AXITEC AXIblackpremium User manual

„AXIblackpremium“
In-roof system
for roof-integrated photovoltaic systems
AXITEC GmbH, Otto-Lilienthal-Str. 5, 71034 Böblingen
[email protected] www.axitecsolar.com
Installation Manuel

Index
Inroof-System Seite 2 von 64
DE141113 Axitec GmbH, Otto-Lilienthal-Str. 5, 71034 Böblingen, Germany, [phone]
Index
1 General information on the installation instructions......................................................... 4
1.1 Revisions ................................................................................................................ 4
1.2 Validity ................................................................................................................... 5
1.3 Approval (DiBt)...................................................................................................... 5
1.4 Target group ........................................................................................................... 5
1.5 Exclusion clause ..................................................................................................... 5
1.6 Warnings, symbols, markups ................................................................................. 6
1.6.1 Warnings in this documentation............................................................... 6
1.6.2 Symbols and Awards................................................................................ 7
2 Safety Precautions .............................................................................................................. 8
2.1 Proper use ............................................................................................................... 8
2.2 Safety instructions .................................................................................................. 8
2.3 Personnel qualification ........................................................................................... 9
2.4 Changes and modifications..................................................................................... 9
2.5 Danger sources ....................................................................................................... 9
2.5.1 Electrical Installation................................................................................ 9
2.5.2 Work on the roof .................................................................................... 11
3 Work in relation to water protection .............................................................................. 12
3.1 Requirements during varying application area ..................................................... 12
3.2 Supplementary information rainproof / waterproof roofing................................ 13
3.3 Increased requirements ......................................................................................... 14
4 Description of the in-roof system..................................................................................... 15
4.1 Overview .............................................................................................................. 15
4.2 In-roof modules .................................................................................................... 16
4.3 Substructure.......................................................................................................... 17
4.4 Mounting bracket.................................................................................................. 17
4.5 Components for roof mounting / edge connection ............................................... 21
4.5.1 Edge connection profile.......................................................................... 21
4.5.2 Connection plates ................................................................................... 23
5 Assembly in-roof system................................................................................................... 29
5.1 Tools, equipment .................................................................................................. 29
5.2 Preparatory activities ............................................................................................ 30
5.2.1 Statics of the construction according toDIN 1055 /Euro code 1............ 30
5.2.2 General planning .................................................................................... 30
5.2.3 Special substructure at 5400Pa pressure ................................................ 34
5.3 Cable laying.......................................................................................................... 36

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5.4 In-roof assembly................................................................................................... 38
5.4.1 Photovoltaic modules assembled............................................................ 38
5.4.2 Roof connection ..................................................................................... 48
5.5 Potential compensation and lightning protection ................................................. 55
6 Connection to the inverter ............................................................................................... 58
7 Disassembly ....................................................................................................................... 59
8 Control ............................................................................................................................... 60
9 Disposal.............................................................................................................................. 61
10 Parts list in-roof system AC-xxxY/156-ZZ S IN ............................................................ 62
10.1 Accessories AXIblackpremium In-roof system AC-xxxM/156-60 S IN ............. 63
11 Notes................................................................................................................................... 64
11.1 Legend article description .................................................................................... 64
11.2 Laminate size........................................................................................................ 64

