ESDEC FlatFix Fusion User manual

FlatFix Fusion
Flat roof mounting system for solar panels
in a dual landscape setup
EN
FLATFIX FUSION MOUNTING SYSTEM FOR FLAT ROOFS
MANUAL
©ESDEC BV 2019
Rev. 10.09.19

CONTENTS
page
1. Introduction 1
2. General installation conditions 1
3. Product description 3
4. Parts overview 3
4.1 Exploded view 3
4.2 Parts list 4
5. Mounting preparation 5
5.1 Check of tools and accessories 5
5.2 Determining and measuring position of solar panels 6
5.3 Cleaning roof 6
6. Installation 7
6.1 Mounting roof support to base elements 7
6.2 Mounting extra roof supports (optional) 7
6.3 Mounting of TPO Protective Mat (optional) 7
6.4 Levelling and mounting base profile to base elements 8
6.5 Positioning FlatFix Fusion segments 10
6.6 Mounting ballast holders 10
6.7 Perimeter ballast (optional) 12
6.8 Mounting 1st solar panel 13
6.9 Levelling and mounting remaining solar panels 14
6.10 Mounting optimisers & cables 15
6.11 Levelling of multiple rows (optional) 16
6.12 Levelling ballast holders (optional) 17
6.13 Placing ballast 18
6.14 Mounting and levelling stabilisers 19
6.15 Mounting second row of solar panels 20
6.16 Mounting wind deflectors left/right 21
6.17 Multiple rows in succession 22
6.18 Shortening base profiles (optional) 22
7. Annex 23
THESE INSTALLATION INSTRUCTIONS MUST BE STORED CAREFULLY FOR FUTURE USE!
For the warranty terms and conditions, we recommend contacting your supplier. Please also refer to our General Sales & Delivery
Conditions, which are supplied on request.
The manufacturer denies any responsibility for damage or injury as a result of a failure to carefully follow these installation instructions,
and failure to take common precautions in the transport, mounting and use of the FlatFix Fusion mounting system.
As a result of our continuous pursuit of improvement, it may occur that the product deviates in detail from that which is described in this
manual. For this reason, the instructions provided serve only as a guideline for installing the product stated in this manual.
This manual is compiled with the greatest possible care, but the manufacturer cannot be held responsible for any errors in this manual or
any resulting consequences.
Furthermore, all rights are reserved and nothing in this manual may be copied in any way whatsoever.
Rev. 10.09.19 MANUAL FOR FLATFIX FUSION MOUNTING SYSTEM FOR FLAT ROOFS

This manual describes the installation of the FlatFix Fusion mounting system for at roofs (for solar panels in landscape
setup).
Read the manual carefully so that you are fully aware of the entire content. Follow the instructions in the manual carefully.
Always carry out the actions in the correct order.
Store the manual in a safe and dry location. If you lose the manual, you may always request a copy from Esdec BV
or download it from www.esdec.com. Where there is a reference to the construction plan, we also refer to the FlatFix
Calculator that allows you to generate a construction plan.
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Rev. 10.09.19 MANUAL FOR FLATFIX FUSION MOUNTING SYSTEM FOR FLAT ROOFS
1. Introduction
2. General installation conditions
General
A failure to adhere to the guidelines stated in this document and/or in the construction plan may lead to all warranty and
product liability claims lapsing.
The details, comments and recommendations in this document are binding and must be checked to ensure they are
complete and up-to-date. Esdec BV retains the right to revise this document without notication.
Stability and condition of the roof
The roof must be in good condition and strong enough to bear the weight of the solar panels, incl. associated materials,
ballast, wind and snow load. Check the stability of the roof/structure and where necessary employ a builder to correct it.
Make sure the load reserve of the roof is not exceeded either locally or in its entirety.
Insulation / roofing material
The continual pressure loading capacity (point load) of the insulation and the roong material must be checked thoroughly
and found to be sound before installation. The suitability of the roof supports combined with the roong material must be
checked and found to be sound, and if necessary or desirable extra roof supports must be tted at the required locations. In
case of doubt, employ a roofer.
Safety warnings
• FlatFix Fusion mounting systems must be tted as standard by qualied technical personnel (at least two skilled
people).
• The addition or omission of parts may have a detrimental effect on the function of the system and is strongly
discouraged!
• Before placing the solar panels, the roof must be clean, dry, at and free of algae and the like.
• Avoid tting in high winds and a wet, slippery roof surface.
• Fitting of the FlatFix Fusion mounting system may only take place at temperatures between 5º and 40ºC (due to the
tments of the plastic parts).
• Always work on a roof using fall protection and safety nets and edge protection where necessary.
• Wear shoes with reinforced toecaps and sturdy anti-slip soles.
• Always wear the proper protective clothing when carrying out the work.
• Always use lifting aids / hoist systems when moving the material (solar panels, etc.).
• Always place a ladder on a sound and stable surface.
• Always place the ladder at an angle of around 75º and ensure it sticks out about 1 metre above the roof edge.
• If possible, fasten the top of the ladder with a rope or strap.
• Preferably work in accordance with the “Working safely on roofs” handbook.
Range of application of FlatFix Fusion
• Wind zone (1 to 3 with the exception of coastal areas).
• Roof height (3-12m) If your roof is higher, contact your supplier.
• Type of roong material: Concrete, bitumen / EPDM / PVC / TPO.
• Roof pitch: maximum 3º. Between 3º and 7º (between 2° and 7º with PVC), the base plates must be sealed. For a roof
pitch of over 7º, contact your supplier.
• Setup: Landscape mounting.
• Maximum solar panel dimensions: length 1170–1310 mm, 1475–1615 mm, 1550–1690 mm, 1655–1795 mm, 1830–
1970 mm, 1940–2080 mm, 980–1050 mm, thickness 25–50 mm. (See table on Page 02)

Table of panel dimensions range
Edge zone
The distance of the solar panels to the edge of the roof must be around 1/5 of the height of the building, with a minimum
distance of 30 cm (due to the strongly turbulent wind ows in this zone). No solar panels may be tted to this zone, neither
partially nor fully. The edge zone to be observed follows from the FlatFix Fusion calculator.
Ballast
If your roof is higher than 12 metres, we recommend you consulting your supplier to assist in determining the correct
ballasting.
Use stone or grit as ballast. Consult the construction plan.
Standards, guidelines and regulations
When tting a mounting system, it is important that you follow the mounting instructions and associated standards to
prevent incidents. Especially, considering the following standards, guidelines and regulations:
• Dutch Building Code
• PPE Personal Protective Equipment
• KEMA Inspection of Electrical Equipment
• DIN 1055 Design loads for buildings
• DIN 18299 General rules applying to all types of construction work
• DIN 18451 Scaffolding works
• NEN EN 1991
• NEN 7250
Removal and dismantling
Remove the product as per local legislation and regulation. At the end of the design life, all materials are recyclable.
The aluminium base proles are fastened to the base elements using a click system. Use combination pliers to dismantle
the base prole.
Warranty
The warranty is subject to the warranty conditions and the general conditions of Esdec BV. These can be found on our
website www.esdec.com.
Liability
The manufacturer does not accept any liability whatsoever for damage or injury caused by a failure to (strictly) comply with
the safety guidelines and instructions in this manual, or due to negligence during installation of the product stated in this
document and any related accessories.
• printing errors reserved
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Rev. 10.09.19 MANUAL FOR FLATFIX FUSION MOUNTING SYSTEM FOR FLAT ROOFS

The mounting system is made of top-grade plastic base elements, which are connected lengthways to aluminium base
proles. Widthways the FlatFix Fusion segments are connected to stabilisers. The necessary mounting materials are also
supplied for mounting the solar panels in a landscape setup. The FlatFix Fusion mounting system may be used for all types
of roong material.
Placing ballast
The FlatFix Fusion system is not xed to the roof and only rests on the surface. Only when the roof pitches above 3° (2° for
PVC) should the roof supports be sealed to the roof. Take note of the processing instructions of the sealant and the roong
material in reference to the compatibility.
The system is made wind-proof by reinforcing the ballast. The ballast weight is partly related to the height of the building
and the conguration. Place the ballast in the ballast holders. Consult the construction plan for ballast positioning and
amount.
Securing the panels
The solar panels are positioned on top of the base elements and are secured using universal centre clips, end clips and
mounting screws. The mounting screws are screwed directly into the mounting holes of the base elements.
Grounding/levelling the FlatFix Fusion mounting system
The system is grounded quickly and easily. There are various possibilities for grounding the FlatFix Fusion mounting
system:
• The solar panels are levelled using the integrated levelling function in the centre clip.
• Multiple rows and ballast holders are levelled using a standard multi-core cable and special clips.
• The base proles are levelled using earthing devices (can also be supplied pre-assembled).
• The stabilisers are levelled using earthing brackets.
• The wind deectors left/right are levelled using mounting screw 6.5 x 19.
Grounding is done once the levelled elements are also levelled with the earthing rail.
3. Product description
4. Parts overview
4.1 Exploded view
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4
5
2
14
14A
3
2A
2
17 12
11
1
9
8
10
7
16
16
15*
15*
13
18 6
19
20
21

