professional solar mounting systems mounting and project planning

Professional Solar Mounting SystemsMounting and Project Planning

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Mounting and Project Planning

This guide will provide you with instructions for the project planning and mounting of Schletter© Solar Mounting Systems. Schletter Systems are made of high quality, durable components and offer solutions for most mounting scenarios with engineering of customized products to fit your needs. Please note that correct selection, mounting, and installation of the components affect the integrity of the PV system. The PV system should only be installed by certified, experienced PV installation companies. Schletter personnel are readily available for consultation regarding the application and mounting of your PV system.

CONTENT DESCRIPTION SYSTEM PAGE

General Application Information 3

System Characteristics 4

Fastening Systems for Tiled and Shingle Roofs Roof Hooks 5Various Roof Types Corrugated and Trapezoidal Sheet Hanger Bolts, FixE™ 7 Metal Roofs Fix2000™, FixT™, Vario FixV™ 8 Standing Seam roofs FixPlanTM, Standing Seam Clamps 9 (and system roofs)

Elevation Elements Standard Support Designs Light™, Profi™ 10 Special Support Designs SolTub™, Windsafe™, 11 AluLight™

Combined Construction Vertical Continuous Beam CompactVario™ 12Forms Horizontal Continuous Beam CompactGrid™ 13 Without Continuous Beam CompactDirect™ 13 Yield Optimization for Trapezoidal FixZ-7™ 14 System Mounting Pitched Roof Standard, GridNorm™ 15 Flat Roofs 18 Awning and Façades 20

Application Suggestions Framed Modules 21for Module Mounting Frameless Modules LaminatEcoTM 22 Module Adhesive Plates OptiBond™ 22

Special Systems Industrial membrane roof IsoTop™ 23 Special dimensioning for flat roofs Windsafe™, AluLightTM Carport Park@Sol™ Ground mount FS System™, PVMax3™

Accessories Anti-theft device SecuFix™ 24 Lightning and over voltage protection Rapid Grounding ClampTM 24 Cable management MaxKTM 25

Important Suggestions Safety and Liability 26

Additional Mounting Lightning and Over Voltage 27Information Cable Laying 27

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In addition to this mounting instruction guide, please ask for more information on the following tools:

System calculations, program-aided load calculations, drawings, and charts give important direction on dimensioning and individual system verifications.

Systems Overview Brochure offering various system combinations and possible solutions including: The Klick™ system, cross beam connector system, universal roof fastening elements, elevation elements for flat roofs, system mounting, façade fixation, module mounting, special systems, accessories and lighting, over voltage, and cabling.

Components Overview Brochure covering the available components in a pictorial arrangement of attachments, clamps, rails, systems, accessories, and hardware.

Schletter Excel® Calculator facilitates the PV system rack configurations, including price calculation, and parts list creation. Schematic pictorials provide mounting information.

Product sheets and application suggestions contain further system specific information, mounting examples, and new developments. On the Internet, all current information is always available for download. In the U.S. visit www.schletter.us and in Canada visit www.schletter.ca for more information. Load determination / superimposed load calculation for simple project planning, allows access to location-specific load determinations and load-calculation software.

Certifications and Associations: We meet the highest quality standards of solar racking systems, and are continually working to improve our product application development and standards. We partner and interface with solar industry installers across the Americas.

General Application Information • Efficient, simple mounting saves time and costs • 10-year warranty provides customer confidence and reliability • Proprietary calculation tools and support programs save time during the

planning process to create a complete racking system and initial offer• Complete documentation and span charts allow for cost-effective system

planning

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The Klick™ System

The fastening points for bolts can be chosen at any location by means of clicking square nuts into the top channel of any Schletter rail. Available for both M8 and M10 size hardware, the KlickTM System reduces the time and inconvenience of mounting bolt-on components, such as micro-inverters or junction boxes.

Cross Beam System

The standard cross beam (aka purlin) is the interface between roof fastening device and module attachment, as well as between perpendicular rails in a double layer grid system.

Components are connected together using the Schletter KlickTopTM System. The KlickTop System uses a sliding wedge to lock components together and comes preassembled in place, eliminating loose nuts or bolts. KlickTops are used by inserting the rail and tightening a single allen-socket bolt. The bolt is accessed from above for easy use.

KlickTop units arrived preassembled on all ground mounts and flat roof tilt-up mounts. KlickTopTM units are available upon request with roof hooks, standing seam metal clamps, tubular standoffs, or other roof attachment components.

Universal Fastening Elements

For use on a variety of roofs, including:• Asphalt shingle• Tiled roof• Trapezoidal sheet metal roof • Corrugated roof • Sandwich roof • Standing seam roof

Schletter uses only high-grade, durable materials, including certified aluminium, quality steel, and rubber-formed parts made of vulcanized UV-resistant materials. The fastening fixtures offered are universally applicable to pitched roofs, slanted roofs, and elevations. Schletter’s engineering and design staff will assist in finding the best fastening element for each application.

System Characteristics

In the development of the mounting system, it is important to consider system safety, durability, and mounting times. Further factors are universal compatibility and utilization of standard components, such as bolts, nuts, and other hardware. Such components are shown below.

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Determination of the rail position The rails should be positioned approximately one-fourth of the module height away from the lower and upper module edge (see module manufacturer’s documentation for more information). The position of the support rails for module rows above each other must be aligned to the tile rows. Rails must be installed parallel to tile configuration (perpendicular to the rafters).