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1General information on the installation instructions
These installation instructions describe a fast and secure in-roof installation of
the photovoltaic system.
Read these installation instructions carefully before installation.
Installer:
After the installation, hand over the assembly instructions to the
respective operator of the solar system. Instruct the operator that this
instruction guide is part of the product and should be kept for the entire
service life of the system.
Operator:
Store this instruction guide for the entire service life of the system. For
information on the formal requirements of PV systems please contact
your system operator. It is important to consult the responsible local
authorities and the energy providers, before the installation of the PV
system, about the regulations and approval requirements. Only when
you take this request into account can you guarantee an economic
success. In your own interest, please obtain the necessary permits from
the authorities and the required contracts from the energy providers.
Observe the applicable documents.
We reserve the right to change the technical parameters and designs. In carrying out the installation,
assembly and maintenance work on the solar modules, the time of manufacture of the module
concerned, the data sheets and customer information apply.
1.1 Revisions
Date
Version
What is new?
21/02/2011
DE110221
Completely new product
10/03/2011
DE110310
Insert missing images+certificate 1200J
10/03/2011
DE110318
Corrections
23/05/2011
DE110523
Cylinder head screws corrected from 5 to
4.5
30/05/2011
DE110530
Correction Table 3-3 dim. Connection plates
20/09/2011
DE110920
Expansion with 60Z in-roof
16/12/2011
DE111216
Text correction, new bill of materials 60Z
01/07/2013
DE130701
Roof inclination/rain density, 54-cell no long-
er applies
13/11/2014
DE141113
AXIpower removed;Assembly reference 5400Pa
17/12/2014
EN141217
Englisch version include WEEE
Table 1-1: Revisions
The most recent version supersedes all previous revisions of the assembly in-
structions.

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1.2 Validity
This assembly instructions apply exclusive to the assembly of photovol-
taic modules "AXIblackpremium in-roof system" of the Axitec GmbH.
1.3 Approval (DiBt)
The "AXIblackpremium in-roof system" of the Axitec GmbH currently
enjoys no approval by the DiBt (German institute for building technolo-
gy).
1.4 Target group
These installation instructions are intended for installers of photovoltaic
systems and trained personnel that are particularly familiar with the
installation, operation and maintenance of photovoltaic systems.
1.5 Exclusion clause
These instructions apply only to the in-roof product of AXITEC GmbH.
AXITEC GmbH assumes no liability for damages that emerge in that
these instructions were not followed. Please note that the system install-
er accepts all responsibility for the wiring and dimensioning of the sys-
tem and the observance of all necessary safety regulations when laying
out and installing. These instructions do not establish any liability
against AXITEC GmbH. The AXITEC GmbH is liable only in the
framework of contractual agreements or in the context of accepted guar-
antees. It accepts no responsibility for the functionality and security of
the modules. Also refer to the instructions for the other system compo-
nents, which can belong to the entire PH system. Where appropriate, the
statics must be drawn up for the entire project. Should your questions
not be answered adequately in this manual, you should first of all con-
tact your system provider.
The Axitec GmbH reserves the right to alter, to amend or to delete this
documentation or parts thereof without previous announcement.
You can find further information on our homepage
www.axitecsolar.com

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1.6 Warnings, symbols, markups
1.6.1 Warnings in this documentation
In these assembly instructions, warnings are used in order to avoid inju-
ries or damage to property.
Read and observe these warnings always.
The warnings are indicated by the following symbols and signal words:
DANGER
Imminent danger.
Failure to comply can result in death or serious injury.
CAUTION
Possible threatening danger.
Failure to comply could result in death or serious injury.
ATTENTION
Dangerous situation.
Failure to comply could result in minor injuries.
ATTENTION
Critical situation.
Failure to comply can cause damage to property.

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1.6.2 Symbols and Awards
In these assembly instructions, symbols and mark-ups are used for an
easy and fast understanding.
Symbol
Description

Prerequisite that must be fulfilled before
you start an action.

Action with one step or with several
steps, the sequence of which is not
relevant.
1.
2.
3. ...
Action with several steps, the sequence
of which is relevant and therefore
predetermined.

–
First level list.
Second level list, also in handling
instructions.
(see chapter 1.6.2, S. 6)
Cross-reference to a place in these
assembly instructions
Table 1-2: Symbols and Mark-ups
NOTE
Important information to the understanding or for optimizing the
assembly processes.

