Centrosolar CENPAC Series User manual

www.centrosolar.comwww.centrosolar.co.uk
CENPAC
Mounting instructions
CENPAC 3.x
CENPAC 5.x

Content
1 Implementation 5
1.1 Notes on these instructions 5
1.2 Description of the mounting system 5
2 CENPAC components 6
3 Installation 8
3.1 Constructions 8
3.2 Preliminary planning for mounting the installation 9
3.3 Rules relating to individual rafter conguration 9
4 Mounting process 10
5 Commissioning the system 20
6 Guarantees and warranties 21
7 Disclaimer 21
3

4

5
1 Implementation
Dear customers,
With the CENPAC product from Centrosolar AG, you have
acquired a strong, high-quality product.
This reliable complete system combines the benets of
a customized PV installation with the possibilities of an
immediately available standard solution and guarantees
optimal returns under nearly all conditions. It is also un-
complicated and quick to mount.
1.1 Notes on these instructions
If you have any questions on the installation or any com-
ponents of the installation, please contact your local Cen-
trosolar ofce.
Repairing and operating a PV installation require solid
expert knowledge. This is why all work on the installation
should only be carried out by correspondingly qualied
and authorized specialist personnel. Read these mount-
ing instructions carefully and attentively before installing
and commissioning the system. Keep the instructions in
an easily accessible place. The instructions are part of the
product, they only apply to the complete CENPAC sys-
tems of Centrosolar AG. Pay special attention to the notes
on safe use. Centrosolar will not accept liability for dam-
age arising due to failure to observe these instructions.
Please observe:
Ensure that the correct safety instructions are followed for
mounting and operation. Pay attention to the relevant gen-
eral preliminary remarks from Centrosolar AG, available at
www.centrosolar.com.
Failure to observe the requirements in these mounting in-
structions can lead to the exclusion of all guarantees, war-
ranties and product liability.
The following details, notes and recommendations for
action may not be complete and should be constantly
checked to see whether they are complete and up-to-date.
1.2 Description of the mounting system
The bearing capacity of the roof in connection with the as-
sembly of a Centrosolar photovoltaic installation and the
arrangement of the fastening points are to be shown in a
structural analysis for which the building owner is respon-
sible. There is no liability on the part of Centrosolar AG for
the structural suitability of the mounting construction.
The MS Constocc Excellent mounting system basically
consists of module support proles and 2-C groove pro-
les. Please see the summary of the mounting materials
(chapter 2) for an exact overview of the necessary com-
ponents. Assembly takes place in a cross-cross arrange-
ment. This is mechanically the most stable and safe in-
stallation of photovoltaic modules. The 2-C groove proles
are constructed vertically. The module support proles are
inlaid proles fastened horizontally onto the 2-C groove
proles.
All connecting elements and system parts are manufac-
tured from aluminium or stainless steel. The system pro-
les are delivered anodized in black.
For the suitable rafter conguration of your complete
CENPAC system, please see the rafter conguration
plans in the document folder.
In case of different rafter distances, congure your rafters
according to chapter 3.3 or contact your local Centrosolar
ofce.
Proper use
Check the delivery is complete by way of packing list and
parts list before commencing the mounting. Electrical in-
stallation work that may exceed the range of the safety
extra low voltage may only be carried out by electrotechni-
cal specialists.
The mounting system MS Constocc Excellent was de-
signed solely for holding the PV modules. Any other use
is regarded as improper. Proper use also includes adher-
ing to the mounting instructions Centrosolar AG cannot be
held liable for damage resulting from failure to observe the
mounting instructions, in particular, the safety instructions
or improper use of the product.

6
2 CENPAC components
Parts list for the various individual constructions
The CENPAC contains all the components needed for installing the respective constructions. Individual components
of the delivery will remain unused depending on which construction is chosen.
Article No. Article
Number in parts
CENPAC 3.X (2 series of 8 modules) CENPAC 3.X (4 series of 4 modules) CENPAC 5.X (3 series of 8 modules) CENPAC 5.X (2 series of 12 modules)
1X******* PV module S ****54 Excellent 16 16 24 24
3E0000005 Module support prole 1,981 mm, black 12 10 16 18
3E0000006 2-C groove prole 1,681 mm, black 10 710 15
3E0000007 2-C groove prole 1,533 mm, black 10 15 20 15
3E0000000 Rail connectors (complete) 19 20 32 30
3E0000001 Set of hammer head bolts 40 38 52 60
3H1100001 Roof hook A2 40 38 52 60
3Z0000088 Wooden screw 80 76 104 120
3E190000002 Clamping jaw, complete 30 29 40 45
3E1300001 Protective cover, large 6 10 8 6
3E1300002 Protective cover, small 20 14 20 30
3V1900022 Distance disc module SM5410TI/S 1,478 mm 2222