Choice and arrangement of roof hooks Roof hooks are arranged vertically according to the intended cross beam positions and north-south directions. Adjustable roof hooks are available for height adjustment in case of uneven roofs. If the substructure does not give any suitable attachment locations for support rails, often a cross rail system is recommended. For more information, see GridNorm™, page 18.

Attachment of roof hooks The covering tile is lifted and set aside. The attachment plate of the roof hook aligns over a rafter. A distance of 0.08 – 0.20” (3 – 5 mm) must be maintained between roof hook and tile. This distance can be achieved by using plywood or a Schletter metal distance piece. (See item #400 893 in accessories)

The roof hook is fastened to the rafter with at least two lag bolts, 5/16” (8 mm). At least two-thirds of the screw length must be pre-drilled. Ensure that at least 2.75” (70 mm) of the lag bolts have a grip in the rafter. Reference design documentation for further information on bolt embedment. Screw lengths of 3” (80 mm) for non-decked roofs and screw lengths of 4.75” (120 mm) for decked roofs are typical. Only use bolts allowed by system design specifications.

Replace covering tile.

Fastening Systems for Various Roof Types

Tools:

Ratchet wrench with 13 mm socket wrench and a drill with 6 mm pilot bit. If using impact driver, use caution not to over tighten. Refer to Tool List.

Tiled and Shingle Roofs Stainless steel roof hooks are used to attach to asphalt shingle or concrete tile roofs. A variety of hook profiles are available to match nearly any type of tile, including flat tiles, scalloped tiles, and S-tiles.

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Weather Protection

When roof hooks are applied on slopped roofs, it may be desirable to reseal the roof for weather protection. Schletter recommends the use of poly-urethane caulk or silicone sealant where the roof membrane is penetrated, such as with a screw or bolt, and to apply self-sealing adhesive membrane at the roof attachment or an EPDM gasket at roof attachments with washers.

Schletter provides flashing and installation guidelines that coincide or exceed general industry standards.

Calculation Notes Bearing profiles: The maximum span widths of the bearing profiles for the respective wind and snow loads can be calculated using the Schletter Excel® Calculator or by contacting Schletter engineering. On pitched roofs, the span widths of the profiles are not the limiting factor in most cases (e.g., Profi or Solo 05 span 63” (1.6 m) in case of normal snow loads). With standard applications, the profiles should not cantilever for more than 15.75” (0.4 m) at the sides.

Roof hooks: Use the Schletter Excel® Calculator to determine if the spacing of the roof hooks is sufficient. This is especially important where high wind and snow loads are a factor. It is generally recommended to use a roof hook on every rafter in order to distribute the load more evenly over the roof. In case of high snow loads, sheet metal substitute tiles are generally recommended to prevent roof hooks from putting pressure on the tiles.

The required number of roof hooks can be found using the Schletter Excel® Calculator, or by contacting Schletter engineering. When determining the number of required roof hooks, it may be necessary to consider a higher number of roof hooks for the edge and corner areas of the roof. In the edge areas, one roof hook for each of the first two rafters is generally recommended in order to compensate for the higher stress caused by wind loads.

Contact Schletter for access to the Excel® Calculator

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Fastening of mounting sets The roof cladding is drilled through at the appropriate locations, making sure that drill points are not situated in the water-bearing valleys of the sheet metal, but rather on the top areas of the plate profile. By pre-drilling, the fastener bolt penetrates the rafter or the purlin. Screw the hanger bolt in such a manner that only the metric thread stands out of the roof cladding (and, if possible, a bit of the shaft) to act as a seating for the gasket. Greasing the screw makes the process easier. Creation and check of the sealing For sealing, the rubber gasket is pushed down as far as possible and slightly pressed onto the roof cladding with the flange nut.

Alignment of mounting plates In the case of cross rails, an upwards arrangement of the plates is recommended. In the case of vertical rails, the plates should be arranged according to the symmetrical load distribution and screwed with flange nuts.

See System Mounting, page 22, to continue

Corrugated and Trapezoidal Sheet Metal Roofs

For corrugated or trapezoidal (u-shaped) sheet metal roofs, use the fastening sets consisting of a special hanger bolt with EPDM sealing and a mounting plate. Usually, a fastening set with a hanger bolt M12 x 300 mm (11.8”), M12 x 200 mm (7.9”) is recommended. For special types of attachments with reduced horizontal distances, M10 x 200 mm (7.9”) is available.

Tools, Drill DiameterHanger bolts M10: combination wrench with wrench size 15, power screwdriver with 7 mm (0.28”) insert. Wood is pre-drilled with a diameter of 0.25” (7 mm); the roof is pre-drilled with a diameter of 0.5” (15 mm).

Hanger bolts M12: combination wrench with wrench size 18, power screwdriver with insert 9 mm (0.35”). Wood is pre-drilled with a diameter of 0.3” (8.5 mm); the roof is pre-drilled with a diameter of 0.6” (16 mm).

If the rafters run north/south under the roofs (as is the case with most standard shingled roofs), it is best to run rails east/west and mount the panels in portrait. If the supporting roof members are purlins running east/west (as is the case with many metal roofs), it is best the run the modules rails north/south and mount the panels in landscape. In some cases, the combination of roof structure and necessary panel layout may require the use of two layers of rails (called a GridNormTM System).

Fastening Elements—FixE™

Universal fastening system for round, corrugated roofs

FixE Mounting Instructions (available for wood and steel)

Note: M10 or M12 bolts must be used for this system but the largest bolt that can be drilled into 2x4 construction is M8. Therefore, this system can only be used on 4x4, rough cut, or reinforced construction.

