not mounted with the topmost cover profi le.

The top module row must nevertheless overlap the cover profi les at the lower end, in the same way as with previous rows.

When mounting the modules, please ensure that each panel is placed with the lower edge against the lower cover profi le capping of the previous row. This capping serves as a buffer and prevent the modules arranged above from slipping.

Ridge-side termination

• Sheet metal mounting railsFor verge-side cladding, arrange the sheet metal mounting rails between the cover profi les and align with the profi le fi n here (see image). The rail is hereby pressed against the rubber seal of the topmost cross profi le. Sheet metal mounting rails are delivered pre-drilled and are screwed to the topmost cross profi le, through the seal, with drilling screws.

Screw here

Align the sheet metal mounting rail fi n here.

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• Position side cladding

In order to ensure outfl ow of water, you must work from bottom to top.

The fi rst cladding piece is custom-assembled. All further side cladding sheets are delivered to a standard length. The topmost side cladding sheet is angled verge-side.

6. Verge-side cladding

Slide the side cladding, eaves-side, under the folded edge of the eaves apron cladding and fasten.

Secure side cladding using adhesives and roofi ng nails.

folded side

Projection 35 mm

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Mount edge fl ashing on the inlay battens.

• Mounting of the overhang fl ashingMount the right-angled inlay battens on the rubber seals of the plug-on profi le.

Mount cover profi le and secure with drilling screws as outlined above. The edge fl ashing is now secure.

Be aware of the upper end-cap piece.

• OverlappingAll further side sheets must be mounted with an overlap of at least 15 cm. Secure the side sheets using adhesives and roof nails at distances of approx. 1 m.

Inlay battens

Edge fl ashing

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Position the remaining ridge sheets and feed these into the hanging rails. In doing so, cen-tre the distances (approx. 20 mm) between the ridge fl ashing sheets along the length of the cover profi les.

• Begin with the ridge corner sheetSlide the ridge corner sheet under the folded edge of the side cladding. In so doing, the upper edge of the sheet must be positioned on the roof batten. The roof battens may need to be extended.

7. Ridge-side cladding

Slide ridge corner sheet and ridge sheet up-wards and under the metal sheet mounting rails as far as the end-stop.

The hollow seam of the ridge- and ridge corner sheets must be slide under the sheet hanging rails.

Upper edge

Folded side

Close the remaining joins with the joint con-nectors.

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Fasten ridge sheets and joint connectors using adhesives and roofi ng nails.

As a precaution, pull the ridge sheet upwards once again, to the end-stop.

Fix self-adhesive foam wedges (Meterware) ridge and verge-side to the edge fl ashing as a wind-brake.

Fix ridge-side ventilation sheet to the upper edge using adhesives to prevent slipping.

Position foam wedge in the cavity area be-neath the tiles.

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• Mount eaves ventilatorBegin with the left-hand eaves ventilation plate. Slide the eaves ventilation plate from below into the eaves cross profi le.

Slide the remaining ventilation plates simi-larly from below into the eaves cross profi le, slotting each, respectively, into the existing ventilation plate.

Align each eaves ventilation plate with its respective designated drill-hole and use drilling screws to secure each to the eaves cross profi le.

Finally, relay the roof covering from the exposed area as far as the module fi eld. Smooth out standing seams if required, however, please ensure that water-fl ow is not affected in so doing. Rework individual roof-ing tiles as required.

For further information relating to our systems, please refer to our website:www.schletter.eu under Downloads in the Solar section.

© S

chle

tter G

mbH

, 201

2, I4

0020

0DE

, V3

slide slot

8. Eaves ventilation / optional

bipv 2-11 mounting instructions - schletter · this document offers information relating to the...

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