mercor MCR PROLIGHT User manual

Nr dok: HO.23.02162 rew.: BStatus: Wydany
Installation manual
MCR PROLIGHT
Continuous
Rooflights

Installation manual of mcr PROLIGHT continuous rooflight with smoke vents
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Table of Contents
I. Components of continuous rooflight and components of continuous rooflights
with sandwich panels........................................................................................................3
II. Installation of the rooflight base.....................................................................................13
III. Installation of an overlay base ........................................................................................18
IV. Installation of a safety nets / an anti-burglar grids..........................................................20
A. Installation of a safety net...............................................................................................20
B. Installation of the anti-burglar grid.................................................................................23
C. Installation of PAS anchorage points..............................................................................25
V. Double glazings –possible configurations and installation sequence............................27
VI. Assembly of the top section of the continuous rooflight................................................37
VII. Additional operations limiting errors in roofing works at the tympanum panel ............54
VIII. 1200 J reinforcements to the top section structure..........................................................55
A. Types of 1200J reinforcements.......................................................................................55
B. Spacing of 1200 J braces ................................................................................................56
C. Installation of 1200 J reinforcements..............................................................................58
IX. Assembly of triangular rooflight.....................................................................................61
X. Installation of a double-leaf vent integrated into a continuous rooflight........................67
XI. Installation of a single-leaf vent in a continuous rooflight.............................................74
XII. Installation of wind deflectors ........................................................................................78
XIII. Instruction for the installation of the continuous rooflight crossing the roof ridge........80
XIV. Roof ridge crossing: how to install the 1200 J reinforcements.......................................98

Installation manual of mcr PROLIGHT continuous rooflight with smoke vents
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I. Components of continuous rooflight and components of continuous rooflights
with sandwich panels
1. Sheet metal base
(standard base sheet thickness 1.5 or 2.0 mm and self-supporting base sheet thickness 2.5 mm)
End base module
Longitudinal base module
Longitudinal base connector
End base connector
Corner connector

Installation manual of mcr PROLIGHT continuous rooflight with smoke vents
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Fasteners:
- M10 x 20 bolts,
- M10 nuts,
- M10 bolt washers,
- ø 6.3x32 mm self-drilling screws (not supplied for overlay bases),
- ø 4.8x12 mm rivets,
- PES 40x3 tape,
- PES 20x5 tape.
Upper bracing of the base
Lower bracing of the base

Installation manual of mcr PROLIGHT continuous rooflight with smoke vents
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2. Top section of the rooflight
After delivery to the jobsite, the aluminium
profiles should be stored in accordance with
the instructions placed on the packaging.
Aluminium profiles of the N60/D60 system:
Bearing profile N60
Pressing profile D60
Edge profile Km10
Edge profile Km16
Edge profile Km20
End panel profile Tm 60
End panel profile TM 60-II

Installation manual of mcr PROLIGHT continuous rooflight with smoke vents
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Aluminium profiles of the N80/D80 system:
Bearing profile N80
Pressing profile D80
Edge profile Kd10
Edge profile Kd16
Edge profile Kd20
Edge profile Kd25
Edge profile Kd33
Tympanum panel (tympanum wall of the rooflight)
Vent supporting frame –“spider”
Edge profile end cap (2 pcs RIGHT, 2 pcs LEFT)

Installation manual of mcr PROLIGHT continuous rooflight with smoke vents
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Gaskets
(not in scale)
Polycarbonate panels mounted in the area of the vent base
700 mm / 1050 mm / 2100 mm
wide polycarbonate panels
Polycarbonate panels mounted on
both sides of the vent
Polycarbonate panels
mounted below the vent
Polycarbonate strips mounted
under the vent supporting frame
- polyester panels (rooflights with Broof(t1) class) (dimensions the same as polycarbonate panels),
- ø 6.3x32 mm self-drilling screws,
- ø 5.5x 32 … 50 mm pan head sheet metal screws,
- ø 5.5x 38 … 55 mm countersunk sheet metal screws,
- PES 40x3 tape.
SIM gasket pressed
into the pressing profile
JP-EPDM gasket
(of the edge profile) supplied in sections
Masking gasket of the end panel
(tympanum panel)

