AEROCOMPACT CompactFLAT SN10plus User manual

CompactFLAT
SN10plus longside
Assembly Instructions
Version: 02/2021
Language: English | Original language: German
Original installation instructions
Important! Read carefully before installation!

SN10plus longside
www.aerocompact.com 2
Notice
Subject to changes due to technical improvements. These assembly instructions correspond to the technical
status of the delivered product and not to the current development status of the manufacturer.
If pages or parts of the assembly instructions are missing, please contact the manufacturer's address given
below.
The original language of these assembly instructions is German. Any assembly instructions in another lan-
guage are a translation of the assembly instructions in German.
The assembly instructions are protected by copyright. Without written permission from AEROCOMPACT®
the assembly instructions may not be copied, reproduced, microfilmed, translated or converted for storage
and processing in computer systems, either in part or in full.
Copyright by © AEROCOMPACT®
Manufacturer
AEROCOMPACT® Holding
Sonnenstraße 10
A 6822 Satteins | Austria
Update
This manual is subject to change without notice. This does not represent any obligation on the part of the
manufacturer.
Creation date
02/2021
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SN10plus longside
www.aerocompact.com 3
TOC
About This Document 5
Applicable Documents 5
Explanation of Symbols 5
Symbols in Illustrations 5
Target group 6
Appropriate use 6
Liability, Warranty, Guarantee 6
Guarantee 7
General information on liability 7
Systems with clamping on the short side of the module 7
Systems with roof protection pads 7
Safety 8
Requirements of personnel 8
Working safely 8
Breakthrough protection 8
Climbing aids 8
Weather conditions 8
Dangers from the environment 9
Protection against falling objects 9
Personal protective equipment (PPE) 9
System overview 10
Basic components 10
Roof protection pads 11
Ballasting 11
Accessories 12
Assembly 13
Measure the area 13
Preassemble the front supports 14
Premounting the rear support 14
Installing roof protection pads 15
Version 1: Roof protection pad PP 200/120-CL and PP 250/120-CL 15
Version 2: Roof protection pad PP 150/80 17
Place rail lines 18
Install ballast 18
Variation 1: Ballasting on the base rail 18
Variant 2: Cross struts as ballast rail 19
Variant 3: Ballast tray 20
Microinverter montieren (optional, USA) 22
Installing modules 22
Installing the roof anchor 24
Bonding 24
Maintenance 25
Complete System 25
Fittings 25
Disassembly 26
Disassemble components 26
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SN10plus longside
www.aerocompact.com 4
Dismantle clamps 26
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SN10plus longside
About This Document
www.aerocompact.com 5
ABOUT THIS DOCUMENT
These installation instructions describe the procedure for installing the product. Read these assembly instruc-
tions carefully before starting the assembly. Follow the instructions carefully to ensure correct installation of
the product.
Applicable Documents
The following documents are a part of these installation instructions and are absolutely necessary for the
correct assembly of the system:
oProject report from AEROTOOL
oPlanning documents and drawings
Explanation of Symbols
In order to make these assembly instructions easy to understand, uniform safety instructions, symbols, terms
and abbreviations are used. The following symbols indicate notes which are not relevant to safety, but
which make working with the assembly instructions easier.
Requirements for an action are depicted with this symbol. Make sure that all requirements are met before
you carry out the following actions.
Action steps are depicted with this symbol. Carry out the steps in the specified order.
The result of the action is depicted with this symbol.
This note provides useful information for a smooth assembly of the product.
Symbols in Illustrations
Activities
Certain activities are required to carry out the assembly. These activities are shown in the illustrations with
the following symbols.
Check AEROTOOL planning documents Visual inspection
Activity by hand Observe right angle
Optional component,
optional installation method
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SN10plus longside
About This Document
www.aerocompact.com 6
Tools
Certain tools are required to carry out the assembly. These tools are shown in the illustrations with the fol-
lowing symbols.
Measuring tape, measure Cordless screwdriver, screwdriver
Pencil, mark Torque wrench,
Observe torque
Chalk line
Target group
These installation instructions are intended for trained personnel who are familiar with the installation of
photovoltaic systems. The personnel should also be familiar with working on roofs and know the local reg-
ulations regarding work safety. The personnel must also observe the instructions in the Safety chapter.