7
Article No. Article
Number in parts
CENPAC 3.X (2 series of 8 modules) CENPAC 3.X (4 series of 4 modules) CENPAC 5.X (3 series of 8 modules) CENPAC 5.X (2 series of 12 modules)
200003300A Powerstocc 3.6 Excellent/Powerstocc 5.5 Excellent 1111
417522001 Adapter set H+S 1111
417522007 Adapter set LC4 1111
411530600 Draka solar cable 1 x 6 mm², 100 m 1111
3E2000001 Cable retainer EDGECLIP 5 38 38 46 46

8
3 Installation
3.1 Constructions
CENPAC 3.x
2 x 8 modules 4 x 4 modules
Overall dimensions: Generator eld
dimensions:
Overall dimensions: Generator eld
dimensions:
9732 x 4,214 mm
(width x height)
7,932 x 3,214 mm
(width x height)
5766 x 7,280 mm
(width x height)
3966 x 6,280 mm
(width x height)
CENPAC 5.x
2 x 12 modules 3 x 8 modules
Overall dimensions: Generator eld
dimensions:
Overall dimensions: Generator eld
dimensions:
13698 x 4,214 mm
(width x height)
11898 x 3,214 mm
(width x height)
9732 x 5,747 mm
(width x height)
7,932 x 4,747 mm
(width x height)

9
3.2 Preliminary planning for mounting the
installation
Some preliminary planning is necessary before starting to
mounting the system.
Selecting the suitable constructions and rafter con-
guration
Calculate the available connected roof surface and rafter
distance for the installation. Select the suitable CENPAC
construction based on the roof dimensions and the nec-
essary overall dimensions of the CENPAC constructions
(see chapter 3.1). A choice must nally be made from the
rafter conguration plans (see installation instructions)
that corresponds to the distance of your rafters. Proceed
in accordance with chapter 3.3 if there is a difference in
rafter distances.
Positioning the PV installation
Position your CENPAC bearing in mind the Generator eld
dimensionsas close as possible to the centre of the roof.
Bear in mind that a margin of at least 500 mm must be
observed at all times. The actual mounting can now begin
(chapter 4).
If the distance relating to your rafters differs from that in
the drawings and you cannot carry out your rafter con-
guration yourself in accordance with chapter 3.3, please
contact your local Centrosolar ofce.
3.3 Rules relating to individual rafter
conguration
 Rafter distances of 600 – 800 mm are permitted
 Max. range that can be straddled with the module
supports: 1,500 mm
 Permissible cantilever: 50 – 400 mm
 Carry out the rafter conguration on the sides of the
generator eld on the two outer rafters
 Twice the number of roof hooks on the 2-C groove
proles in the border of the generator eld (to the
ridge, the eaves and the verges)
 Module support proles must be xed on at least two
2-C groove proles
Terminology
Overall dimensions
The overall dimensions state the free roof space that must
be available for the installation of the complete CENPAC
system in order to enable the CENPAC to be installed on
your roof safely. The overall dimensions also included the
necessary margins and an additional rafter adjustment
area as well as the generator eld dimensions.
Generator eld dimensions
The generator eld dimensions are clear from the genera-
tor surface of all PV modules of the complete CENPAC
system.
Margins
The margins stated here are safety-relevant distances of
500 mm to which your PV installation must at least adhere
to the eaves, the ridge and the verge of the roof.
Cantilever
The cantilever is the overhang of the module support pro-
les over the external 2-C groove prole in the generator
eld. The permissible cantilever may be between 50 and
400 mm. During the preliminary mounting planning, the
cantilever is dened by the overhang of the module sup-
port proles over the centre of the outer rafters.
Rafter conguration plans
These are CAD plans for the rafter conguration on the
roof. These plans for the rafter distances of 600, 650, 700,
750 and 800 mm for the individual constructions of the
complete CENPAC system are enclosed. They explain
the optimal conguration of the rafters by way of the en-
closed roof hooks, the positioning of the mounting proles
as well as the cantilever to be applied.