Installation manual of mcr PROLIGHT continuous rooflight with smoke vents
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Vents
Arc-shaped support made of steel
(for installation of opening
mechanisms of the smoke vent)
Single-leaf smoke vent
Double-leaf smoke vent

Installation manual of mcr PROLIGHT continuous rooflight with smoke vents
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Opening mechanism of
double-leaf smoke vent
Opening mechanism of
single-leaf smoke vent
Control system for natural ventilation vent
with type E actuators from K+G
(shown is a double-leaf system)
Control system for natural ventilation
vent suitable for JMBx actuators from Jofo
(shown is a single-leaf system)

Installation manual of mcr PROLIGHT continuous rooflight with smoke vents
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Protective elements
a. Safety net resistant to 1200J impact
Safety net bracket
Safety net
b. Pipe-type anti-burglar grid
Grid supporting profile
Cover for grid supporting profile
Grid stiffening profile
Cover for grid stiffening
Grid pipe
c. PAS anchor point
( MCR-PP-PAS-1.1 personal anchor point )

Installation manual of mcr PROLIGHT continuous rooflight with smoke vents
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Components of sandwich panels
PE (polyethylene foam) strips fitted
in the C-shaped spacers.
Two types of brackets
(so-called C-shaped spacers)
mounted on the vent support frame.
An appropriate bracket should be chosen
to suit the bearing profile.
Expanding sealant tape supplied in a
roll, for the N60 profile use the seal
25/25 (6,6 m/roll), for the N80 profile,
the seal 15/40 (4,3 m/roll).
Expanding sealant tape after
application expands vertically from
the initial height of 4-8 mm to 25 mm
- for N60 profiles and from 7-12 mm
to 40 mm for N80 profiles. The time of
expansion depends, to a large extent,
on the ambient conditions. At high
temperatures less time is needed.
Additional insulation
Auxiliary components for vent supporting frame

Installation manual of mcr PROLIGHT continuous rooflight with smoke vents
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PCA panels with separators
Masking gasket for tympanum panel
The masking gasket is
pressed under the pressing
profile in the SIM gasket
groove. The tail of the gasket
extends to the vertical
surface of the tympanum
wall of the rooflight.
Polycarbonate panels with adhered
separators –this applies only to
certain configurations with sandwich
panels.

Installation manual of mcr PROLIGHT continuous rooflight with smoke vents
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II. Installation of the rooflight base
The rooflight base is supplied in pieces.
12 3
6
5
74
8
9
1. Tympanum wall base,
2. Longitudinal base,
3. Tympanum connector,
4. Longitudinal base connector,
5. Corner connector,
6. Bracing of the base,
7. Fasteners (M10x20 bolts, washer, M10
nylon lock nut), Fasteners (for spans up to
4 m): - self-drilling screws, ø6.3x19 mm
and ø 6.3x22 mm (self-supporting base)
–4 pcs per side per bracing, for spans in
excess of 4m –self-drilling screws ø 6.3x22
mm, ø 6.3x25 mm (self-supporting base)
–6 pcs per side per bracing.
Figure 1 Rooflight base components
1. Check the size of the clear opening prepared for rooflight installation.
2. Lay out the base components according to the following drawings.
2
1
3
3000 lub 2500 3000 lub 2500 3000 lub 2500 A
6a 6b 6c
1. Tympanumbase,
2. Longitudinal base,
3. Longitudinal base –end module
(A = to suit the rooflight length),
6a. Bracing to be placed at contact line between
two base pieces (if PCA 10 or 16 mm),
6b. Additional bracing (if PCA 20 or 25 mm
or skylight width >=5.5 m),
6c. Additional bracing (if A>1.5 m).
Figure 2 Arrangement of the base components (when the rooflight is built on the roof slope or along the roof ridge)
3000 or 25000
3000 or 25000
3000 or 25000
1
3000or 25000
2
3
6a
6b
6c
3000 or 25000
3000 or 25000