Appropriate use
The CompactFLAT flat roof system is designed exclusively for installing PV modules on flat roofs or similar
flat surfaces. Proper use also includes correct installation in accordance with these installation instructions.
PV modules used with the CompactFLAT system should be approved by the module manufacturer.
AEROCOMPACT accepts no liability for loss of performance or damage of any kind to the PV modules.
Any other use of the CompactFLAT system is considered improper.
Liability, Warranty, Guarantee
These assembly instructions and the project report supplied with the product are integral parts of the
product. The information, data and instructions given in the assembly instructions were up to date at the
time of printing. No claims can be made for products already delivered that deviate from the information,
illustrations and descriptions.
The project report supplied with the system contains the static calculation related to the location. Follow
the position of the modules on the roof, the number and position of the building protection pads and the
ballast distribution exactly according to the project report. If the module layout on the roof changes due to
local conditions, e.g. unforeseen interference areas, the structural analysis must be recalculated. The Aero-
compact system is designed and planned using the AEROTOOL software.
Aerocompact accepts no liability for damage and malfunctions caused by:
oImproper use
ouse of non-certified components.
ounauthorized modifications to the product.
oimproper handling of the product.
oInstallation errors
oFailure to comply with the installation instructions or planning documents.
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SN10plus longside
About This Document
www.aerocompact.com 7
Guarantee
The warranty period for the system is 25 years. The warranty period for galvanized steel parts is 10 years. The
guarantee is only valid if the installation is carried out professionally and all system components are pur-
chased from Aerocompact. If the assembly instructions or the planning documents are disregarded, the war-
ranty will be invalidated.
Photovoltaic racking systems are not maintenance-free. Carry out maintenance annually and immediately
after unusual weather events, e.g., after heavy storms or heavy snowfall, etc. If the maintenance is not carried
out at the specified interval, the warranty will become void.
General information on liability
We would like to point out that the flat roof system is being sold as part of a sales contract. Assembly/-
processing by the purchaser or third parties is not carried out on behalf of or for Aerocompact and must be
carried out by qualified personnel strictly in accordance with the assembly instructions. The Aerocompact
system must be designed and planned with the AEROTOOL software. Aerocompact is not responsible for the
project-related statics of the roof structure, for obtaining and documenting the roof manufacturer's
approval for the installation of the corresponding fasteners on the respective roof (in terms of warranties),
nor for the professional execution.
Errors and damage as well as limited or insufficient functionality of the system due to incorrect installation
and/or installation that deviates from the installation instructions and/or the project report (AEROTOOL)
exclude any material defect for which Aerocompact is responsible. In the event of improper handling, the
rights of the buyer due to a material defect shall expire. The system warranty is only valid if all system com-
ponents are purchased from Aerocompact.
Systems with clamping on the short side of the module
For a system with a clamp on the short side of the module, it is assumed that the module may also be used
with this installation method (clamp on the short sides of the module). This approval can either be generally
available as part of the module certification or, under certain circumstances, can also be given by the mod-
ule manufacturer on a project-specific basis.
Systems with roof protection pads
The roof protection pad included in the scope of delivery is matched to the roof surface defined in the pro-
ject. Due to the many available roof surfaces on the market, the responsible designer should ensure the com-
patibility of and the coefficient of static friction between the protection pad and the roof surface of the
building used in the design. The friction value is determined during the planning process with a coefficient
of friction test.
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SN10plus longside
Safety
www.aerocompact.com 8
SAFETY
Requirements of personnel
The person must be physically and mentally fit. Under no circumstances must the installation personnel be
under the influence of medication, alcohol or drugs.
Persons who are not healthy and fit must not work on roofs.
Personnel who are in training must only carry out work under the supervision of qualified personnel who
are authorized to train personnel.
Working safely
The company carrying out the installation is responsible for ensuring that the local regulations for work
safety and accident prevention are observed.
Breakthrough protection
Roof windows, skylights, large ventilation flaps etc. often cannot withstand the weight or impact of a person.
Such objects must be secured in a similar way as the edge of the roof.
Corrugated fibre cement roofs can be prone to breakthrough over the entire surface. Define walking routes
and secure them with load distribution measures.
On roofing or roof structures that do not have sufficient load-bearing capacity (e.g. thin sheets, corrugated
fibre cement), always work with load distribution aids.
Climbing aids
Only use suitable, intact and tested ladders. Set up and secure ladders according to instructions.
Separate rules apply to mechanical climbing aids (lifts, lifting platforms, ...).
Never use the PV mounting system as a climbing aid.
Weather conditions
In case of unsuitable weather conditions, work on the roof must not be continued any longer than neces-
sary - or not started at all.
Never carry out assembly work in strong winds. Strong wind practices above all exerts enormous forces on
the large-area PV modules. There is a risk that a module could be torn off the roof and people could be
injured.
Never work in wet conditions or at temperatures below freezing point. Depending on the roof pitch there is
a risk of slipping.
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SN10plus longside
Safety
www.aerocompact.com 9
Dangers from the environment
Keep sufficient distance from overhead electrical lines. The following distances must be observed:
1 m to 1,000 V
3 m: 1,000 to 11,000 V
4 m: 11,000 to 22,000 V
5 m: 22,000 to 38,000 V
> 5 m: if the voltage is unknown
Protection against falling objects
Areas below the roof on which work is being carried out must be protected from any falling objects. Where
this does not succeed, affected areas must be closed to the public.
Persons involved in the construction project must wear safety helmets.
Personal protective equipment (PPE)
Personal protective equipment is required to prevent injuries during assembly work.
Wear protective goggles when drilling.
Wear safety boots.
Wear cut-resistant work gloves during assembly.
Helmets are required for all persons involved on the construction site.
Use fall protection.
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SN10plus longside
System overview
www.aerocompact.com 10
SYSTEM OVERVIEW
Basic components
1End clamp | CLE10
2Back support SN10 | SN10F
3Torx screw M8x16 A2-70 | 701 507
4Base rail | BR2390
5Starting piece base rail | BR130
6Front support SN10 | SN10B
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SN10plus longside
System overview
www.aerocompact.com 11
Roof protection pads
Different roof protection pads are supplied depending on the substrate.
1Roof protection pad PP 150/80
2Roof protection pad PP 250/120-CL
Roof protection pad PP 200/120-CL
Ballasting
1Cross brace | CS1800, CS2050, CS2300
2Ballast tray | BT-1800, BT-2050, BT-2300
3Ballast terminal | CLB10
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SN10plus longside
System overview
www.aerocompact.com 12
Accessories
1Angle connection to mechanical attachment | AC200, AC80
2Wire clamp for bonding | WCL8-10
3Aluminium wire round 8 mm for bonding | AWR8
4Cable tie clip to module | CLP-M
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SN10plus longside
Assembly
www.aerocompact.com 13
ASSEMBLY
Measure the area
Take the dimensions of the module field from the planning documents.
Measure the length of the module field and mark the line.
Measure the width of the module field and mark the line.
Determine the distance between the module rows according to the module manufacturer's instruc-
tions + 2 cm distance between the modules.
Measure the distance and mark the lines.
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SN10plus longside
Assembly
www.aerocompact.com 14
Preassemble the front supports
The base rails are each connected to a front support. The front row of modules starts with a short base
rail. This is followed by as many long base rails as module rows are mounted.
The base rails are mounted end-to-end. The joint is aligned at the front mark of the front support.
Place base rails and front support.
Hand tighten the screws.
Tighten the screws to 10 Nm or 7.38 ftlb with a torque wrench.
Premounting the rear support
1. determine the distance between rear support
and front support according to the table.
Make a gauge for dimension B.
Module (A) 950 960 970 980 990 1000 1010 1020 1030 1040 1050
Distance (B) 847 857 867 876 886 896 906 916 926 935 945
Module (A) 1060 1070 1080 1090 1100 1110 1120 1130 1140 1150
Distance (B) 957 967 977 987 997 1008 1017 1028 1038 1048
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SN10plus longside
Assembly
www.aerocompact.com 15
Place the base rails.
