ESDEC CLICKFIT BASIC User manual

EN
MOUNTING SYSTEM FOR STEEL ROOFS
MANUAL
© ESDEC BV 2014
Rev. 20.01.14
mounting system for steel roofs
for solar panels in portrait setup

Rev. 20.01.14 ASSEMBLY MANUAL FOR STEEL ROOFS
CONTENTS
pag
1. Introduction 1
2. General installation conditions 1
3. Product description 3
4. Components overview 3
4.1 Exploded-view 3
4.2 Component list 4
5. Mounting preparation 5
5.1 Control of tools and accessories 5
5.2 Determining and measuring position solar panels 6
5.3 Cleaning the roof 6
6. Installation 7
6.1 Pre-mounting of suspension bushes on solar panels 7
6.2 Pre-mounting of connection strips 7
6.3 Securing of mounting brackets 8
6.4 Securing of mounting rail 9
6.5 Suspending solar panel onto mounting rail 10
6.6 Mounting 1st solar panel on the rails 11
6.7 Mounting of other solar panels on the rails 12
6.8 Final mounting /multiple rows underneath one another 13
7. Appendix 14
THIS ASSEMBLY MANUAL NEEDS TO BE PROPERLY SAVED FOR FUTURE USE! For the duration and conditions
of the warranty we advise you to contact your supplier. In addition, we refer to our General Conditions which are avail-
able upon request.
The manufacturer explicitly rejects all liability for damage or injury resulting from not strictly adhering to this assembly
manual and failure to observe the usual care during transportation, assembly, and use of the ClickFit assembly
system.
It is possible that the product differs slightly from the description in this manual, as a result of our continuous efforts
towards improvement. For this reason the instructions need to be seen as only a guideline for the installation of the
product in this manual.
This manual has been prepared with the utmost care, but the manufacturer cannot accept responsibility for possible
errors in this manual or any possible consequences thereof. Furthermore, all rights are reserved and nothing in this
manual may be reproduced in any possible way.

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Rev. 20.01.14 ASSEMBLY MANUAL FOR STEEL ROOFS
1. Introduction
This manual describes the installation of the ClickFit mounting system for steel roofs (for solar panels in portrait placement).
Read the manual carefully in order to be aware of its full content. Follow the instructions in the manual carefully. Always
carry out the instructions in the right order. Store this manual in a dry and safe place. If the manual gets lost, there is the
possibility of requesting a new copy at Esdec B.V.
2. General installation conditions
General
Noncompliance with the instructions in this document can lead to the expiration of all warranty and product liability claims.
The data, remarks, and advice in this document are binding and have to be checked for completeness and validity. Esdec
BV reserves the right to adapt this document without further notice.
Stability and condition of the roof
The roof must be in good condition and sufciently strong to carry the weight of the solar panels, including additional
materials, wind and snow loads according to MCS012 and BRE guidelines. Check the stability of the roof and adjust the
roof/structure where necessary, engage a constructor when in doubt. Note that the load reserve of the roof is not exceeded
locally or as a whole.
Health & Safety
• The assembly of the ClickFit mounting system always needs to be carried out by qualied technical personnel (at least
two skilled persons).
• Adding or leaving out parts can have a negative effect on functioning and is strongly discouraged!
• For placement of the solar panels the roof needs to be clean, dry, smooth, and free of mould, etc.
• Avoid assembly when there is hard wind or a wet slippery roof.
• On a sloping surface, always use fall protection and if necessary, with safety nets and edge protection.
• Attention: Never stand in the gutter.
• Wear shoes with an enforced nose and sturdy anti-slip soles.
• Always wear the right protective clothing when carrying out the assembly.
• Always use a carrying installation or lifting help when moving the material (solar panels, etc.).
• Always place ladders on a sturdy and stable surface.
• Always place the ladder under an angle of approximately 75º and let it protrude around 1 metre over the roof edge.
• If possible, secure the ladder on the upper side with rope or lashing.
• If Safe working at heights training should be adhered to.
• Construction (Design and Management) Regulations 2007 (CDM)* and general construction site training must be
followed.
• Anyone handling photovoltaic (PV) modules should be trained in correct manual handling practice.
• All appropriate Health and Safety regulations should be followed correctly.
Application range ClickFit
• Maximium allowable wind load to be determined by ClickFit calculator with a maximum of 2500 N/m2.
• Solar modules: Framed solar modules from all makes and models with a frame height between 29 and 52mm with a
maximum size of 2 x 1m (2m2) per solar module.
• Roof height (3 - 9 m). If your roof is higher, you must contact your supplier.
• Type of roof covering: Steel plate
• Roof slope: between 10 – 60 degrees (35 degrees is optimal).
Weather thightness
• Install all components as specied within this guide to ensure weather tightness of the roof.