2 Safety Precautions
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2Safety Precautions
2.1 Proper use
The photovoltaic system is provided solely for the production of solar
power. An assembly is carried out exclusively on roof structures in ac-
cordance with existing assembly instructions.
No artificially concentrated sunlight may be directed on the mod-
ules/facility!
For an analogous application, however other use, no guarantee can be
accepted. It is in general considered to be improper.
Application class
The solar modules are dimensioned for use in the application class A
(unlimited accessibly, dangerous voltage, system of hazardous power).
Modules that are dimensioned for this application may be used in
systems of over 50V direct current or larger 240W, to which a general
access with contact is to be assumed.
Modules, whose security was checked in accordance with this part of
the IEC 61730 and 61730-4 and that belong to this application class, are
considered to meet the requirements of Class II.
2.2 Safety instructions
The operator of the photovoltaic system is responsible for compliance
with all relevant laws and regulations.
Photovoltaic systems are only to be taken into use, operated and
maintained in accordance with the following directions and stand-
ard.
Assembly instructions
Warning and information signs on the photovoltaic module
Further applicable documents
System-specific regulations and requirements
Valid international, national and regional regulations, in particular
for the installation of electrical devices and systems to work with
DC and provisions of the responsible energy supply companies for
the parallel operation of solar power systems
Directions of the construction trade association
Accident prevention regulations

2 Safety Precautions
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2.3 Personnel qualification
The operator and installer accept responsibility that the installation,
maintenance, commissioning and disassembly are carried out by trained
and qualified personnel.
Ensure that the personnel have understood these installation
instructions to implement them.
Ensure that the personnel are acquainted with and can comply
with the relevant accident prevention and safety directions.
Ensure that the personnel use the appropriate protective clothing/
equipment.
2.4 Changes and modifications
Changes and modifications to the assembling system can damage the
photovoltaic module or impair functions.
Without exception and including all the activities described in
these installation instructions, no changes or modifications are
allowed to the mounting system.
2.5 Danger sources
The photovoltaic module is to be treated as a glass product.
Do not place on free lying/exposed edges.
Do not step on or expose to an improper burden.
2.5.1 Electrical Installation
Ensure that the electrical installation and commissioning are
carried out by a licensed electrician.
Make sure that even at low solar radiation, the entire open-circuit
voltage is available.
Also at low temperatures, the maximal allowable system tension
of the photovoltaic modules are not exceeded.
The electrical output of the solar modules is measured under
standard test conditions (STC): 1kW / m 2exposure at module
level with a spectrum of AM 1.5 and a cell temperature of 25 0
C.
A solar panel can produce more current and voltage than
specified under STC conditions.
For determining the voltage rated values of the components,
power rated values of conductors, sizes of the fuses and
dimensioning of controls to be connected to the output of the PV

2 Safety Precautions
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EN141217 Axitec GmbH, Otto-Lilienthal-Str. 5, 71034 Böblingen, Germany, [phone]
Bemessung von Steuerungen, die an den Ausgang von PV-
modules, the Isc and Uoc values indicated on the module need to
be multiplied by a factor of 1.25.
Solar modules can be connected in series to provide the desired
system voltage. In this case, the max. system voltage of the solar
modules are never to be exceeded.
Solar modules can be connected in parallel to achieve the desired
voltage. If more than 2 modules (strings) are connected in
parallel, then each module (string) should be provided with a
fuse (16A) to protect against high currents in the event of an
error. The type of fuse must set in accordance with local
regulations.
Light arcs to direct current-carrying conductors!
Fatal injury through simultaneous contact of both poles.
Do not disconnect cable under current.
Connect or insulate bare cable ends.
Higher tension than protective low voltage!
Injury to people by adding of the voltage in series circuit.
Take appropriate safety and protective precaution.
Moisture in the electrical installation!
Injury to people, damage to the facility.
Work on the system to be performed only on dry surfaces.
When assembling make sure that photovoltaic modules, cables,
etc. are dry.
Arcs
Voltage
Moisture

2 Safety Precautions
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2.5.2 Work on the roof
NOTE
A scaffolding with capture arrangement is prescribed from a height of 3
m (eaves)
When fitting a scaffold is not possible or the roof is very steep:
Creating a safety harness and fasten onto a viable component.
Use suitable fall safeguards when working on the roof.
Provide appropriate shelving space for tools and materials.
Set up safeguards to protect against falling objects.
Observe all relevant regulations for working on the roof.