Place the first back support (1) using the gauge and hand tighten.
Place the second back support (2) mirror-inverted flush with support (1) and hand tighten.
Place the gauge after the support (2) and screw on a front support (3) mirror-inverted hand-tight.
Tighten the screws to 10 Nm or 7.38 ft lb with a torque wrench.
Installing roof protection pads
Version 1: Roof protection pad PP 200/120-CL and PP 250/120-CL
The roof protection pads PP 200/120-CL and PP 250/120-CL are used for sensitive roof surfaces, e.g. mem-
branes, bitumen etc. as well as for gravel roofs.
The roof protection pads are fitted as standard at the beginning and end of each base rail and in the area
of the rear supports. Depending on the ballast, additional roof protection pads are installed per rail.
Take the exact number and position of the roof protection pads from the AEROTOOL planning doc-
uments.
Positions PP 200/120-CL
less ballast
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SN10plus longside
Assembly
www.aerocompact.com 16
more ballast / additional roof protection pads for optimal point load distribution
Positions PP 250/120-CL
less ballast
more ballast / additional roof protection pads for optimal point load distribution
Installing roof protection pads
Place the roof protection pads so that the clip is facing upwards with the curvature.
Install the roof protection pads underneath the base rail.
Ensure that the tabs of the roof protection pad are completely enclosed by the profile.
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SN10plus longside
Assembly
www.aerocompact.com 17
In order to avoid damage to the substrate, ensure that the roof protection pad protrudes over the end of
the base rail or that the transitions between the base rails are covered.
Version 2: Roof protection pad PP 150/80
The roof protection pads PP150/80 are used for less sensitive roof surfaces, e.g. concrete roofs, etc.
Placement
The roof protection pads are fitted as standard at the beginning and end of each base rail and in the area
of the rear supports. Depending on the ballast, additional roof protection pads are installed per rail.
Take the exact number and position of the roof protection pads from the AEROTOOL planning doc-
uments.
less ballast
more ballast / additional roof protection pads for optimal point load distribution
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SN10plus longside
Assembly
www.aerocompact.com 18
Installing roof protection pads
Pull off the protective backing from the roof protection pad.
Place the roof protection pad underneath the base rail and adhere it in place.
Ensure that the tabs of the roof protection pad are completely enclosed by the profile.
Place rail lines
Align the rail lines with the selected grid.
Install ballast
Depending on the circumstances, the system is ballasted differently.
Variation 1: Ballasting on the base rail
With this ballasting variation, the ballast blocks are mounted directly on the base rails. Up to 3 ballast blocks
can be fixed with one ballast clamp. The ballast blocks can be mounted in front and/or behind the back sup-
port.
Take the exact number and position of the ballast blocks from the AEROTOOL planning documents.
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SN10plus longside
Assembly
www.aerocompact.com 19
Ballast in front of the back support (under the module)
Attach the ballast clamp to the base rail.
Place the ballast blocks on the base rail flush with the back support.
Align the ballast clamp and place the ballast block .
Fix the ballast clamp:
Tighten the screw until the wings of the ballast clamp are flush with the ballast blocks.
Place the ballast blocks .
Variant 2: Cross struts as ballast rail
The ballast rails can be mounted in the following positions:
behind the first front support (under module)
in front of the first back support (under module)
behind the second back support (under module)
in front of the second front support (under module)
behind the second front support
Take the exact number and position of the ballast rails and blocks from the Aerotool planning doc-
uments.
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SN10plus longside
Assembly
www.aerocompact.com 20
When ballast rails follow each other:
Lay out the ballast rails so that they overlap at the supports.
Hand tighten the ballast rails to the base rail.
Tighten the screws to 10 Nm or 7.38 ft lb with a torque wrench.
Lay out ballast blocks according to Aerotool planning documents.
Variant 3: Ballast tray
The ballast trays can be mounted in the following positions:
behind the first front support (under module)
in front of the first back support (under module)
behind the second back support (under module)
in front of the second front support (under module)
behind the second front support
Refer to the Aerotool planning documents for the exact number and position of the ballast trays.
Align BT-2050 and BT-1800 ballast trays
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