AEROCOMPACT CompactMETAL TS08 User manual

CompactMETAL
TS08/15
Assembly Instructions
Version: 01
Language: English | Original language: German
Original installation instructions
Important! Read carefully before installation!

TS08/15
www.aerocompact.com 2
Legal 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 at 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
[e-mail]
www.aerocompact.com
Update
This manual is subject to change without notice. This does not represent any obligation on the part of the
manufacturer.
Creation date
06/2021
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TS08/15
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 module side 7
Safety 8
Requirements of personnel 8
Working safely 8
Breakthrough protection 8
Climbing aids 8
Weather conditions 8
Dangers from the environment 8
Protection against falling objects 9
Personal protective equipment (PPE) 9
System Overview 10
Basic components TS system 10
Accessories 11
Bonding Accessories 11
Module Accessories 12
Installation Variations 12
Assembly 13
Measure the area 13
Installing the TS short rail 13
Tighten screws with attached rubber washer 14
Install height adapter (optional) 14
Installing the tilt adapter (optional) 16
Installation options 16
Installing the tilt adapter 16
Option PS 16
Option PM/PL 16
Install microinverter (optional) 17
Mount microinverter with the microinverter clamp (MA-MO) onto the module frame. 17
Installing modules 17
Bonding 19
Bonding with bonding jumper (USA) 20
Maintenance 22
Complete System 22
Fittings 22
Disassembly 23
Disassemble components 23
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TS08/15
www.aerocompact.com 4
Dismantle clamps 23
Appendix 24
UL Certification Notes 24
Load Rating 24
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TS08/15
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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TS08/15
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 TL25/38 system is designed exclusively for installing PV modules on metal roofs consisting of
trapezoidal sheets.
The system must be properly installed in accordance with these installation instructions.
PV modules used with the TL25/38 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 TL25/38 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. If the mod-
ule layout on the roof changes due to local conditions, e.g. unforeseen interference areas, the structural ana-
lysis must be recalculated. The Aerocompact system is designed and planned with 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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TS08/15
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 point out that the product is sold within the framework of a purchase agreement. Assembly/installation
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 installation instructions. The Aerocompact system
must be designed and planned with the AEROTOOL software. Aerocompact is not responsible for the pro-
ject-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
buyer's rights of warranty for material defects shall not longer be valid. The system warranty is only valid if
all system components are purchased from Aerocompact.
Systems with clamping on the short module side
For a system with a clamp on the short side of the module, it is assumed that the module may also be used
in this mounting form (clamp on the short sides of the module). This release can either be generally avail-
able as part of the module installation instructions or can be given by the module manufacturer for specific
projects.
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TS08/15
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 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 the freezing point. Depending on the roof pitch
there is a risk of slipping.
Dangers from the environment
Keep sufficient distance from overhead electrical lines. The following distances must be observed:
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TS08/15
Safety
www.aerocompact.com 9
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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TS08/15
System Overview
www.aerocompact.com 10
SYSTEM OVERVIEW
Basic components TS system
1Middle clamp | CLM10
2End clamp | CLE10
3Thin sheet metal screw* | EJOT JF3-2-5,5x25 E11
4Trapezoidal sheet metal short rail 80 mm, 150 mm | TS08, TS15
* This component is intended for single use.
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TS08/15
System Overview
www.aerocompact.com 11
Accessories
1Height adapter 1.3 in (33 mm) | EL05 Elevation
2Height adapter 3.3 in (83 mm) | EL10 Elevation
3Safety Bolt | LSP
4Front tilt adapter 0.8in (20 mm) | PS Pitch
5Rear tilt adapter (100 mm) | PM Pitch
6Rear tilt adapter 180 mm | PL Pitch
Bonding Accessories
1Grounding Clamp 8 - 10 mm | WCL8-10
2Aluminium wire round 8 mm for grounding | AWR8
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TS08/15
System Overview
www.aerocompact.com 12
Module Accessories
1Microinverter interlocking on X-Rail | MA-RA
2Microinverter clamp US | MA-MO
3Cable tie clip to module | CLP-M
Installation Variations
Installing the modules directly on trapezoidal sheet metal short rail
Installing the modules on the EL05/EL10 height adapter
Installing the modules on the PS, PM/PL tilt adapters
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TS08/15
Assembly
www.aerocompact.com 13
ASSEMBLY
Measure the area
The rails are installed on the peaks/ crowns of the metal roof. . The distance between the rails
depends on the width of the modules and the distance between the peaks/ crowns.
Take the dimensions of the module field from the Aerotool planning documents.
Determine module size.
Determine the distances between the peaks/ crowns.
Determine and mark the positions of the short rails.
Installing the TS short rail
Depending on the layout in the planning documents, the TS08 short rail can alternatively be mounted
with 3 thin sheet metal screws.
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TS08/15
Assembly
www.aerocompact.com 14
Make sure that the short rails are mounted parallel with the ribs.
Position the front and rear short rail and screw down tightly.
Clamp a metal rail or wooden jig to the short rails as a guide.
Install the other short rails .
Tighten the screws until the rubber gasket compresses evenly all around (see figure).
Tighten screws with attached rubber washer
Mount screws with EPDM seal always with mechanical depth stop.
Ensure sealing: Tighten the screws until the seal is compressed evenly all around. The seal should be com-
pressed by approx. 30 %.
correct
screw is tightened too tight
screw is not tightened enough
screw is tightened unevenly
Install height adapter (optional)
Use height adapters to achieve a greater distance between the roof surface and the modules.
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TS08/15
Assembly
www.aerocompact.com 15
The height adapter must be mounted as flush as possible above the short rail. If necessary, a tolerance of
max. 1 cm / 0.4 inch is allowed.
Install the height adapter on the short rail:
Place the hammerhead in the mounting channel.
Tighten the screws with 15 Nm or 11 ft lb.
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TS08/15
Assembly
www.aerocompact.com 16
Installing the tilt adapter (optional)
Installation options
Using the Pitch products, modules can have an additional tilt of 5° to 15°.
Front: EL05 height adapter with PS tilt adapter
Rear: EL05 height adapter with PM/PL tilt adapter
The height of the elevation must not exceed 300 mm.
Installing the tilt adapter
The tilt adapters are only installed in combination with the EL05 height adapter.
Option PS Option PM/PL
Attach tilt adapter to EL05 height adapter as required.
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TS08/15
Assembly
www.aerocompact.com 17
Use the safety bolt to secure each tilt adapter to the height adapter on the starting and ending rows of an
array.
Install microinverter (optional)
Mount microinverter with the microinverter clamp (MA-MO) onto the module frame.
The microinverter is installed directly onto the module frame.
Install the microinverter onto the module according to the module manufacturer's instructions.
Installing modules
Depending on the accessories used, the following options are available:
Installing modules on the short rails.
Installing the modules on the height adapters.
Installing the modules on the tilt adapters.
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TS08/15
Assembly
www.aerocompact.com 18
When installing the modules, make sure that the module clamps are placed as centrally as possible on
the short rails or adapters.
Do not enter the modules under any circumstances.
Place the end clamps on the outermost row of short rails.
Place the first module .
Tighten the screws of the end clamps with 15 Nm or 11 ft-lbs.
After the first module, attach the middle clamps .
Position second module .
Tighten the screws of the middle clamps to 15 Nm or 11 ft lbs.
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TS08/15
Assembly
www.aerocompact.com 19
Continue placing the modules row by row.
Make sure that the modules are installed in a line.
Tighten the screws of the end clamps with 15 Nm or 11 ft lb each.
Reposition / replace clamps
Demount clamp: Unscrew the screw at the clamp completely.
Depending on the mounting situation, squeeze the clamp laterally and pull it out or pull it laterally out of
the rail.
Bonding
For bonding, AEROCOMPACT provides the bonding wire clamp as an accessory. These are each moun-
ted on the support rails.
Dependent on the mounting setting, each module row is bonded by the module clamps with grounding
pins.
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TS08/15
Assembly
www.aerocompact.com 20
Bonding modules through module clamps
Bonding the individual module rows
Grounding the array by terminating to on-site ground
Attach the T-Bolt Assembly to the rail.
Place the grounding wire onto the rails.
Attach the clamp and tighten with the nut.
Tighten the nut with 15 Nm or 11 ft lb.
Connect the wire to the on-site ground.
Bonding with bonding jumper (USA)
Depending on the installation, the module rows are connected to each other by the module clamps.
Bonding through module clamps
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