3 Work in relation to water protection
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3Work in relation to water protection
The lower roof has the task to divert appearing condensate or appearing water in adverse weather
conditions through the brick-like construction and to prevent therewith damage to the building.
The determination of the parameters are based on:
- Rain tests at the CSTB (centre technique et scientifique you bâtiment, France)
- Rain tests according to PREN15601, TU Berlin, Germany
- Specifications of the ZVDH (central association of the German roof-builders association)
- Specification of the SIA (Swiss Society of Engineers and Architects)
3.1 Requirements during varying application area
For the Axitec in-roof/roof-integrated module the following applications with regard to water-tight
protection during work has been determined:
Roof inclination
Comment
15o
Lower limit for the use of the Axitec in-roof
module
15o - 22o
Watertight sub-roof required
>22o
Rainproof sub-roof required
< 32o
The water drainage installations of the sub-roof
must lead to the gutter
Sanitation
>32o
It can be constructed on the sub-roof
<32o
The existing sub-roof needs to be replaced with a
"rainproof roof" if necessary.

3 Work in relation to water protection
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Raintest prEN 15601 at the TU Berlin CSTB Raintest Jules Verne in Nantes
3.2 Supplementary information rainproof / waterproof roofing
Rainproof sub-roof
Characteristic of a rainproof sub-roof is the waterproof design/execution of the surface as well as the
seams and abutting joints. With a rainproof sub-roof the counter batten/lathing is not bound into the
rainproof sub-roof. Penetrations, built-in parts and connections are to be carried out in such a way that
they are rainproof. The fastening of the sheets takes place in the upper third of the height overlap. The
penetrating force of drifting snow and rain through the ventilation openings are not to be avoided in
ventilated roof construction systems.
Watertight sub-roof
Characteristic of a watertight sub-roof is the waterproof design/execution of the surface as well as the
seams and abutting joints. In watertight sub-roofs, the counter batten/lathing is not bound into the
rainproof design/execution. Penetrations, built-in parts and connections are to be carried out in such a
way that they are watertight. The fastening of the sheets takes place in the upper third of the height
overlap. The sealing must be guided over the counter battens so that with the fastening of the support
slats through the restraining lath/counter batten the sealing penetrates only at the highest pointing area.
The larger the expected load of the sub-roof is, the higher should the restraining lath be. Wood should
not be wrapped on all sides by diffusion-tight sheets because penetrated or trapped moisture can not dry
out with certainty. Alternatively, moisture resistant materials can be used for the counter battens.

3 Work in relation to water protection
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Rainproof sub-roof watertight sub-roof
3.3 Increased requirements
Special climatic conditions, exposed position of the building, constructional features and large distances
between ridge and eaves (> 8 m) require additional rain blocking measures, such as the use of a counter
slat out of moisture resistant materials or increasing the counter slat.

4 Description of the in-roof system
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EN141217 Axitec GmbH, Otto-Lilienthal-Str. 5, 71034 Böblingen, Germany, [phone]
4Description of the in-roof system
4.1 Overview
PIC 4-1: Exploded view of the photovoltaic system
1
Eaves skirt
and the sealant-jointing tape
8
Battens for tiles
2
Sheet grips
9
Extension sheet side top left
3
Mounting bracket
10
Extension sheet first corner left
4
Cylinder head screws (4.5 x
35 )
11
SOLRIF framed photovoltaic module
5
Extension sheet metal side
left
12
Abutting/shock cover
6
Edge extension profile left
13
Extension sheet first middle
7
Mounting board 100 x 30
Battens for tiles