4.2 Parts list
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1. Solar panel
5. Roof support
Item no: 100-7012
7. Ballast holder
Item no: 100-72__
For length, see Annex section 7
2. Base prole 940 mm
Item no: 100-7194
2A. Base prole
Item no: 100-71__
For length, see Annex
section 7
8. End clip
Item no: 100-41__
For type, see Annex section 7
9. Mounting screw 6,5 x __
Item no: 100-65__
For type, see Annex section 7
10. Universal centre clip
Item no: 100-3022
4. Base element low
Item no: 100-7021
12. Stabiliser
Item no: 100-72__
For length, see Annex section 7
14. Wind deector left
Item no:100-7204
11. Cable clip optimiser ready
Item no: 100-7041
3. Base element high
Item no: 100-7030 14A. Wind deector right
Item no: 100-7205
13. Mounting screw 6,5 x 19
Item no: 100-6519
15. Earthing device
Item no: 100-7502
*optional
Deliverable pre-assembled
Item no: 1007021-S
Item no: 1007030-S
16. Earthing clip Item
Item no: 100-7505
*optional
17. Earthing bracket
Item no: 100-7503
*optional
18. Self-tapping screw 6,3 x 32
Item no: 100-3015
3A. Base element high
with levelling
Item no: 100-7030-S
4A. Base element low
with levelling
Item no: 100-7021-S
19. Low base extension
Item no: 100-7021-WP
*optional
20. Roof support adapter
Item no: 100-7011
*optional
6. TPO Protection mat
Item no: 100-7015
*optional
21. Self-tapping screw 6,0x25
see section 6.7
Item no: 100-3010

5. Mounting preparation
5.1 Check of tools and accessories
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1
2
3
4
5
6
or
S10mm S10mm
Sealant pistol optional
for roof pitch > 2º/3º
Below is a list of necessary tools/aids:
Tape measure Brush Ratchet with hexagon
head
Powered screwdriver
Marker/chalk
Scaffold or stable safe
ladder
Water pump pliers Metal saw
Ear protection
Safety helmet Safety goggles Protective clothing Safety shoes
Dust mask Safety gloves

5.2 5.2Determining and measuring position of solar panels
When determining the location of the solar panels on the at roof, the movement of the sun throughout the whole day and
the entire year are very important to take into account. Place the solar panels on an area of the roof that never falls into
shade. The shadows of chimneys, trees or adjacent buildings all have an unfavourable effect on the yield of solar panels.
Measuring and marking out
To place a panel (in the landscape setup), you roughly need the same space for each setup as the panel is long.
With this system, a solar panel is placed on each side to create a pitched roof shape. If multiple rows of solar panels (in
pitched roof shape) are placed in succession, you must leave a distance between them to prevent shadows on the panels.
The distance of the solar panels to the edge of the roof must be around 1/5 of the height of the building, with a minimum
distance of 30 cm due to the strongly turbulent wind ows in this zone
*(see construction plan for the correct distance).
Mark the outlines of the panel eld on the roof with chalk or a marker.
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5.3 Cleaning roof
Clean the roof with a brush.
Ensure that the place where the solar panels are to be placed on the roof is clean, dry and at. The presence of grit, sand,
stones, algae, dust, etc. can lead to instability of the system and/or damage to the roof.
min. 30 cm*
min. 30 cm* min. 30 cm*
min. 30 cm*
Depending
on choice

6. Installation
6.1 Mounting roof to base elements
As standard, the high base element is placed on a single roof support.
1. Secure the roof support to the high base element using the click connector. Use the centre click connector to the
underside of the high base element for this. Optional: In situations where ballast is to be placed, two roof supports are
secured under the high base element. Use the two click connectors at the centre (1A) for this.
2. Secure the roof support to the low base element using the click connectors.
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1. 2.1A. Situation with ballast
CLICK!
CLICK! CLICK!
6.2 Mounting extra roof support (optional)
If an extra roof support is needed, these can be applied exibly using the roof support adapter. Secure the roof support to
the adapter using the click connectors. This setup can then be clicked onto a base prole at any point lengthways.
CLICK!
CLICK!
6.3 Mounting of TPO Protective Mat (optional)
The optional TPO protective mat can be used to protect the TPO roong material. Bend the three rubber lips of the
protective mat open and place the roof support under the lips of the protective mat. Ensure that the roof support is fully
enclosed by the rubber lips.

