ESDEC FLATFIX WAVE User manual

www.esdec.com
REV01
MANUAL
FLATFIX WAVE

DISCLAIMER
This assembly manual must be kept in a safe place for future use!
For the duration and conditions of the warranty, we recommend
that you contact your supplier. We refer to our General Terms and
Conditions of Sale and Delivery, which are available on request. The
manufacturer rejects all liability for any damage or injury resulting
from failure to follow this assembly manual carefully and observe the
usual precautions during transport, assembly and using the FlatFix
Wave assembly system.
GENERAL INSTALLATION CONDITIONS
General
Failure to comply with the instructions in this document may result
in the lapse of all warranty and product liability claims. The data,
comments and opinions contained in this document are binding and
should be checked for completeness and up to date status. Esdec BV
reserves the right to change this document without notice.
Stability and condition of the roof
The roof must be in good condition and strong enough to support
the weight of the solar panels including additional materials, wind
and snow loads. Check the stability of the roof and adjust the roof/
structure if necessary, if in doubt, call in a structural engineer. Ensure
that the load threshold of the roof is not exceeded, either locally or as
a whole.
Safety warnings
• The installation of the FlatFix Wave assembly system must be carried
out as standard by qualied technical personnel (at least 2 skilled
persons).
• The addition or omission of parts may adversely aect the operation
and is strongly discouraged!
• Before installing the solar panels, the roof must be clean, dry, at and
free of algae, etc.
• Avoid assembly in strong winds and on a wet and slippery roof
surface.
• Always work on the roof with fall protection and, if necessary, with
safety nets and edge protection.
• Wear shoes with a reinforced tip and rm non-slip soles.
• Always wear suitable protective clothing when performing work.
• When moving the material (solar panels, etc.) always use a hoisting
aid/hoisting installation.
• Always place a ladder on a strong, stable surface.
• Always place the ladder at an angle of about 75º and allow it to
protrude about 1 metre above the roof edge.
• If possible, secure the ladder at the top with a rope or tension strap.
• Preferably work according to the manual “Safe Working on Roofs”.
• NB: In the assembly of the standard unit and the start unit, make
sure that hands and/or ngers are not trapped in the area of the
hinged parts!
Range of application of FlatFix Wave
• Suitable for all wind zones, terrain categories and building heights,
provided the maximum wind pressure does not exceed the maximum
panel specication.
• For roof heights above 12m please contact your supplier.
• Roof material: Concrete, Bitumen, EPDM, PVC, TPO. For other roof
coverings, please contact your supplier.
• Roof slope: Up to 5º counts as a at roof. If your roof slope is > 5°,
please contact your supplier.
• Maximum eld size: 40 x 40m.
Due to continuous improvement eorts, the product may dier in
detail from what is described in this manual. This means that the in-
structions given are only intended as a guide for the installation of the
product mentioned in this manual.
This manual has been compiled with the greatest possible care, but
the manufacturer cannot accept liability for any errors in this manual
or their consequences. In addition, all rights are reserved and no part
of this manual may be reproduced in any form whatsoever.
Edge area
The distance from the solar panels to the edge of the roof must be
approximately 1/5 of the height of the building with a minimum
distance of 30 cm, due to the very turbulent wind currents in this area.
No solar panels must be installed in this area, either in whole or in
part.
The edge area to be maintained is derived from the FlatFix Wave
calculator.
Ballast
If your roof is higher than 12 metres, we recommend that you consult
your supplier to help you determine the correct ballast.
Standards, regulations and rules
When installing the assembly system, it is important to follow the
assembly manual and related standards to prevent accidents.
In particular, observe the following standards, regulations and rules:
• Buildings Decree 2012 (regulations for the construction, use and
demolition of buildings)
• NEN 7250:2014 - Structural aspects of solar energy systems
• NEN-EN 1990 - Basis of structural design
• NEN-EN 1991-1-3 - General loads - snow load
• NEN-EN 1991-1-4 - General loads - wind pressure
• NEN 1010:2015 - Electrical installations for low voltage (HD-IEC 60364)
• NEN-EN-IEC 62305 - Lightning protection
• Workplace safety laws and regulations - safe working and working
conditions
• NEN 3140 - safe operation of low-voltage installations
• VCA checklist - Safe working on the work oor
• Scaolding directive & workplace safety A-sheet ladders/scaolding
Removal and disassembly
Dispose of the product in accordance with local laws and regulations.
At the end of the service life, all materials are recyclable.
The plastic roof supports are attached to the units and the wind de-
ectors by means of a click system.
Warranty
Warranty according to the Esdec BV warranty terms. These can be
found on the website www.esdec.com
Liability
The manufacturer accepts no liability for damage or injury caused by
failure to comply (strictly) with the safety guidelines and instructions
in this manual, or by negligence during installation of the product and
the accessories listed in this document.
• Typing errors reserved
01