10
4 Mounting process
1 - Removing roof tiles
Select the rst rafter from the left for mounting
the rst roof hook using the rafter conguration
plan and taking account of the margins and the
maximum cantilevers to be observed.
Remove the roof tiles above the rafter to be al-
located.
It may be necessary to remove several roof tiles
from the system in order to carry out the mount-
ing depending on the individual rafter distances.
Note: Each rafter must be allocated when using
a CENPAC including the wind and snow exten-
sion package. Please observe the assembly in-
structions of the extension package.
2a - Positioning of the roof hook
The roof hooks can now be mounted onto the
cleared rafters. When positioning the base of
the roof hook, ensure that it lies at on the rafter.
Please ensure: The roof support shaft (a) may
not lie directly on the tile.
2b - Positioning of the roof hook
The roof hooks are tailored to battens 30 x 50
mm. A batten 40 x 60 mm requires the installa-
tion of separators, e.g., of 10 mm thick impreg-
nated wood. (b)
a
b
a

11
3 - Mounting roof hooks
The roof hook is to be positioned in such a way
that at least two holes run on the base of the
roof hook around the centre to the rafter.
The roof hook is fastened to the rafter using the
wooden screws supplied. The screws are tight-
ened towards the stop.
Please maintain the boreholes at a distance of
25 mm to the edges of the rafter.
4 - Modication of the roof tiles
After the hook has been mounted, the lower
parts of the tiles, where the support shaft comes
from the roof are to be removed using a right an-
gle grinder. The roof panel must then be closed
except for some openings that ensure stability.
Carrying out these steps carefully will help to
prevent possible subsequent damage.
5 - Aligning the roof hooks
When aligning and fastening the roof hooks to
the rafters, ensure that the roof hooks are verti-
cal to one another.

12
6 - Positioning the 2-C groove prole
The next step involves fastening the 2-C groove
proles to the roof hook.
The mounting of the 2-C groove proles takes
place from below (the eaves) towards the ridge.
The longer 1,681 mm 2-C groove proles are
mounted in the lowest row. The mounting of the
shorter 2-C groove prole with 1,533 mm will
also take place.
7 - Mounting the 2-C groove prole
The mounting of the 2-C groove proles com-
mences from the outer margins. The alignment
(horizontal) should be carried out by using a
plumb line.
The outer 2-C groove proles will initially be
mounted hand-tight in the generator eld (left
and right) and connected via a plumb line. The
other proles are then mounted using the plumb
line. The 2-C groove proles can then be fas-
tened.
8 - Fastening the 2-C groove prole
In order to fasten the 2-C groove proles, guide
the hammer head screw, pre-mounted with nut,
spring washer and washer through the slot on
the the of the roof hook.
Now turn the hammer head screw 90° and
thread this into the side slot of the 2-C groove
prole.

13
9 - Adjusting the 2-C groove prole
After the hammer head screw has been inserted
into the 2-C groove prole, it will be rotated 90°
once more until the hammer head plate engag-
es its prole.
For more efcient adjustment of the 2-C groove
proles, you should initially only tighten the
hammer head screws hand-tight. Via the grating
on the 2-C groove proles, a maximum height
compensation of 40 mm may take place.
The torque of the M10 nuts per hammer head
screw is 50 Nm.
10 - Connecting the 2-C groove prole
Connecting links are available for connecting
the 2-C groove proles.
The connecting link can already be fastened
onto one side of the 2-C groove prole.
Join both 2-C groove proles to one another.
Now place the connecting link from above into
the centre of the prole and turn the hammer
head screws clockwise at 90°. Now fasten the
nuts tightly.
Please ensure: The slot on the screw must be
at a 90° angle to the direction of the rails.
11 - Mounting the protective covers
Both sides of the prole openings should then
be closed. Insert the 2-C groove protective cov-
er into the hollow section of the 2-C groove pro-
le. Light taps with a rubber hammer will nally
set the protective cover in the prole.
It is recommended to provide the proles with
the protective covers whilst still on the oor.
ca. 250-400 mm

14
12 - Positioning the module support
The module support proles are mounted from
below (the eaves) starting towards the ridge.
The overhang of the module support proles
may not exceed the outer 2-C groove proles
by over 400 mm.
The connections of the 2-C groove proles are
established with the module support proles via
clamping jaws . The prole protective covers,
that were mounted in the 2-C groove prole in
the previous stage are for positioning the mod-
ule support proles.
13a - Positioning the clamping jaw
Guide the clamping jaw from above into the
groove of the 2-C groove prole . The hammer
head screw is xed in the 2-C groove prole
with a rotation of 90° .
13b - Mounting the clamping jaw
Before fastening the hexagon bolt, position the
clamping jaw so as to maintain a distance of ca.
2 mm between the angle stub of the protective
cover and the rear end of the xed clamp.
The front part of the xed clamps is on the
toothed part of the module support up to the
stop.
The nuts on the hammer head screws M10
(clamping jaws) should be tightened with a
torque of 50 Nm.
ca. 2 mm