6.4 Levelling and mounting base profile to base elements
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The high and low base elements are also available pre-assembled: 1007021-S and 1007030-S If you assemble them
yourself, then follow the instructions below.
Grounding/levelling the base proles (optional)
1. Place the earthing device in the grooves of the high base element before clicking the base prole in the high base
element. The use of one earthing device is equal to a joint surface of 3 mm2. Two earthing devices (one device on each
side of the base element) is equal to a joint surface of 6 mm2. The teeth of the earthing device bite into the base prole and
guarantees a solid and durable connection.
2. Set the base element (incl. roof support) upright and slide the tip of the base prole (length 94 cm) in the opening of the
high base element until it clicks into place.
3. Place the earthing device in the grooves of the low base element before clicking the base prole in the low base element.
4. Slide the low base element (incl. roof support) to the other tip of the base prole until it clicks into place.
5. One side of the FlatFix Fusion segment is ready.
1.
3.
5.
CLICK!
CLICK!
2.
4.

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6. Slide the tip of the second base prole (length 94 cm) in the opening of the high base element until it clicks into place.
7. Place the earthing device in the grooves of the low base element before clicking the base prole in the low base element.
8. Slide the low base element (incl. roof support) to the other tip of the base prole until it clicks into place.
9. The rst FlatFix Fusion segment is ready. Repeat the steps above until you have enough FlatFix Fusion segments to t
the rst two rows of solar panels.
6.
7. CLICK!
CLICK!
9.
8.

6.5 Positioning FlatFix Fusion segments
The place of the solar panels on the roof is used to determine the position of the FlatFix Fusion segments. Spread the
FlatFix Fusion segments evenly along the line where the solar panels are to be placed. The FlatFix Fusion segments may
be placed centre-to-centre at a maximum of 2 m apart (see calculator for distance).
Use the chalk or marker to mark out on the roof where the FlatFix Fusion segments are to be tted. Ensure the FlatFix
Fusion segments are aligned with each other.
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6.6 Mounting ballast holders
The ballast positions are determined using the calculator. Place the ballast holders at the locations indicated by the
calculator. ATTENTION! Ensure that the high base elements are always tted with two roof supports at the location of the
ballast holders!
First insert the ballast holder at an angle between the FlatFix Fusion segments in such a way that the tted holes of the
ballast holder are positioned over the upright ridges of the high base element.
Make sure that the FlatFix Fusion segments are positioned straight beside each other for the alignment of the solar panels!
Measurement solar panel
Measurement solar panel
Measurement solar panel

Place the second ballast holder between the FlatFix Fusion segments in such a way that it overlaps the rst ballast holder
and that the tted holes of the ballast holder are positioned over the upright ridges of the high base elements.
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Place the third ballast holder between the FlatFix Fusion segments in such a way that it overlaps the second ballast holder
and that the tted holes of the ballast holder are positioned over the upright ridges of the high base elements. Repeat these
steps until all ballast holders have been placed.

6.7 Perimeter ballast (optional)
Perimeter ballast, with ballast trays being mounted in the direct vicinity of the high base, under the panel.
Under the panel:
Mount an extra roof support with adapter to the base prole under the panel. Place the adapter in such a way that it is also
hooked over the rib under the high base. This way, the adapter also functions as a spacer for the ballast tray to be placed.
The ballast tray must then be screwed to the base prole using the self-tapping screw 6.0x25 (Item no. 100-3010) through
one of the pre-punched holes in the ballast tray. Where two ballast trays positioned beside each other overlap, one screw is
enough.
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1.
CLICK!
2. 3.

