Mounting Systems Premium Series User manual

FD3-S Premium Line
Installation Manual

Content
1. Introduction 3
1.1 Short description 3
1.2 About these instructions 3
1.3 Warning 4
1.4 Safety 4
1.5 Tools 4
2. Basic information about system 5
2.1 Elements and components 6
3. