AEROCOMPACT CompactPITCH XM-P User manual

CompactPITCH
XM-P
Assembly Instructions
Version: 01
Language: English | Original language: German
Original installation instructions
Important! Read carefully before installation!

XM-P
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
[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
04/2022
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XM-P
www.aerocompact.com 3
TOC
About This Document 4
Applicable Documents 4
Explanation of Symbols 4
Symbols in Illustrations 4
Target group 5
Appropriate use 5
Liability, Warranty, Guarantee 5
Guarantee 6
General information on liability 6
Systems with clamping on the short module side 6
Safety 7
Requirements of personnel 7
Working safely 7
Breakthrough protection 7
Climbing aids 7
Weather conditions 7
Dangers from the environment 7
Protection against falling objects 8
Personal protective equipment (PPE) 8
System Overview 9
Basic Components XM-P 9
Accessories 11
Module Accessories 11
Bonding and Grounding Accessories 11
Installing Rails and Cross Connectors 12
Assembly 13
Measure the area 13
Installing Metal Tiles 13
Mount support base 14
Fasten metal tile and support bracket 15
Screw cover (optional) 16
Close roofing 16
Rail X40/X50 17
Installing the X40/X50 rail in a cross-mount (optional - not available in the USA) 17
Mounting the microinverter with a T-Bolt Assembly (MA-RA) 18
Installing modules 18
Bonding 21
Maintenance 22
Complete System 22
Fittings 22
Dismantling 23
Disassemble components 23
Dismantle clamps 23
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XM-P
About This Document
www.aerocompact.com 4
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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XM-P
About This Document
www.aerocompact.com 5
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 Drilling machine, drill
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 CompactPITCH flat roof system is designed exclusively for installing PV modules on tiled roofs or similar
roof coverings. The system must be properly installed in accordance with these installation instructions.
PV modules used with the CompactPITCH 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 CompactPITCH 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 specific to the location. If the
module layout on the roof changes due to local conditions, e.g. unforeseen interference areas, the structural
analysis must be recalculated. The Aerocompact system is designed and planned using the AEROTOOL soft-
ware.
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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XM-P
About This Document
www.aerocompact.com 6
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. Perform 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 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 qual-
ified 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
structural integrity 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 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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XM-P
Safety
www.aerocompact.com 7
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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XM-P
Safety
www.aerocompact.com 8
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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XM-P
System Overview
www.aerocompact.com 9
SYSTEM OVERVIEW
Basic Components XM-P
1Mid-Clamp | CLM10
2End-Clamp | CLE10
3Rail X40/X50 | X40-xxxx, X50-xxxx
4Screw | SDS-W-8x100, SDS-W-8x120, SDS-W-8x140, SDS-W-8x160
5Stainless Steel Support Bracket | XM-PSH
6Metal Roof Tile | XM-Pxxx
7Aluminum Support Base | XM-PAB
8T-Bolt M8x20 | HKM08
9M8 Serrated Nut | SEK08
For the screws, check/consider the minimum requirement according to ETA-11/0024:
Screw diameter: min. 8 mm / 5/16 or 0.315 inch
Effective screw-in depth: min. 80 mm / 3 5/32 or 3.15 inch
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XM-P
System Overview
www.aerocompact.com 10
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XM-P
System Overview
www.aerocompact.com 11
Accessories
1Cover Plate for Screws | XM-PSC
Module Accessories
1Microinverter T-Bolt Assembly for Top Rail-Channel | MA-RA
2Microinverter Clamp for Module Frame | MA-MO
3Cable Tie Clip for Module Frame | CLP-M
Bonding and Grounding Accessories
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XM-P
System Overview
www.aerocompact.com 12
1Grounding Clamp 8 - 10 mm | WCL8-10
2Aluminium Wire 8 mm for Grounding | AWR8 (please use properly sized copper wire in the USA)
Installing Rails and Cross Connectors
1Rail X40, 3300 mm, 4400 mm, 5500 mm | X40-3300, X40-4400, X40-5500
2Rail X50, 3300 mm, 4400 mm, 5500 mm | X50-3300, X50-4400, X50-5500
3Cross Connector X40, X50 | XDL
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XM-P
Assembly
www.aerocompact.com 13
ASSEMBLY
Measure the area
Follow the position and dimensions of the module field from the Aerotool planning documents.
Determine module size.
Determine and mark the position of the metal tiles according to the Aerotool planning documents.
Installing Metal Tiles
Remove the roof tile, that will be replaced by
the metal tile.
Expose roof structure :
Move roof tiles in the row above .
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XM-P
Assembly
www.aerocompact.com 14
Mount support base
Depending on the roof batten thickness, adjust the steel clamp to the correct level of the aluminum sup-
port.
Roof batten (W x H) Level
60 x 40 mm
50 x 40 mm
50 x 30 mm
Height < 30 mm
For roof battens wider than 50 mm, bend the tabs inwards.
On the rafter hang the aluminum support base onto the roof batten .
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XM-P
Assembly
www.aerocompact.com 15
Fasten metal tile and support bracket
Insert the metal tile and strike it against the roof batten with the back stop angle.
Hang the support bracket .
Position the support bracket above the rafter .
Make sure that the metal tile rests fully on the
support base.
When screwing, observe the minimum edge dis-
tance to the edges of the roof battens accord-
ing to ETA-11/0024.
For the screws, check/consider the minimum
requirement according to ETA-11/0024:
Screw diameter: min. 8 mm / 5/16 or 0.315 inch
Effective screw-in depth: min. 80 mm / 3 5/32 or
3.15 inch
Screw the metal tile set to the rafter with 2 wood
screws.
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XM-P
Assembly
www.aerocompact.com 16
Screw cover (optional)
Option 1: Screw cover plate
The screw cover plate is used when the screw
points are not covered by the existing roof tiles.
Hang the screw cover plate onto the rail
above the support bracket.
Option 2: Metal tile with screw cover
Certain types of metal tiles have a tab to cover
the screws.
Cover the screws by folding down the screw
cover.
Close roofing
Move adjacent tiles to the original position.
Ensure that the roof continues to be leak-proof.
In the case of a roof pitch which is < 20°, fill the
rear corners of the aluminum roof tile with sil-
icone or a suitable sealant to prevent water pen-
etration in the event of snow.
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XM-P
Assembly
www.aerocompact.com 17
Rail X40/X50
Attach the T-Bolt Assembly to the rail .
Attach the rail to the hook of the metal tile and fasten it with the nut .
Tighten the nuts to 15 Nm or 11 ft-lb.
Make sure that the rail rests on the hook of the
metal tile.
Installing the X40/X50 rail in a cross-mount (optional
- not available in the USA)
At each point where the rails cross, the rails are joined together with a cross connector.
Attach a cross connector to the top rails for each crossing point.
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XM-P
Assembly
www.aerocompact.com 18
Attach each of the cross connectors with the upper rail to the lower rail.
Make sure that the cross connector is fully clicked into place.
Tighten the Allen screw on each of the cross connectors to 15 Nm or 11 ft-lb.
Mounting the microinverter with a T-Bolt Assembly (MA-RA)
The microinverter can be installed on the rail below the module.
Attach the T-Bolt Assembly to the rail.
Hand-tighten the bolt .
Installing modules
Do not enter the modules under any circumstances.
Tip: When installing, wire the modules at the same time.
The cables can be attached to the module with the cable tie clip (CLP-M).
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XM-P
Assembly
www.aerocompact.com 19
Attach the end-clamps to the edge of the module field on the 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 mid-clamps .
Position second module .
Tighten the screws of the mid-clamps to 15 Nm or 11 ft lbs.
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XM-P
Assembly
www.aerocompact.com 20
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.
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