02
1 BILL OF MATERIALS
STABILIZERS
3. FlatFix Wave Stabilizer 2900
1009110
1. FlatFix Wave Dual Start unit 4P
1009101
2. FlatFix Wave Dual Unit 4P
1009100
2A. FlatFix Wave Dual Unit 2P
1009102
5A
1
7
4
3
2
6
4. FlatFix Wave Cable bracket
1009124
UNITS
TOOLS & EQUIPMENT
8
4
3
3A
5B
3A. FlatFix Wave Stabilizer 3530
1009111
ACCESSORIES
8. FlatFix Wave Ballast bracket
1009123
5. FlatFix Wave Wind Deector
A and B ( = Wind deector kit)
1019103
6. FlatFix Wave Connector pin
1009122
7. FlatFix Wave Roof support
1009120
WIND DEFLECTORS
6
7
5B
5A
7. FlatFix Wave Roof support
1009120
BALLAST
105
105
80
210
4 kg

03
2 PREPARATIONS FOR ASSEMBLY
3 PLACE DUAL START UNIT
1 PREPARING THE ROOF AND ALIGNING (THE FIELDS)
2 MEASURING AND MARKING (OF FIELD)
2 UNFOLD THE TOP OF THE DUAL START UNIT UNTIL IT
IS COMPLETELY FLAT AND CLICKS INTO PLACE
3 PLACE THE HIGH BASE (2x) IN STANDING POSITION
SO THAT IT CLICKS
NB: Follow the installation drawing and make sure the
elds are well coordinated.
Calculate how much space you need based on the
dimensions of your panel.
1. Keep at least 30 cm around the panel eld free.
2. Draw eld contours at right angles with 3-4-5 rule. Use a
chalk or blemish cord for this. Also mark each panel with a
short stripe.
3. Mark the panel edges.
4. Mark with chalk the place on the roof where the start units
are to be placed.
NB: Make sure your roof is in good condition! If in doubt,
consult your roof specialist.
NB: The distance from the solar panels to the edge of
the roof should be approximately 1/5 of the height of
the building. See the installation drawing that is calcu-
lated with the Esdec calculator for the correct distance.
Tip: Lift the dual start unit slightly at the coupling, by its
own weight the unit clicks rmly into place.
min. 30 cm
min. 30 cm
min. 30 cm
min. 30 cm
Click!
Click!
Click!
Click!
Click!
Tip: Check the measurement using the 3-4-5 rule.
NB: Make sure that your hands/ngers are not trapped
in the area of the hinged parts!
min. 30 cm
3
45
5
4
3
4
1 PLACE THE DUAL START UNIT DIRECTLY ON THE
RIGHT PLACE ON THE ROOF
See Annex A for an explanation of how to attach additional
roof supports to the unit.

04
4 POSITONING THE DUAL START UNITS
1 POSITION THE 2nd DUAL START UNIT
2 POSITIONING OF THE OTHER DUAL START UNITS
Place the rst dual start unit at the edge of the panel eld,
with a centre-to-centre distance (A). To do this, use the
measuring bar at various places on the dual start unit.
A
A
A
B
Make sure that the dual start units are aligned with each
other.
A
B
Tip: Ballast the aligned units to prevent them from shifting.
A
B
A
B
A
L
A B
(panel)
See Annex B for an explanation of the use of the
Measuring bar.

05
5 PLACE DUAL UNITS
4 PLACE THE HIGH BASE (2x) IN STANDING POSITION
SO THAT IT CLICKS
Click!
2 COUPLE DUAL UNITS TO THE DUAL START UNITS
1. Slide the lugs of the dual unit coupling into slots of the dual
start unit at an angle of 45 degrees.
2. Pull back the cams so that the coupling is rmly engaged.
3. Carefully turn the dual unit downwards until it is completely
at and clicks into place.
Click!
3 OPEN THE TOP OF THE DUAL UNIT UNTIL IT IS
COMPLETELY FLAT AND CLICKS INTO PLACE
NB: Make sure that your hands/ngers are not
trapped in the area of the hinged parts!
Click!
Tip: Lift the dual unit slightly at the coupling, by its own
weight the unit clicks rmly into place.
Click!
Click!
Click!
1 PREPARE COUPLING
Click!
Press the coupling down until it clicks.