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Trapezoidal (U-shaped) Sheet Metal Roofs

When it is not possible to fasten to the substructure for trapezoidal sheet metal roofs (e.g., in the case of self-supporting trapezoidal sheet metal roofs or sheet metal roofs made of overlapping elements), Fix2000™ provides a quick and simple fastening solution.

• The screws must not spin free of grip during the mounting process (use a depth-stop).

• A minimum thickness of 19.7 mil (0.5 mm) steel sheet metal and 31.5 mil (0.8 mm) aluminum sheet metal is required for use with the Fix2000.

• The roof must have sufficient load bearing reserves to support the additional load of the PV installation

• The fastening of the trapezoidal sheet metal must be able to absorb the additional wind suction forces (a roof-parallel installation does not increase the uplift forces)

• In case of overlapping elements, a sufficient adhesive force between the layers must be applied


Calculations

The Fix2000 fastening elements must be able to transfer the exact load forces to ensure reliable system calculations. For Fix2000 calculations, the wind load is more relevant than the snow load. The snow load is transferred into the roof by all the ribs of the sheet metal; due to a slight elastic deformation, the ribs between the clamps are also loaded. The cross rails should be arranged vertically to the ribs.

It is essential for the wind load to transfer and the trapezoidal sheet metal be sufficiently attached to the substructure. These two conditions must be met for mounting of the Fix2000 to take place. Only by using an adequate amount of Fix2000 elements will the adhesive force of the clamps to the sheet metal take place. Individual verifications for the load transfer into the sheet metal are required. Usually, a horizontal distance of 47 – 55” (1.2 – 1.4 m) between the clamps is sufficient for this to occur; more clamps should be placed at the edges. Tilted systems on Fix2000 are only recommended when the adhesive force of the sheet metal can be definitively verified.

Please see the application suggestions for Fix2000 for additional product information.

For Trapezoidal Sheet Metal• FixT™: Universal fastening system for trapezoidal sheet metal roofs• VarioFixV™: Standard stock item that works with all u-shaped sheet metal roofs, cut-

ting installation time.

FixT Product Sheet VarioFixV Product Sheet

Fix2000 application Review datasheet for measurements on Fix2000

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Positioning of standing seam clampsArrange the clamps vertically according to the required cross rail positions. For horizontal applications: One clamp should be positioned on each standing seam and the cross beam should not bear more than a maximum of 15.75” (0.4 m) to the left and right.

Fastening of standing seam clampsPut the clamp on the seam and loosely tighten. Alignment is completed when the cross rails are fastened. The clamp must be shifted onto the seam as far as possible. For more information, see System Mounting, page 22

Standing Seam Roof, Sheet Metal Roofs For fastening, the cross rail profile is screwed onto special standing seam clamps. Various designs are available for different types of roof systems. An alternative to the standard clamps is the FixPlan™ for direct attachment to the substructure.

Tools:Ratchet wrench 13 plus insert 13, torque wrench (if necessary, power screwdriver with torque setting)Alternative: FixPlan, tools as needed for corrugated roof kit mounting (see above)

1121001-000 112002-000 112003-000 112005-000-A 112006-000 400879-12 Standard KalZip, Bemo Zambelli Series 465 Zambelli Baur.500 Fischer KlipTec Alternative.: FixPlan FixPlan Mounting Instructions Components Overview

Please Note:

Torque for standing seam clamp screws should be 11 lbs/ft (15 Nm).

Rule of thumb: Fasten tightly with a short ratchet. When fastening onto sheet metal roofs, the roof cladding must be able to absorb the wind load. Careful review should be performed by the installer on the installation site to ensure the roof has proper support.

ATTENTION: With system roofs (e.g., Kalzip), the standing seams must not be altered in shape when the clamps are tightened to make sure that the roof sheeting is not blocked in case of thermal expansion.

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Elevation Systems for Flat Roofs Standard Support Designs

With systems on single supports, usually one module row is fastened to rails, which rest on single supports. The individual supports may be fastened to the roof or loaded individually. Standard angles are 30 degrees and customized angles are available upon request.

• LightTM Support Series: Designed specifically for cross mounting and vertical mounting with narrow spans.

Module heights: ca. 31.5 – 63” (0.8 m – 1.6 m) • ProfiTM Series Economically priced angle support, structurally

suitable for upright mounting and wider spans. Module heights: Profi 15: ca. 51 – 67” (1.3 – 1.7 m) Profi 22: up to ca. 86” (2.2 m)

B

A

Note:Do diagonal struts and respective tensile struts have to be checked individually?

If the support is tightly attached (e.g., with concrete or FixT): NoIf the row is not horizontal (e.g., east/west roof, elevation to the south): Yes

Bottom beam hole distances

Light U07 1 m Item 430911

LightU07 1.3 mItem 430912

Light U07 1.5 mItem 430913

Profi U07 1.5 mItem 430941

21.14 +/- 0.315 25.00 +/- 0.315 37.00 +/- 0.315 37.00 +/- 0.315

29.80 +/- 0.315 33.66 +/- 0.315 45.67 +/- 0.315 45.67 +/- 0.315

The pre-assembled supports are unfolded and screwed using M8 socket head screws and M8 self-locking nuts. For connection to the fastening element, oblong holes (0.51” / 13 mm) with 10 mm adapter plates are typically available. Contact Schletter to determine optimal support design.