Edge zone
The distance from the solar panels to the side of the roof, gutter and ridge should be determined according DTI GUIDE 2nd
addition. No solar panels should be placed in this zone as a whole or in part.
Dimensions
All sizes and dimensions are in centimetres, unless stated otherwise.
Standards, prescriptions and regulations
Upon installation of the mounting system, it is important to follow the installation manual and the associated standards to
prevent accidents. Keep the following standards, prescriptions and regulations particularly in mind:
• Buildings Decree Construction
• PPE Personal Protective Equipment
• KEMA Inspection of Electrico-technical Materials
• DIN 1055 Design overloads for buildings
• DIN 18299 General rules for all construction sectors.
• DIN 18451 Scaffolding
• BS7672
• MCS and MIS standards
• Building and planning regulations
• Health and safety
• DTI Guide 2nd addition
Planning and building works notification
Make sure to notify the applicable bodies in regards to planning and building works.
Support
For technical or customer support please contact:
Esdec BV
Paderbornstraat 4
7418BP Deventer
The Netherlands
Tel: [phone]
email: [email protected], info@click-t.com
or contact your local dealer/distributor.
Removal and demounting
Remove the product according to local laws and regulations.
Guarantee and maintenance
Guarantee and maintenance according to general terms and conditions and guarantee terms of Esdec BV. These can be
found on the website www.esdec.nl or www.click-t.com
Liability
The manufacturer accepts no liability for damage or injury caused by not (strictly) adhering to the safety prescription and
instructions contained in this manual, or by carelessness during installation of the product specied in this document and
the eventual related accessories.
• printing errors may occur
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3. Product description
The ClickFit mounting system consists of mounting brackets, mounting rails and the necessary mounting materials to mount
the solar panels in portrait placement on the roof. The ClickFit mounting system for steel plate can be used for all steel
roofs, among others the common steel corrugated roof and trapezium roof plates. (The plate steel thickness needs to be at
least 0.4 mm.)
Roof attachment
The mounting brackets are xed to the steel plate with special screws. Because the mounting brackets are not attached to
the roof rafters or purlins, the solar panels can be placed anywhere. Height differences in the roof can easily be solved with
a special click-up cube or heightening cube (optional). Self-sticking EPDM sealing tape is used for waterproong.
Attaching the mounting rail
The mounting rail is attached to the mounting bracket with a snap connection. No further materials or tools are needed for
this.
Attaching the panel
The handy mounting help contributes to a fast and safe assembly and has a double function as an anti-slip security for the
solar panels. The solar panels are secured with universal modular clamping plates, end clamps, and mounting screws. The
mounting screws are screwed directly into the mounting rails, in which a special screw thread has been made.
4. Components overview
4.1 Exploded-view
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432
1
8
5
6
7
11
10
14
13
12
9

1. Solar panel
2. Stainless steel hexagonal
bolt M6 x 20
Article no. 100-0620
3. Nylon Suspension bush
Article no. 100-9001
4. Stainless steel hexagonal nut M6
Article no. 100-0600
5. Mounting rail
Article no. 100-1001
6. Connection strip pro
Article no. 100-3040
10. End clamp
End clamp CFA Article no.
100-3003
End clamp CFB
Article no. 100-3004
For type see appendix Ch. 7
11. Mounting screw 6.5 x
Article no. 100-65
For type see appendix Ch. 7
12. Modular clamp plate
Article no.: 100-3020
8. Mounting bracket
Article no. 100-2060
13. End cap Black (optional)
Article no. 100-3030
14. Colour cap Black (optional)
Article no. 100-6500
4.2 Component list
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10A. End clamp Black (optional)
End clamp CFA Black
Article no. 100-3950
End clamp CFB Black
Article no. 100-3951
For type see appendix
Ch. 7
12A. Modular clamp plate Black
(Optional)
Article no. 100-3952
6A. Mounting screw 6.5 x 19
Article no. 100-6519
9. Self-sticking EPDM sealing tape 30 mm
Article no. 100-0005
7. Self-tapping plate screw 6.0 x 25
Article no. 100-3010
8A. Heightening cube 15 mm (optional)
Article no. 100-3065