06
6 ASSEMBLY OF STABILIZERS AND CABLE BRACKETS
1 POSITIONING STABILIZERS IN CONNECTION
2 ASSEMBLE STABILIZERS ON HIGH BASE
3 ASSEMBLE CABLE BRACKETS ON STABILIZERS
Place the stabilizers at an angle to the edge of the high base
and turn them back to the base until they click.
Tip: Click on 2 stabilizers (front & back) at the same time for
easier assembly.
Click!Click!
NB: Follow the installation drawing for the positions of
the stabilizers. Place the stabilizer in the centre aligned
with 4 high base elements whose ends protrude an equal
distance.
Click on the cable brackets at the top of the stabilizer.
NB: Align the rst stabilizer well and then align the other
stabilizers.
NB: Make sure that the cable brackets face the back of
the stabilizer.
NB: Place the cable brackets in the space between 2
stabilizers. See Annex C for further specications.
Click!
=
=
==

7 PLACING THE BALLAST
2 PLACE STANDARD BALLAST (3x4 kg.)
Place the standard ballast (3x4 kg.) in the units on the high
base. Place 1st ballast stone against the ridge.
1 PLACING THE BALLAST (GENERAL)
NB: The installation drawing is the guideline for the bal-
last positions. Using the calculator, the ballast positions
are determined. Place the ballast at the points indicated
by the calculator.
07
3 PLACE OPTIONAL BALLAST (5x4 kg.)
Tilt the ballast bracket at
an angle in the unit on
the high base.
Tilt the ballast bracket back into
the module.
Slide the bracket against the
high base and then click the
bracket into the long edge!
Place the ballast (3x4 kg.)
in the ballast track and the
other ballast (2x4 kg.) in the
module.
4
Click!
4 PLACE THE BALLAST IN POSITION ON THE BALLAST
BRACKET AT THE POSITION OF A STABILIZER
NB: If there is a wire tray, there is only
room for 2 stones, instead of 3 stones, in
the ballast area. Then place this 3rd stone
in the unit on the other side of the high
base.

1 POSITION AND CLAMP THE SOLAR PANEL ON THE
HIGH BASE ELEMENTS
2 CLAMP THE SOLAR PANEL ON THE FRONT SIDE
2. Slide the panel edge under the clips of the high base
elements as far as it will go.
1. Place the rst solar panel on 2 high base elements.
Make sure the panel is properly centred. Tilt the panel so
that the lower edge of the panel is ush with the high base
elements.
Slide the clips of 2 panel locks over the edge of the front
panel until the panel is rmly clamped in place.
Click!
8 ASSEMBLY OF SOLAR PANELS AND CABLES
3 PLACING CABLES OR MC4 CONNECTOR
1. Place the cables or MC4 connector of the solar panel in
the gutter of the stabilizers at the place of the high base
elements.
2. Insert the cables or the MC4 connector into the cable
supports.
3. Connect the cables or MC4 connector to the stabilizers
using cable ties.
MC4
Connector
Cables
4. Connect the connectors of the cables of the rst and second
solar panel to each other.
5. Assemble the second solar panel.
6. Repeat the steps to complete the rows.
See Annex C for an explanation of cable management.
08
12 mm
12 mm

09
9 ASSEMBLE WIND DEFLECTOR A TO THE FIELD
4 SLIDE WIND DEFLECTOR A AGAINST THE PANEL
FRAME AND BEND THE FLANGE UNDER THE FRAME
3 ASSEMBLE WIND DEFLECTOR A ON THE UNIT WITH
CONNECTOR PINS
1. Hook the outer connector pin into the hole of the unit.
2. Hook the middle fastening pin into the hole of the high
base.
3. Squeeze the springs to shorten the connector pin.
2 ASSEMBLE 2 CONNECTOR PINS TO WIND DEFLECTOR
A
1 ASSEMBLE THE ROOF SUPPORTS UNDER WIND
DEFLECTOR A
1. Slide the roof supports over the ange of wind deector A.
2. Click the wind deector on the roof supports.
Click!
AB
1. Slide wind deector A against the panel frame on the side
of the eld by inserting the connector pin.
2. Bend the anges under the panel frame by hand.
3. Make sure wind deector A is properly connected to the
panel frame.