Installation manual of mcr PROLIGHT continuous rooflight with smoke vents
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1. Tympanumbase,
2. Longitudinal base,
3. Longitudinal base
–roof ridge module
(B = to suit the rooflight length),
6a. Bracing to be placed at contact
line between two base modules
(if PCA 10 or 16 mm),
6b. Additional bracing
(if PCA 20 mm or 25 mm
or rooflight width >= 5.5 m),
6c. Supplementary bracing
(if A > 1.5 m).
Figure 3 Arrangement of the base components (when the rooflight is built across the roof ridge)
3. The rooflight base should be mounted on the prepared roof curb/ framework/ trimmers using fasteners
adequate to the frame/ curb material. Adequate fasteners include: Ø5,5 mm or Ø 6,3 mm self-drilling
screws, Ø6 mm wood or metal screws/ bolts, Ø8 mm expansion plugs. The intervals between adjacent
fasteners should not exceed 50-60 cm.
4. The adjacent base components should be connected with connectors (3 or 4) and M10x20 bolts with a
washer and nut. In self-supporting rooflights, the number of connectors is doubled, and they are arranged
in two rows.
5. The tympanum bases should be placed with the edges parallel to each other on an even, horizontal
surface. Next, connect them together using an adequate end base connector and M10 fastening kit.
Now attach/ connect the vertical end panel base, prepared/ assembled as described above, to/with the
longitudinal base piece.
Attention! If the elements of the base are not installed exactly in parallel, there is a risk that the
tympanum end cannot be installed properly!
2
4
6a
6b
6c
4
2
1
3000or 25000
1
3000or 25000
3000 or 25000
3000 or 25000
3000 or 25000
3000 or 25000
ridge

Installation manual of mcr PROLIGHT continuous rooflight with smoke vents
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Figure 4 Assembly of the end panel base
6. Verify clear the opening dimensions of the rooflight base.
7. Mount the corner connectors at the joint between the longitudinal base and the tympanum base.
1. Tympanum base piece,
2. Longitudinal base piece,
3. Corner connector,
4. Fasteners (M10x20 bolt, washer, nut).
Figure 5 Connection of the tympanum base with the longitudinal base pieces (corner)
8. Install bracings at the contact line between two base modules using the following fasteners:
- for spans up to 4m, use fasteners Ø 6,3x19 mm, Ø 6,3x22 mm, and use 4 pcs per side per bracing,
- for spans over 4m, use fasteners Ø 6,3x22 mm, Ø 6,3x25 mm, and use 6 pcs per side per bracing.
IMPORTANT: Edges must be parallel!
IMPORTANT: Edges must be parallel!
4
1
2
3

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Additional bracing should be installed at the middle of the base module length. Additional braces are
used for rooflights with 20 mm and 25 mm thick PCA sheets and any rooflight >= 5,5 m wide.
The connectors should be the same as for the bracings.
Supplementary bracings should accompany the additional bracings if the ridge modules or end modules
are longer than 1,5 m. The connectors should be the same as for bracings.
For self-supporting bases, bottom bracings should be used at contact lines between base modules.
1. Longitudinal base module,
2. Tympanum base module,
3. Upper bracing,
4. Lower bracing.
Figure 6 Example of bracing installation in the self-supporting rooflight base
9. Once the base has been assembled, thermal insulation and waterproofing barrier can be installed. The
roof design documentation must be taken into account. Most often, thermal insulation and waterproofing
barriers are installed by the company responsible for the installation and insulation of the roof structure.
1. Rooflight base,
2. Thermal insulation of the rooflight base,
3. Roof waterproofing system,
4. Thermal insulation of the roof,
5. Roof structure.
Figure 7 Typical thermal insulation and waterproofing method
IMPORTANT: In the course of works, the waterproofing barrier may be overlain several times at the base corners.
During waterproofing work verify that the difference in level on the top of the uppermost layer between the base corners
and the centre of the end panel base does not exceed 10 mm.
(See Figure 24 Installation of edge profiles, according to the attachment to the installation manual.)
Do not install the top section of the rooflight if the difference in level exceeds 10 mm.
4
3
1
2