15
14 - Adjusting the cantilever
The one-sided overhang of the module support
over the outer 2-C groove proles (cantilever) is
permitted up to 400 mm.
The fastening of the further clamping jaws takes
place analogous to the mounting of the previous
clamping jaws.
15a - Aligning module supports
There are two distance gauges included in the
delivery of your mounting system that serve
as mounting aids for the other module support
proles.
15b - Use of distance gauges
When using the distance gauge, the end faces
of the longer angle stub of the proles should
lie on the upper reinforced edges of the module
support proles. The short axle stub of the pro-
les lies on the upper lip of the upper module
support prole.
In the lower module support prole, the distance
gauge also lies with the shorter axle stub on the
upper lip of the module support prole
The module supports below may not be walked
upon when aligning and installing the module
supports.
max. 400 mm

16
16 - Module support connection
The mounting of all further module supports
take place in the same way.
The horizontal connection of the module sup-
port proles takes place via connecting links.
The connecting link is to be inserted half way
into the mounting prole and screwed in.
Differences in height in the roof space should
be compensated by adjusting the 2-C groove
proles so that undesired tension in the module
supports is to be kept as low as possible.
17 - Mounting module supports
The mounting of all further module supports
take place in the same way.
Note: When using a CENPAC including the wind
and snow extension package, snow load rails
should also be installed according the mounting
instructions for the extension package.
18 - Mounting the protective covers
Insert the module support protective cover into
the prole ends of the module support follow-
ing the mounting of all module support proles.
Light taps with a rubber hammer will nally set
the protective cover in the prole.
It is recommended to provide the proles with
the protective covers whilst still on the oor.

17
19 - Laying cables
The returning string lead should be laid near
the module support before inserting the PV
modules into the mounting system. The fasten-
ing of the string lead can take place using the
EDGECLIPs 5 on the proles. All modules for
the CENPAC are connected in a single string
in series.
The EDGECLIP 5 can be tted by simply "click-
ing" into the required places of the module sup-
port prole.
20a - Mounting the PV module
The modules are mounted from above (ridge)
in series towards the eaves. In the rst step of
mounting the module, the respective module is
placed on the lower tongue of the upper module
support and into the guide slot up to the stop.
20b - Mounting the PV module
In the second step, the module is lowered to the
tongue of the lower module support prole .

18
20c - Mounting the PV module
Pulling in the module into the prole slot of the
low module support prole represents the com-
pletion.
21 - Laying the cables for the PV module
Place the next module as described before in a
distance of ca. 400 mm for the rst module into
the module supports . The free space between
the modules can now be used for connecting
the solar leads (connection leads with plug and
bushing). For this, connect the plus and minus
lead of the neighbouring modules.
For information on laying the cables of your PV
installation, please see the respective cabling
plan of the document "Installation instructions".
22 - Module mounting
The solar lead can now be fastened using
EDGECLIP 5 and cable connectors. Then push
the modules towards one another and continue
with the other modules in the sequence de-
scribed.
max. 400 mm

19
23 - Mounting the protective covers
The module support proles are tted with pro-
tective covers on the side of the end of the gen-
erator.
These will be tted by tapping lightly with a rub-
ber hammer in the prole.
Mounting the remaining components of the complete CENPAC system:
For information on the installation and cabling and registering your CENPAC, please refer to the document "Instal-
lation information" and the documentation enclosed with the individual components.
You can contact your local Centrosolar ofce at any time should any questions on the installation arise.

20
5 Commissioning the system
Commissioning the photovoltaic system is part of the ex-
pert and proper construction and installation. This may
only be carried out following a careful visual examination
and a professional electrical inspection. A record should
also be prepared on commissioning the system.
Bear in mind the following checklist when commissioning
the system:
Visual examination
 Bolting the components on the roof construction
 Cable installation on modules, generator connection
boxes DC disconnection points, inverters
 Potential equalization (if available)
Electrical examination
 String open-circuit voltages
 String short-circuit currents (use load break switch)
 PV generator open-circuit voltage
 Voltage drop in fuses (with PV installations with string
fuses)
 Insulation resistance of the PV generator
 Insulation resistance of the direct current main lines
 Insulation resistance of the alternating current line
 Loop resistance of the alternating current circuit
Record
 Declaration by the installation operator
 Location of the installation
 Technical details on the photovoltaic installation
 Results of the visual examination
 Results of the electrical examination
 Module layout plan
 Module interconnection plan
 Ready signal by signature of the tter
Please observe
This list is only for your information. It is not necessarily
complete.
Please also observe DIN EN 62446 (VDE 0126-23): Net-
work coupled PV systems - minimum demands of system
documentation, commissioning inspection and repeat
tests,