2 CONNECT WIND DEFLECTOR B TO WIND DEFLECTOR
A
3 ASSEMBLE WIND DEFLECTOR B TO THE FIELD
1. Hook the fastening pin into the hole of the unit.
2. Slide wind deector B against the eld by inserting the
connector pin.
3. Bend the anges under the panel frame by hand.
4. Make sure wind deector B ts well on the panel frame.
4 ASSEMBLE THE OTHER WIND DEFLECTORS A AND B
ON THE REST OF THE FIELD
Assemble the other wind deectors A and B on the rest of
the eld. (Repeat the steps in Sections 9 and 10).
1 ASSEMBLE THE ROOF SUPPORT UNDER WIND
DEFLECTOR B
1. Slide the roof support over the ange of wind deector B.
2. Click the wind deector on the roof support.
10 ASSEMBLE WIND DEFLECTOR B ON THE FIELD
10
5 THE PANEL FIELD IS NOW READY!

ANNEX A - ADDITIONAL ROOF SUPPORT
1 ASSEMBLE THE ADDITIONAL ROOF SUPPORT TO THE
UNIT
Place the roof support in the correct position underneath
the unit. Place the hook of the roof support through the
hole in the unit.
Turn the roof support 90 degrees until it engages.
Click!
11

A
A
ANNEX B - MANUAL FOR THE MEASURING BAR
1 SETTING THE MEASURING BAR
Take size L from the solar panel. Set size L on the
Measuring bar (= 1st handle to 3rd handle).
Turn the Measuring bar so that the handles face down.
4
Set size A with a tape measure.
A = recommended distance between the panels
Place the units at the correct
distance from each other. Align
the units. Use multiple Measuring
bars for this.
L
L
A
12
L
A
L

ANNEX C - CABLE MANAGEMENT
13
1 TABLE
Open space ≤ 350mm Open space > 350mm End of row without stabilizer End of row with
stabilizer
1x cable bracket 2x cable bracket 3x cable bracket 0x cable bracket
1x In the middle 2x 10cm relative to the ends 1x 10cm relative to the end 2x 5cm
relative to the high base 15 metres
Cable ties Cable ties Cable ties 2x cable tie (detail)

ANNEX C - CABLE MANAGEMENT
14
2 TIP: ASSEMBLE A SMALL WIRE TRAY ON THE HIGH
BASE ELEMENTS OVER THE (START) UNITS
1 TIP: ASSEMBLE A LARGE WIRE TRAY ON THE SIDE OF
THE (START) UNITS
1. Fold out the lips of the high base elements.
2. Bring the top bar of the wire tray over these lips.
3. Fold the lips further around the rod to enclose it.
1. Fold out the lips on the side of the units.
2. Bring the top bar of the wire gutter over these lips.
3. Fold the lips further around the rod to enclose it.
Make sure that the wire tray does not rise above the units.
3 CONNECTORS AND CABLES TO BE FIXED IN THE
STABILIZER AND ON THE CABLE SUPPORTS
1. Connect the MC4 connectors.
2. Place the MC4 connector with the cables in the channel
section of the stabilizers and in the openings in the cable
supports.
3. Secure the MC4 connector and the cables with cable ties
through the perforations in the stabilizers.

ANNEX D - GROUNDING, BONDING AND LIGHTNING PROTECTION
15
1 SELECTION DIAGRAM
LPS = lightning installation
LPL = lightning protection level URL QR CODE: https://www.esdec.com/nl/kennisportal/
Watch
[SCAN QR]
Risk analysis in
accordance with
NEN-EN-IEC 62305-2
LPS needed?
LPS present?
Installaon within
50 cm of LPS?
Bond to LPS in accordance
with the required LPL in
cooperaon with
lightning specialist.
Install LPS according to
the required LPL in
cooperaon with the
lightning specialist.
Get advice to create a safe
area for PV by means of
Air-terminaon rods
in cooperaon with
lightning specialist.
Overvoltage protecon
in accordance with NPR8110
Proceed with the installaon
in accordance with NEN1010
(NPR5310 part 712-6.3
NEN EN IEC 62305)
yes
no
yes
no
yes
no
Delivery
Oplevering- en
controlerapport PV
installaes Techniek
Nederland en Holland Solar
Esdec oplever- en/of
inspecechecklist
[SCAN QR]
Delivery and inspecon
report PV installaons
Technology Netherlands
and Holland Solar
Esdec delivery and/or
inspecon checklist
[SCAN QR]