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SolTub™

• Load with gravel or concrete blocks • Ideal load distribution on the roof • Variety of tray widths available • All metal construction

If necessary, a roof surface protection mat could be required depending on roof surface. SolTub Product Sheet

Windsafe™

• Non-penetrating or penetrating solution• Flexible design with choice of fixed module tilt angle• Load optimized through wind tunnel tests• Nearly 70% pre-assembled resulting in reduced

installation time• IBC code compliant

The Windsafe System is load optimized with wind deflectors on each row of racks, deflecting the air while reducing ballast weight as well as overall system load on the roof.

Manufactured and delivered up to 70% pre-assembled, the Windsafe System is equipped with triangle supports that are outfitted with a KlickTop™ cross beam connector. The connectors are in the exact position required to ensure efficient on-site assembly.

Windsafe Product Sheet

AluLight™

• Significantly reduces loading on roof• Ideal for flat roofs requiring a high concentration of

modules• Fast and easy installation• Minimal parts to assemble• Complete structural calculations included

The AluLight System allows for modules to be mounted on flat roofs where the concentration of panels on the roof is important and where reduction of loading on the roof is required. Proper roof fasteners and concrete slabs incorporated into the system ensure the AluLight trough sits securely and in-line, making it ideal for exacting high-wind conditions where load weight is a concern.

AluLight Product Sheet

Special Support Designs The modularity of the Schletter system allows for multiple combinations with different fastening and loading possibilities. Below are some of the systems available.

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Combined Construction Forms

The benefit of using compact module support construction is the enhanced integration of the roof construction in the calculated arrangement of the module elevation and load distribution into the roof structure (usually by continuous beams). Therefore, the continuous beams are installed vertically to the roof construction (using CompactVarioTM or CompactGridTM). If it is possible to screw the supports directly to the roof structure (using CompactDirectTM ), the span of the module beam must be aligned to the distances of the roof structure.

CompactVario™

Schletter’s CompactVario is a flexible module elevation system for both flat and pitched roofs, ideally suited for bridging wide purlin distances. A complete series of double groove profiles DN0-DN2,5 are available as distribution rails in north-south direction, offering the most economic solution.

See mounting instructions for CompactVario

CompactVario is engineered to require no drilling at the installation site. A wide range of fastening elements for different roof systems is available. Please also consider:

FixT™ Product Sheet (trapezoidal/u-shaped and overlapping roofs) FixE™ Product Sheet (corrugated sheet metal)

First, define the positions of the continuous rails, then mount according to the fastening element instructions (FixT, FixE, Fix2000 etc.). When mounting cross rails, the lower groove of the rail comes with standard screws with square screw heads, sized M10 x 25 mm (0.98 inches). Insert the screws into the corresponding holes in the fastening elements. Secure them with M10 flange nuts. Click the square nuts into the upper groove and attach the fittings using M10 x 20 mm (0.79 inches) hexagon head screws.

Measurement X with support series 07:Light 1.0 m = 31.93” (811 mm)Light 1.3 m = 38.0” (965 mm)Light 1.5 m = 53.54” (1360 mm)Profi 1.5 m = 53.54” (1360 mm)

Unfold the supports and assemble them using a socket wrench and M8 screws with M8 self-locking nuts

Screw the cross rails into the supports using standard square head screws, M10 x 25 mm (0.98 inches), and M10 flange nuts. For more information, see Module Mounting, page 22

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CompactGrid™ When the necessary number of fastening points on the roof cannot be obtained, or when a better distribution of the connection points is necessary because of a limited firmness of the roof (e.g., on sheet metal roofs), CompactGrid is an excellent option.

The system’s continuous rail system offers an excellent solution for elevated installations where the roof structure is inclined to the east or west. The application of Schletter’s well-proven, double-grooved mounting rails makes it possible to optimize the support distances and to transfer the loads evenly and safely into the roof cladding or substructure. The installation of diagonal strut kits prevents any potential twisting of the module rows.

CompactGrid Mounting Instructions

CompactDirect™

With some elevated systems, the distances of the module rows are determined by shade distances. In such cases, a load distribution beam is required for an unimpeded arrangement of the module rows while optimizing the total number of modules.

Roofs that are aligned in east-west direction with purlins in north-south direction often allow direct mounting of the supports. In these cases, the flat roof supports are directly attached to the roof (i.e. rafters) using hanger bolts or the FixTTM/FixETM fastening systems. The connection point must be as close as possible to the assemblage points of the supports. All standard Schletter support systems are suitable for this method.

As with the CompactVario™, connecting CompactGrid to the substructure is performed using Schletter’s industry proven FixT™ connectors. The distances of the continuous beams must be altered to correspond with fastening element holes as closely as possible.In certain circumstances, the support must be adapted to the fastening system distance by drilling an additional hole (10 mm). The support attachment is done by clicking the square nuts into the upper groove of the rail and securing them with M10 x 20 mm (0.79”) hexagon screws, using the required insertion plates (see below).

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FixZ-7™

Flush-mounting or a roof-parallel mounting is not optimal on flat sheet metal roofs with less than a 10 degree inclination due to the low module output yields and insufficient self-cleaning of the modules found with higher tilts. The Schletter FixZ-7 offers the perfect solution for these problematic cases by offering an additional 5 to 7 degrees of tilt.

FixZ-7TM Product Sheet

FixZ-7TM is designed for module heights ranging from 4.3 – 5.6 feet (1.3 – 1.7 m) and setting angles from 5 – 7 degrees. For technical reasons, FixZ-7 is only suitable for framed modules in portrait (vertical) mounting positions. The setting angle depends on the position of the clamp locations, positioned at a range from 1/4 to 1/5 of the module height (also consider recommendation of module manufacturer). Due to load calculation parameters, mounting on fastening elements other than the Fix2000™ KlickTop™ (standing seam clamps, roof hooks, etc.), is only possible with an additional bottom layer of rails (cross rail combination). Only the KlickTop attachment should be used to fasten the system rails.