1
2
3
4
5
6
5. Mounting preparation
5.1 Control of tools and accessories
and/
or
S10 S8 / S10
Underneath is a list of the required tools/accessories:
Tape measure Brush Ratchet with hexagonal top Battery screwdriver
Marker / chalk Knife
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Scaffold or stable,
safe ladder

5.2 Determining and measuring position solar panels
When determining the position of the solar panels on the steel roof, it is important to take into account the angle under
which the sunlight falls on the roof during the whole day and during the whole year. Place the panels on an area which has
no shadow whatsoever. Shadows created by chimneys, dormers, trees and nearby buildings have a negative effect on the
yield of the panels.
Measuring and marking
For placing the solar panel (in the portrait placement) you need approximately 160x80 cm or 160x100 cm or 200x100 cm
per panel (depending on the type of solar panel).
Make sure to keep out of the edge zone of the roof. Please take in mind the edge zones as described in DTI GUIDE 2nd
addition with a minimum of 30cm.
Mark the contours of the panel eld on the steel plates with chalk or a marker. Draw the lines where the mounting rails will
be positioned (on ¼ of the panel’s upper edge and the panel’s under edge). Then mark where the mounting brackets will
have to be placed, which is on the edges of the mounting rail at most 30 cm from each other and further at most 120 cm
from each other (See calculator for distance between the mounting brackets and maximum allowable wind load).
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5.3 Cleaning the roof
Clean the steel roof plates with a brush.
Remove mould, moss, etc., to minimize surface irregularity during the installation!
min. 30 cm
min. 30 cm
min. 30 cm
min. 30 cm

6. Installation
6.1 Pre-mounting of suspension bushes on solar panels
Mount 2 suspension bushes per solar panel at the rear of the solar panel (= same side as the junction box). First insert the
stainless steel hexagon bolts M6x20 into the existing holes in the frame and secure the suspension bushes accordingly.
Subsequently mount the M6 nuts. The suspension bushes serve as a mounting aid in placing the solar panels.
6.2 Pre-mounting of connection strips
You can secure to the mounting rails mutually to one another with the included connection strips.
Slide the connection strip in the side of the mounting rail and mount it by using the supplied mounting screws 6,5 x19. The
tightening torque of the screw connections is 4.5 N/m.
If the total length of the coupled mounting rails is longer than 20m, a dilatation of a couple of millimetres is recommended.
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6.3 Securing of mounting brackets
Use the position of the solar panels on the roof to determine the position of the mounting brackets.
The mounting brackets are attached at 1/4 of the height of the panel’s upper edge and the panel’s lower edge, with a
distance of 2/4 H between them. Divide the mounting brackets evenly over the line of the mounting rails. The mounting
brackets have to be placed at a maximum distance of 120 cm from each other (See calculator for distance). Place an extra
mounting bracket at each end at a distance of approximately 30 cm.
1. Mark the raised part of the roof plate at the position where the mounting brackets will be placed.
2. Cut the self-sticking EPDM sealing tape into pieces of approximately 9 cm with a knife. Pull the yellow strip loose from the
tape.
3. Attach the EPDM sealing tape to the underside of the mounting brackets. The two holes of the mounting brackets have to
be fully covered.
4. Place the mounting brackets along the marked line on the roof. Ensure that the mounting brackets are positioned parallel
on the raised part. The “ridge” of the mounting bracket has to be on the upper side. The “snap-lip” is on the underside.
Screw the mounting bracket to the roof plate with the self-tapping plate screw 6.0x25mm.
At this point, screw ONLY the upper screw tight. This leaves some room for the mounting bracket to move, which will
make the snapping of the mounting rail much easier. Use a battery screwdriver with caplet S8. Take care that it is set to a
maximum slip coupling of 3N/m to prevent the screw from overturning. As soon as the rubber on the screw is distorted, the
screw is tight and the roof is watertight. (See appendix on page 14)
5. Ensure that the mounting brackets are perfectly aligned.
Attention: Height differences in the roof can be lled up with a heightening cube (optional).
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1
2
3
4
5
6
See Calculator
2/4 H
2/4 H
1/4 H
1/4 H
1
2/4 H
9 cm
2
3
4
5
Click !
OPTION
Heightening cube 15 mm