ANNEX D - GROUNDING, BONDING AND LIGHTNING PROTECTION
16
2 METHOD OF GROUNDING/BONDING
Grounding
Thanks to the integrated part bonding, no additional bonding between the metal parts is required.
1. The teeth at the top of the high base elements engage in the frame edge of the solar panels.
2. The teeth on the underside of the high base elements engage in the prole of the units.
3. Fully tightening the panel lock ensures correct contact of the panel frame with the high base.
Integrated bonding
• The grounding conductor (≥Ø 4mm2) runs parallel to the plus and min. conductors and is connected to a separate grounding point of the
inverter.
• Connect at least one rail in a eld to a ground rail.
• Each individual PV eld will have its own bonding conductor.
• The grounding cable can be tted with a cable eye and screwed to the rail together with serrated spring washers.
• Correct assembly: protected against corrosion and rmly assembled.
INSTALLATION OF THE BONDING CONDUCTOR

ANNEX D - GROUNDING, BONDING AND LIGHTNING PROTECTION
17
3 LPS: LIGHTNING PROTECTION
Lightning protection guidelines.
CONSULT YOUR LIGHTNING PROTECTION SPECIALIST TO ANALYSE YOUR PROJECT.
Preferred application: Isolating lightning protection system (with Air-termination rods)
• Determine the safe separation distance (S) according to NEN-EN-IEC 62305 (at least 0.5 metres).
• Try to respect the separation distance between PV system (PV) and lightning protection system (LPS).
• This way you’re able to keep PV system seperated from Lightning protection system to prevent unwanted lightning current in building.
If this is not possible, connect the PV system to LPS according to the applicable lightning protection level (LPL);
• See table 1, use at least 16mm2 connections.
• Check necessity additional overvoltage protection type 1 and/or type 2.
• Make sure that the cable support systems are also grounded and connected to LPS. NB: Metal cable support systems also belong to the PV
system.
• Make sure that the grounding cable is routed parallel to the DC cables.
IN BOTH CASES: CONSULT YOUR LIGHTNING PROTECTION SPECIALIST IN ADVANCE TO ANALYSE YOUR PROJECT AND TO PREVENT ANY UN-
WANTED SAFETY ISSUES. ESDEC IS IN NO CASE RESPONSIBLE FOR THE APPLICATION AND/OR COMBINATION WITH THE LIGHTNING PROTECTION
SYSTEM AT THE ROOF. USE THE EXPERTISE OF YOUR SPECIALIST AND MAKE SURE A SAFE INSTALLATION CAN BE GUARENTEED ACCORDING -
NEN-EN-IEC 62305 - NEN1010 (NPR5310 – deel 712 par. 6.3)
S
Mesh size LPL level PV System connect every..
5x5 metres I 5 metres
10x10 metres II 10 metres
15x15 metres III 15 metres
20x20 metres IV 20 metres
table 1
LPS = lightning installation
LPL = lightning protection level

ANNEX E – DISASSEMBLING THE PANELS
1 DISASSEMBLE THE PANELS
1. Place the unlocking tool on the
locking lever.
2. Carefully turn the unlocking
tool downwards so that the
panel latch can be slid back.
3. Slide the panel all the way
back in the direction of the
panel. This unlocks the low side
of the panel.
Click!
4. Lift the panel a few cm and
push the panel backwards out of
the high base elements.
5. Now you can lift the whole
panel.
45
18

www.esdec.com
Esdec has been developing, producing and sup-
plying professional roof-assembly systems for
solar panels since 2004. ClickFit and FlatFix are
inspired by the installer who regularly installs
solar panels. Easy, quick, reliable installation
using innovative, high-quality, durable assembly
systems: Esdec makes it possible.
MAKE THE CLICK WITH ESDEC
QUICK
RELIABLE
INNOVATIVE
19-11-2020
Esdec
Londenstraat 16
7418 EE Deventer
Netherlands
[phone]
[email protected]