The distance to the roof edges should be 5 ft (1.5 m) at the sides and 4 ft (1.2 m) at both the northern and the southern roof edge.

Fix2000TM Mounting Instructions

With the FixZ-7 design, the module frame itself is integrated into the support system. The special FixZ-7 profiles are designed for a module inclination of an additional 5 – 7 degrees (in relation to the roof surface). Therefore, the mounting positions of both the front beam and the back beam have to be determined according to the module height.

When mounting the modules, it is very important not to twist the frames (which is why mounting with the FixZ-7 is only possible with framed modules).

Distance to module height Rows to shade destance

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System Mounting

After the fastening elements are mounted, the next step is to apply the cross beams and/or rails.

Pitched Roof Mounting: Cross Beam Mounting With classic pitched roof fastening, two rows of roof hooks and/or other roof fastening elements are attached to the supporting roof substructure. The cross beam profile is mounted onto these profiles. Two cross beam profiles bear one module row, which is aligned and fastened to the cross beams by means of end and middle clamps. Usually, the modules are mounted vertically (portrait).

IMPORTANT!

Due to thermal expansion, ensure that the rows are not too long. Long, continuous rows should be subdivided. On tiled roofs, a maximum length of about 66 ft (20 m); on sheet metal roofs without the possibility of thermal equalization, a maximum length of about 33 ft (10 m) is common.

Tools: Combination 15 mm wrench with 6 mm (0.24“).

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Secure and align the cross beams on the fixation spots

Insert the bolts (usually M10 x 25 mm (0.98 inches) hexagon head or square head) into the groove of the cross beam rails and arrange them at approximate distances. Then insert the first piece of the cross beam (starting with the first screw) in the attachment row (roof hooks, corrugated roof fasteners, standing seam clamps). The most effective method is securing the first bolt with a nut at the roof attachment and then lifting the rail at a slight diagonal, inserting more bolts and securing each of them with a nut (DO NOT TIGHTEN at this point).

If necessary, extend the cross beam rail with a connector plate.

How to even out different heights on roofsa) For tiled and pan tiled roofs: Use height adjustable hooks or use underlayments with fasteners b) For corrugated or trapezoidal (U-shaped) sheet metal roofs: Adjust the mounting plate at the hanger bolt by adjusting the fastening nuts

c) For standing seam roofs: When necessary, use underlayments and appropriate bolts.

Next, the lowest rail should be aligned straight. After fastening the lower row of rails, and with the other rails still attached, ensure that the rails at the sides are aligned to the roof covering. (Important: Make sure that the side rails are aligned at a 90˚ angle. If this does not occur, the rails in the complete module field cannot be aligned in one direction!) Number triples can be used to achieve the 90˚ angle. For example: 23.6”, 31.5” (60, 80 cm) result in a diagonal of 39.4” (100 cm).

After aligning all cross beam rails, secure all connection bolts tightly. Use only special nuts with locking teeth. If the installation is supposed to be integrated in the lightning protection of the building, pay special attention to ensure the side rails are aligned at a 90˚ angle.

All bolts of the substructure have to be fastened tightly and double checked.


Tip:If the wiring is to be installed within the cable duct, water accumulations have to be avoided. This can be done by a suitable alignment or also by drilling individual holes at the lowest spots of the cable duct. When plugs are installed in the cable duct, this has to be especially considered!

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Generally, the use of standard mounting systems is recommended, which offer quick and efficient attachment of the cross rails to the substructures. When this isn’t an option, the GridNorm cross rail system is ideal for instances in which the substructure has poor fastening locations or the position of the cross rails must have improved alignment to the module rows.

Examples of such applications are the module mountings on all trapezoidal (u-shaped) sheet metal roofs with only horizontal battens or the horizontal (landscape) mounting of modules on pantiled roofs with unfavourable row partition.

Suggestions for using GridNorm:

• Arrangement: Usually, the bottom profiles are arranged vertically from the eaves to the ridge and attached onto the fixation spots (roof hooks, corrugated roof kits, etc.). Then the cross beam profiles are arranged onto the vertically mounted profiles in suitable distances to the module. The cross rail connector KlickTop is tightened from above with a socket head bolt.

• Profile distances and span widths: The allowable distances of the profiles and support

spots can be found in the system structural calculations. Remember that the minimum number of fixation spots per square meter must be maintained.

GridNorm Product Sheet KlickTop Product Sheet

GridNorm™ with KlickTop™ for Cross Rail Mounting Cross rail mounting is highly recommended if the substructure does not feature suitable mounting locations.

• Can be assembled with cost-effective standard rails • Flexible mounting options• Compatible with all Schletter system components • Works with cross-rail connector KlickTop for reduced mounting times

Tip: The cross rail mounting (regardless of the mounting system) should be used when the substructure does not offer fastening locations for cross rails. The intention of cross rail mounting is not to reduce the number of required roof hooks for certain module arrangements. The number of required roof hooks per square meter is determined by the structural requirements and is NOT influenced by the mounting systems that are applied.

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Flat Roof MountingWith flat roof elevations, usually a row of vertically arranged modules is fixed onto a pair of cross beams. The pair of cross beams is mounted onto a row of supports.