2
1
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6.8 Mounting 1st solar panel
1. Place the rst solar panel between the upright ridges of the low base element.
2. Tip the solar panel carefully so that it lies between the upright ridges of the base element.
ATTENTION! Optionally a low base extension can be tted for greater panel reach. (See table of panel dimensions range
on Page 02)
3. Place the end clips to the edge of the solar panel and position these at the location of the mounting holes in the high and
low base elements. Tighten the end clip using the mounting screw in the mounting hole.
ATTENTION! The torque of the screw connection is 4.5Nm (max. 6.5Nm). Do not overtighten the mounting screws in the
base element. Consult the manual for your tool to set it to the correct torque.
OPTION
When the
“low base extension”,
the 100-7021-WP,
is tted, a 10 mm
longer screw must be
used at the location
of this extension.
For type, see Annex
section 7

6.9 Levelling and mounting remaining solar panels
Place the second solar panel on the base elements so that it lies between the upright ridges. Then screw the mounting
screw with a centre clip in the mounting holes of the base elements. The centre clip (Universal Module Clamp with
synchronization) has an integrated levelling function so that the panels are mutually levelled, after which the full row can be
levelled on the earthing rail. Make sure that the solar panels are properly aligned before tightening the screw fully!
ATTENTION! The torque of the screw connection is 4.5Nm (max. 6.5Nm). Do not overtighten the mounting screws in the
base element. Consult the manual for your tool to set it to the correct torque. Repeat the steps above for the remaining
intermediate panels.
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Place the last solar panel on the row of the base elements so that it lies between the upright ridges. Then screw the
mounting screw with a centre clip in the mounting holes of the base elements. Then tighten the two end clips using the
mounting screw in the mounting hole. Make sure that the solar panels are straight before tightening the screw fully!
ATTENTION! The torque of the screw connection is 4.5Nm (max. 6.5Nm). Do not overtighten the mounting screws in the
base element. Consult the manual for your tool to set it to the correct torque.
When the “low base
extension”,
the 100-7021-WP,
is tted, a 10 mm
longer screw must be
used at the location
of this extension.
For type, see Annex
section 7
OPTION

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6.10 Mounting optimisers & cables
Clips are supplied with integrated cable management and optimiser fastenings so that the cables are well-routed and
remain secure. There are also notches in the high base elements for feeding the cables through. This prevents the cables
from lying on a (wet) roof. Follow the steps below for mounting:
1. Place the clips over the narrow side of the base proles.
2. Rotate the clips so that they are clamped along the broad side of the base proles.
3. Place the cables in the notches. The clips also allow for the inclusion of a Ø25 mm conduit.
4. Feed the end of the cable through one of the cable guides of the high base element.
5. The plugs of the solar panel can be fastened to the high base element in the cable guide.
Optional: Click the optional optimiser onto the cable clip.
5
Click!
Ø25mm
1
2
3
4
Option

6 mm2
0,24 in2
6.11 Levelling of multiple rows (optional)
If the PV system is made up of multiple rows, these rows can easily be grounded with a multi-core cable of 6 mm2 and
special earthing clips. The design of the earthing clips ensures an effective and durable connection between the multi-core
cable and the solar panel.
1. Place the multi-core cable to one side of the system. The multi-core cable can easily be clamped into the FlatFix Fusion
cable clip. To connect the multi-core cable to the solar panel, a loop must be made to the solar panel.
2. Use the earthing clip to connect the multi-core cable to the solar panel. Insert the multi-core cable into the earthing clip
and clamp the earthing clip securely to the solar panel using a pair of pliers. Place an earthing clip on each rst solar panel
in the row.
If grounding rings are used for the FlatFix Fusion base elements, the remaining solar panels are automatically grounded in
the same row.
1. 2.
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1 2
6 mm2
0,24 in2
6.12 Levelling ballast holders (optional)
The ballast holders can easily be grounded in the same way as the rows.
The earthing clips are pressed onto the ballast holders. The teeth of the earthing clips bite into the ballast holder, creating a
solid and durable connection.
The earthing cable for grounding the rows can also be used to ground the ballast holder. Place an earthing clip on each rst
and last ballast holder of a row to ground all rows separately.
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6.13 Placing ballast
To keep the solar panels in place, you must place ballast in the ballast holders.
As standard you can use 21x10.5x8 cm concrete paving slabs as ballast. These weigh about 4 kg/pc and in terms of size t
well in the ballast holders. As an alternative, you can also use agstones of max. 21x21 cm, kerbing of 20x100 cm or grit. If
you use grit, rst place a concrete paving slab left and right in the ballast holder. This prevents the grit from sliding out of the
ballast holder.
Follow the ballast weights from the calculator precisely!
ATTENTION! Before placing the ballast, you must check that the solar panel eld is in the correct position and that it is
properly aligned relative to the roof edges. The panel eld can still be adjusted slightly at this point. Once the ballast has
been placed, correction is no longer possible!
If your roof is higher than 12 metres, we recommend you contact your supplier. They will then determine
the correct weight as per your situation.
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