4 Description of the in-roof system
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4.2 In-roof modules
The AXIblackpremium in-roof modules consist of standard modules,
mounted with the special SOLRIF®profile frames and are waterproof
bonded.
The profile frames of adjacent modules interlock and form the water
diverting layer of the roof. To en longitudinal sides, the tightness be-
tween the overlapping module edges is guaranteed with an additional
rubber lip.
With roof inclinations > 15° is therewith the rain-proof integration into
the roof covering in accordance with ZVDH possible
The modules have following dimensions:
Dimensions
AC-xxY/156-60 S
IN
Framed module L x W (mm)
1684 x 1017
Laying dimension L x B (mm)
1666 x 985
Thickness of frame without JB
(mm)
17
Mass (kg)
19,5
Table 4-1: Dimensions of the photovoltaic modules

4 Description of the in-roof system
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PIC 4-2: Framed photovoltaic modules (front and back)
1
Photovoltaic module
3
Junktion box
2
SOLRIF®-XL profile
frames
4
Connection cable with
connector
4.3 Substructure
The sub-structure is the base for the in-roof installation of the modules.
It consists of slats and mounting boards that are attached directly on the
roof. It is created using the grid plan (see chapter Fehler! Verweisquel-
le konnte nicht gefunden werden. ).
4.4 Mounting bracket
The modules framed with SOLRIF® XL-profile frames are anchored
with mounting brackets in the substructure. For this purpose, three dif-
ferent types of clamps can be used:
Nr.
Bezeichnung
Art. Nr.
1
Mounting bracket profile, burnished
AD10576
2
Mounting bracket glass or module
AD10575
3
Mounting bracket long at the top for
flat sheet connections
AD10428
Table 4-1: Overview of mounting bracket types

4 Description of the in-roof system
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With the mounting bracket "profile" in each case are two modules an-
chored to the frame parts in the overlapping area. This bracket is usually
required.
Width of bracket:
16.5 mm
Material thickness:
1,5 + 2,0 mm
Material:
Spring steel stainless type 1.4310
Screw type:
Cylinder head screws 4.5 x 35 VA (2 piece)
PIC 4-3: Mounting bracket "profile"
Mounting bracket "profile"

4 Description of the in-roof system
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EN141217 Axitec GmbH, Otto-Lilienthal-Str. 5, 71034 Böblingen, Germany, [phone]
To meet the static requirements, a module can with the mounting
bracket glass be anchored additionally in the glass sector. The
required number of mounting brackets for each module edge can
be obtained from the grid plan in accordance with the static re-
quirements (see chapter Fehler! Verweisquelle konnte nicht
gefunden werden.). For the protection of the glass, the bracket at
the front is coated with a weather-resistant plastic..
NOTE
Mounting bracket glass is planned as an additional measure and subject
to module size and static requirements.
When using the module > 2400 Pa until max 5400Pa at least least 3
mounting bracket glass are to be used!
Width of bracket:
16.5 mm
Material thickness:
1,5 + 2,0 mm
Material:
Spring steel stainless type 1.4310
Screw type:
Cylinder head 4.5 x 35 VA (2 piece)
PIC 4-4: Mounting bracket "glass"
Mounting bracket "glass"

4 Description of the in-roof system
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With the mounting bracket long for sheet metal connections at the top,
the top row of modules is anchored from above. This mounting bracket
is required only when no connecting plates by the Ernst Schweizer AG
and flat sheets are used.
If from above no connecting plates should be inserted, then the mount-
ing bracket frames are used. The required number of mounting brackets
can be obtained from the grid plan in accordance with the static re-
quirements (see chapter Fehler! Verweisquelle konnte nicht gefunden
werden.).
Width of bracket:
16.5 mm
Material thickness:
2.0 mm
Material:
Spring steel stainless type 1.4310
Screw type:
Wood and/or cylinder head 4.5 x 35 VA (2
piece)
PIC 4-5: Mounting bracket long at the top for sheet metal
connections
Mounting bracket "top"