The cross beam profiles are attached onto the support elements. Usually, two cross beam profiles bear one module row, which is aligned and fixed to the cross beams using end clamps and middle clamps. Special alignments of modules are also possible. A variety of supports makes adaptation to different conditions possible.

Tip: For determining row distances, use the Schletter Automatic Shade Calculator

Considerations

• The calculations for all supports must be done while considering the boundary conditions (building height, snow/wind load zone, module height, etc.). The allowable support distances can be found in the system specifications.

• Verification that the roof can safely bear the additional loads of the mounting system, PV panels, and potential snow load MUST BE performed. This is ultimately the responsibility of the installer.

• Wind load must be considered with all systems, though it is even more important when elevated forces can occur at the attachment locations. When supports are combined with fastening elements (e.g., supports on hanger bolts, clamps, etc.), the verification of structural safety has to be carried out within the framework of atypical calculations, because such cases usually cannot be listed in the system schematics. Additionally, a structural verification of the construction conditions on the installation site must be completed.

• If fastening by ballasted loads, the required loads can be found in the system shop drawing. It is essential that the roof substructure can bear both the additional load of the PV system and the required loads.

• The structural calculations for the supports usually refer to vertical loads and not individual lateral and tilt stabilities. For example, it has to be determined on a case by case basis, if the support combinations require stabilization by means of additional diagonal struts, or the like.

• With tight roof cladding, often only a fastening by ballasting without penetration of the roof cladding is possible. In these cases, special care should be taken to ensure no stone or gravel remains under the loadings, potentially damaging the roof cladding (a mat for the protection of the roof cladding is recommended).

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Mounting System Steps

Mount the supports and arrange them on the roof areaThe distance between supports must be determined according to the site conditions (building height, snow load, wind load, module height). In normal cases, 63 – 71” (1.6 – 1.8 m) is typical. The cantilever of the cross beam should be 15.75 – 19.7” (0.4 – 0.5 m) at most.

Screw the supports individually onto the elements (only when mounting on concrete material)

Arrange the supports in a row

Fasten the cross rails loosely onto the supports Insert the bolts into the groove of the cross rail profile and arrange them according to the support distances. Loosely fasten the first cross rail profile (starting with the first bolt) in the first support. Then arrange all supports one-by-one in a row. Connect the cross beam with a connector plate to the lower side. After aligning all cross beam rails to the supports, tighten the bolts completely.

Only use self locking nuts. If the installation is supposed to be integrated into the lightning protection of the building, please review the Considerations for Flat Roof Mounting, on the previous page.

Bring the rack in the right position, if necessary

Tighten all bolts of the substructure (M8: 15Nm; M10: 40Nm)

Cross beam mounting Secure the cross beam onto the supports using the appropriate sized bolts, M10 x 25 mm (0.98”) and M10 flange nuts or through the use of the KlicktopTM.

For more information, see Module Mounting, page 22

Tools: 5 mm (0.59”) extended socket wrench

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Awning and Façade Attachment Mounting to a façade involves fastening panels to vertical walls. If the mounts are in visible locations, attachments with optional colored designs (e.g., anodized or powder-coated) can be delivered. (Please note: anodized or coated elements are only conductive to a limited extent (capacity charge, lightning protection)).

See General Mounting Suggestions, on the next page

Draft a sketch of the plant configuration and determine the desired positions of the façade supports The cross beams should not cantilever more than 15.75” (0.4 m) at the left and right. The maximum support distance is determined by statistical dimensioning charts.• Mount bottom beams • Place module rail and hook into the strut, secure with bolt

Check the position of the cross beams according to the module heightThe cross beams should be positioned in a distance about 1/4 – 1/5 of the module height from the upper and lower edge of the module. The position of the connector boxes must be considered. It is necessary to check if the drilling at the supports are suitable for the modules used. If not, please ask about façade supports with special measurements.

Check the substructure and choose a suitable fixation systemMake sure that both the substructure and fasteners can support the loads (especially in case of both wind and snow loads). Heavy-duty anchors or adhesive anchors are recommended. If necessary, the fastening locations must be integrated into the power plant structural calculations.

Leveling and mounting of the supports of a rowIn order to align the supports, the two outermost elements are attached in the same height (horizontal alignment by means of a level or laser measuring). Stretch a cord between the external supports from the top corner to the bottom corner and align the inner supports to the cord (if necessary, use underlayments).

Secure the cross beam onto the façade supports and alignSecure the bolts (usually M10 x 25 mm/0.98 inches) into the groove of the cross beam rail and arrange at approximate distances. Then insert the first part of the cross beam (starting with the first bolt) into the outermost rail. The best way to do that is by securing the first bolt at the support with a nut and then lift the support slightly, inserting the bolts one by one and securing with nuts (do not tighten yet). If the walls are uneven, corrections can be made by using underlayments at the fastening side of the façade support or by using underlayments between the support and the cross beam (if necessary, use longer bolts).

Extensions of the cross beams are possible by means of cross beam connectors, aligning the lower rail until straight. After fastening the lower rail, attach the upper rail. The alignment at the sides must be exact and at 90˚ angles. After aligning the cross beam rails, screw all connection screws completely and securely. Only use special nuts with locking teeth. If the power plant is designed with the lightning protection of the building, review additional information on page 24 of this manual.

Tighten all screws completely and check each one a second time

Continue with Module Mounting on the next page

15 – 75°

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Module Mounting Suggestions

Framed Modules Module mounting preparationCabling to the module rows must be prepared. Keep the necessary steps for lightning protection (page 24) in mind as the cabling is prepared. For module cabling, at the end of a string of cables, suitable plugs/sockets for the individual module types must be mounted. Connect the first module (as specified by the manufacturer) followed by the other modules.