Installation manual of mcr PROLIGHT continuous rooflight with smoke vents
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10. After the base has been insulated and waterproofed, you can proceed to further assembly of the
continuous rooflight.
a/ the bottom line of the tympanum wall is horizontal
b/ different angles of the tympanum wall bottom and the roof ridge
c/ the same angles of the tympanum wall bottom and the roof ridge
Figure 8 Shapes of the tympanum wall of the roof ridge rooflight

Installation manual of mcr PROLIGHT continuous rooflight with smoke vents
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III. Installation of an overlay base
1. Plinth,
2. Tympanum wall piece,
3. Longitudinal side of the overlay base,
4. Longitudinal side of the overlay base –
end piece.
Figure 9 Arrangement of the overlay base on the on-site roof plinth
1. Roof structure and plinth,
2. Thermal insulation,
3. Waterproofing barrier,
4. Overlay base,
5. Expansion plug,
6. Washer,
7. Hexagonal head screw.
Figure 10 View of overlay base showing spacing of fasteners
Figure 11 Cross-section of overlay base mounted on concrete plinth
1. Check the clear size of the opening prepared for rooflight installation.
2. Lay out the overlay base components on the plinth sides according to (Figure 9 Arrangement of the
overlay base on the on-site roof plinth). Apply PES 40x3 or PES 20x5 tape on the curb.
3. The rooflight base should be mounted on the prepared roof plinth using fasteners appropriate to the
plinth material/ structure. (Table 1 Diameters of screws, lengths of expansion plugs and their distances
depend on the material of base).
4. Place the fasteners on the base sides as per the prepared diagram. In the absence of such a diagram,
place the fasteners at an equal distance in the range of 500-600 mm (Figure 10 View of overlay base showing
spacing of fasteners).
1
3
4
2

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5. Place the fasteners in two rows as shown in mm (Figure 11 Cross-section of overlay base mounted on
concrete plinth).In the case of narrow plinths it is allowed to place the fasteners in one row.
Then the intervals between fasteners must be reduced to 300 - 400 mm.
6. Always place washers under the screw heads.
Note: fasteners are not part of the rooflight kit.
Table 1 Diameters of screws, lengths of expansion plugs and their distances depend on the material of base
Base material
Characteristic dimension
Min. screw diameter
L
A
B
[mm]
Concrete
6
>80
>40
500 - 600
Wood
6
>60
>20
Steel
5,5
~15
>15

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IV. Installation of a safety nets / an anti-burglar grids
Rooflights of up to 3,6 m in width can be equipped with safety nets protecting from fall the of a large soft
body, while security bars can be installed in rooflights up to 6 m wide. Depending on the planned protection
system, the safety nets and bars can be installed solely under the vents or under the entire top section of the
rooflight. Safety nets and bars can be installed only in continuous rooflights with an upright base made of
sheet metal with min. 2 mm thickness.
A. Installation of a safety net
1. The safety net can be installed once the base has been installed.
Fix the brackets at their lower part to the base with a 1 screw first and place the mesh on them:
(Figure 12 Method of mounting the safety net brackets on the base).
The brackets should be spaced at the intervals defined in (Figure 13 Installation of the safety net under the
vent (the opening mechanism does not reach to the top edge of the rooflight base))Figure 13 Installation
of the safety net under the vent (the opening mechanism does not reach to the top edge of the rooflight
base). Then bend and screw the upper parts of the brackets. For fixing brackets to the vertical wall of the
base, use Ø6.3x22 mm self-drilling screws (6 pcs per one bracket: 1 pcs for the lower part and 5 pcs. for the
upper part).
Figure 12 Method of mounting the safety net brackets on the base
1. Rooflight base or plinth,
2. Safety net bracket,
3. Self-drilling screw Ø 6,3x22 mm,
4. Safety net.
Bend the console according to the direction of the arrow
2
2
1
1
3
3
4
4