6.4 Securing of mounting rail
1. Position the mounting rail on the mounting brackets. Make sure that the mounting bracket and the mounting rail are
precisely at a right angle to each other. The mounting bracket can be rotated slightly because it is only attached by the
upper screw.
2. Take care that the end of the mounting rail protrudes approximately 5 cm over the last mounting bracket.
3. Snap the mounting rails one after another to the mounting brackets. There has to be a clear “click”! The mounting
brackets can be sprayed with silicone spray to make the snapping easier.
4. Ensure that the mounting rails are perfectly aligned.
5. Screw the lower self-tapping plate screw 6.0 x25mm to the mounting brackets. (see appendix on page 14)
6. As soon as the rubber on the screw distorts, the screw is tight and the roof is watertight.
Pay special attention to placing the mounting rails straight over each other so that the solar panels can be perfectly aligned!
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Click !
min. 30 cm
4e
3e
2e
1e
1
23 4
5
6
5 cm
1
2
3
4
5
6

6.5 Suspending solar panel onto mounting rail
Suspend the rst solar panel by using the pre-mounted suspension bushes temporarily on to the upper mounting rail. As a
result, you will have your hands free for the rest of the installation.
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6.6 Mounting 1st solar panel on the rails
Slide the rst solar panel to the side of the mounting rail. Then slide the end clamp onto the mounting rail. Choose the right
cavity so the end clamp precisely ts to the solar panel. Let approximately 1 cm of rail protrude visibly besides the end
clamp. Screw the end clamp tight with the mounting screw. The torque of the screw connections is 4.5N/m.
Option: Slide the black end caps in the side of the mounting rails and place the colour caps over the mounting screws.
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1
2
OPTION
XY
1 cm

6.7 Mounting of other solar panels on the rails
Suspend the second solar panel from the mounting rail and slide this towards the rst one until a gap of approximately
7mm remains. Then screw the mounting screw with a modular clamp plate into the mounting rail. The torque of the screw
connections is 4.5N/m.
Ensure that the solar panels are lying perfectly straight before you screw them tight. Repeat this with the remaining solar
panels. Optional: place the black colour caps over the mounting screws.
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7 mm
OPTION

6.8 Final mounting /multiple rows underneath one another
1. Slide the end clamp onto the mounting rail. Choose the right cavity so that the end clamp precisely ts to the solar panel.
2. Screw the end clamp tight with the mounting screw (torque 4.5N/m).
3. In order to obtain a continuous eld of panels, slide the underlying solar panels against the upper row of panels after you
have suspended them from the mounting rail with the suspension sockets. Leave a gap of 1 to 2 cm between the panels.
Then attach the solar panels rmly to the mounting rails by using the mounting screws, end clamps and modular clamp
plates.
Optional: Slide the black end clamps in the sides of the mounting rails and place the colour caps over the mounting screws.
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1 2
3
OPTION
OPTION
OPTION

7. APPENDIX
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Frame height End clamp Screw length
29mm CFA 55 mm
30mm CFA 55 mm
31mm CFB 55 mm
32 mm CFB 55 mm
33 mm CFA 60 mm
34 mm CFA 60 mm
35 mm CFB 60 mm
36 mm CFB 63 mm
37 mm CFA 63 mm
38 mm CFA 63 mm
39 mm CFB 63 mm
40 mm CFB 63 mm
41 mm CFA 70 mm
42 mm CFA 70 mm
43 mm CFB 70 mm
44 mm CFB 70 mm
45 mm CFA 70 mm
46 mm CFA 70 mm
47 mm CFB 75 mm
48 mm CFB 75 mm
49 mm CFA 75 mm
50 mm CFA 75 mm
51 mm CFB 75 mm
52 mm CFB 75 mm
Ensure that the battery screwdriver (with caplet S8) is set to a slip coupling with a maximum coupling of 3N/m so the screw
does not overturn. As soon as the rubber on the screw distorts the screw is tight and the roof is watertight.
Mounting of self-tapping plate screw 6.0x25mm
too loose good !
too tight skewed