Click the square nuts into the upper groove of the cross beam rail in approximate distances using the click-in component (item #430024). Loosely place the first two end clamps at the end of the cross beam rail. Then apply the first module and fit them loosely with the end clamps (the end clamps should be positioned 2 mm or more away from the edges of the cross beams). Now align the first module to the cross beam (use a cord or auxiliary device, available as an accessory).

Mounting of the module rows After aligning the first modules, one middle clamp per cross beam rail is loosely fixed to the corresponding cross beam. Then the next module is loosely clamped, shifted under the module clamp, and fastened. The next middle clamp is attached accordingly. The cables can be placed in the cable duct of the rail, securing them to the cross beam by means of UV resistant cable straps.

Tighten all module attachment screws and check each one a second time

End cap: If desired, the cross beam rails can be finished with an end cap (for Solo™ and Profi™).

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OptiBond™

• Engineered for big module surfaces• Minimum assembly time• Anti-theft device

Technology continues to lean towards thin film modules to reduce cost. The result is modules that have large surfaces with double glass construction. With this size increase, suitable fastening systems must be applied in order to maintain product integrity.

In response, Schletter partnered with several module manufacturers to develop OptiBondTM. OptiBond works in conjunction with an adhesive (not sold by Schletter) that is placed on the OptiBond plate, which is adhered to the back of the module.

OptiBondTM Product Sheet

Frameless Modules The Schletter Laminate Eco-SeriesTM is specifically designed to accommodate the requirements of frameless (laminate) modules. Each middle clamp has a corresponding end clamp. The clamps are designed so that the module only has direct contact to rubber on all sides, including the front side. The result is a frameless module with no direct clamping to metal parts. Laminate Mounting General Suggestions LaminatEco™ Product Sheet

Mounting of the clamps: Mounting end clamps and middle clamps is done in the same manner as the mounting of normal clamps for framed modules. (See previous page)

Mounting of safety hooks: The laminate safety hook prevents gravity from pulling the module out of place. Safey hooks are available in 0.26” (6.8 mm) and 0.31” (8 mm) sizes. The safety hook is shifted under the module clamp and attached using the clamp screw after the respective module is aligned. In case of two-part middle clamps, it is important not to over tighten the module clamps.

For frameless modules with very narrow edges, use caution to avoid covering too much of the module with the clamp. For such narrow edge modules, it is recommended to use distance strips when mounting. Logically, such strips increase the distance between modules, resulting in the need for longer rails. If using the Schletter auto-calculator, take this added distance into consideration. As the distances between the modules become bigger due to the distance strips, make sure that longer rails are ordered and installed. The results of the auto-calculator have to be corrected in such cases.

With larger laminates or in case of cross mountings, the laminate must have additional support in the middle, between the clamps, using support rubber or underlying sheet metal (available upon request).

Cross mounting with LaminatEco Shim for LaminatEco to support the module

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Special System Considerations

IsoTop™ — Industrial Roof• Support widths of up to 33 ft (10 m) • Direct load transfer into the supporting structure of the building• Complete Schletter assistance with project planning

IsoTop Product Sheet

Special Project Planning for Flat Roofs

Windsafe™

• Non-penetrating or penetrating solution• Flexible design with choice of fixed module tilt angle• Load optimized through wind tunnel tests

The Windsafe System is load optimized with wind deflectors on each row of racks, deflecting the air while reducing ballast weight as well as overall system load on the roof.

Windsafe Product Sheet

AluLight™

• Significantly reduces loading on roof• Ideal for flat roofs requiring a high concentration of modules• Minimal parts to assemble

The AluLight System allows for modules to be mounted on flat roofs where the concentration of panels on the roof is important and where reduction of loading on the roof is required.

AluLight Product Sheet

Park@Sol™

Parking lots are an ideal location for PV systems, allowing power production along with shading of vehicles (electrical vehicle charging systems available).

Park@Sol Product Sheet

Ground Mount Systems

The FS SystemTM is individually planned for the respective installation site.Besides the pile-driving technology of the FS System, PvMax3TM is available as a system with concrete foundations.

FS System Product Sheet

PVMax3 Product Sheet

FS SystemTM

PvMax3TM

Park@SolTM

AluLightTM

WindsafeTM

IsoTopTM

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Hammer in Bolt cannot be unscrewed with Reopening (e.g. in case of the metal ball normal tools! damaged modules): Due to the very narrow middle clamp, Cut a groove and loosen the loosening using pliers is not possible. bolt with a large screw driver

AccessoriesAnti-theft DeviceSecuFix™ is a simple-to-install anti-theft device for PV systems and can be added to a system at any time. SecuFix consists of an ordinary socket head bolt and a stainless steel ball at an exact diameter for the specified system. All bolts are secured by simply hammering in the SecuFix metal ball. SecuFix will work in any PV system design.

Lightning Protection and System Grounding

For the grounding of anodized module frames, it is recommended to use special grounding shims or plates in combination with the middle and end clamps to break the anodized layer of the panel frame. The module is connected in a conductive manner to the mounting rack at several spots. An alternative grounding middle clamp (with grounding pins) provides a grounding solution integrated into the middle clamp, installed directly from above.

• Integrated module clamping and grounding• Reduces mounting time• Pre-assembled and ready to use• Rated to 10 AWG*• ETL Listed

System Grounding Product Sheet Rapid2+ Grounding Middle Clamp (ETL Listed) Product Sheet Grounding Conductor Plate (ETL Listed) Product Sheet

*Installer is responsible for verifying that installation meets applicable NEC guidelines

Important: Please remember that all mechanical anti-theft measures generally are only a delay and not a prevention of theft and therefore should be combined with other precautions.

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Hammer in Bolt cannot be unscrewed with Reopening (e.g. in case of the metal ball normal tools! damaged modules): Due to the very narrow middle clamp, Cut a groove and loosen the loosening using pliers is not possible. bolt with a large screw driver

Cable and Wire ManagementA clean and professional cable routing can have an influence on the end-user’s overall impression of the mounting quality. The standard profiles (Profi 05™) of the Schletter system offer the possibility of attractive cable routing by use of a duct that can be supplemented with a lid. The rectangular cable duct can be fastened to the rails at a right angle and then fastened from below.

If extensive wiring is required, we offer the cable duct system MaxK™. Different system components and even an extendable universal duct are available. In cases in which a cable duct would be too much of an effort or when additional cables have to be fixed, ProKlips™ can be inserted in the Klick™ grooves of the rails.

Components Overview Cable Clips Product Sheet MaxKTM Product Sheet

Tool List

Inverter Mounting

Cable Ducts

Cable Clamps

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Important Safety and Liability InformationElectric Installation

Suggestions on electric installation are generally not the subject of this guide. However, the general suggestions listed below should be considered:

• Installation and connections may only be carried out by a certified electrician• Relevant regulations and suggestions on safety must be considered• When water is present, electronic installations should not occur• High direct voltages arise at the series of connections of modules, which can be life threatening in case of direct contact.

Working on the Roof

When performing any type of work on a roof, including flat roofs, the relevant accident prevention regulations must be considered. Installers should always employ safe practices when working on roofs. Always check with local municipalities for safety regulations.

Exclusion of Liability

This instruction gives reasonable suggestions on mounting the fastening system by Schletter Inc.

• In addition to these suggestions, the installation contractor has to consider the relevant regulations and the generally accepted rules of technology.

• The suggestions on dimensioning given in this instruction are only suggestions gained from practical experience; the suggestions on dimensioning from the individual system calculations are mandatory.

• The installation contractor is responsible for the dimensioning of the plants. Schletter Inc. provides the related suggestions in the system calculations.

• The Schletter company is not liable for suggestions on dimensioning given in commercial offers, as not all technical determining factors (snow load zone, building height, wind loads, etc.) can be aligned. We will be glad to assist you in your detailed planning.

• The installation contractor is responsible for the mechanical durability of the installed interface connections at the building surface, and especially for water tightness. The components produced by Schletter are designed according to the loads that are to be expected.

• The Schletter company is not liable if the installed components are handled in an inappropriate manner.

Schletter Inc. grants a voluntary 10 year product warranty on all racking systems, if the following conditions are fulfilled: Correct handling, dimensioning according to the framework requirements (unless there is a separate agreement), normal conditions regarding environment and surrounding. This applies for the environmental conditions that have to be considered according to DIN 1055. For example:• The product durability that is to be expected is considerably higher than the durability of the photovoltaic modules.• For dimensioning for all solar systems, consideration of all possible environmental conditions is not possible. Such

considerations are carried out according to the regulations of the valid norms, we generally recommend an insurance against natural hazards.

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Cable Laying

Cable laying is important in regards to protecting the system from lightning strikes. Damage to the system (i.e., destruction of the inverters by over voltage) is often caused by induction voltage in the module wiring. A lightning strike close to a PV system has a very high current flow. This current flow (respectively its temporal change di/dt) induces an induction voltage into the looped circuit that is formed by the module wiring installed on the roof.

Looped circuits should be avoided as much as possible when planning the racking system, string partition, and cable laying. After running through the modules that are connected in series, the module wiring should be led back in the same module string and re-enter the roof at the exit spot. For the return path along the module rows, the cable duct at the cross beam rail can be used.

Additional Mounting InformationLightning and Over Voltage

Lightning and over voltage protection are generally not the subject of this guide. As such, we recommend the guidance of outside professionals who are experts in these matters. The following general suggestions may assist in planning. Discussions with the system owner should occur as to whether measures should be taken towards lightning protection (arresters, conductions, etc.) and/or measures of inward lightning protection. Special caution is required when systems are installed on roofs that already have external lightning protection. In these cases, the system owner must be informed.

Generally the PV system should be installed with a sufficient separation distance to existing lightning protection systems. In this case, the potential equalization of the PV rack must be implemented independently from the lightning protection system. This is also the case for sheet metal roofs.

If the separation distances cannot be maintained due to the construction conditions, the rack can be connected to the lightning protection system according to the lightning protection standard. This must be done at several locations (e.g., using lightning protection clamp item #430035). In this case, all components of the interior lightning protection should be lightning-proof.


Order ProcessingPhone: (520) 289 - 8745Fax: (520) 289 - 8696E-mail: [email protected]

Logistics/ShippingPhone: (520) 289 - 8760Fax: (520) 289 - 8696

Technical SalesPhone: (520) 289 - 8730Fax: (520) 289 - 8696E-mail: [email protected]

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How to Contact Us

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Schletter Canada, Inc. 3181 Devon Drive Windsor, Ontario N8X 4L3 CanadaTel: 519 946 - 3800Fax: 519 946 - [email protected]

Schletter Inc. 3761 E Farnum Place Tucson, Arizona 85706 USA Tel: 520 289 - 8700Fax: 520 289 - [email protected] www.schletter.us

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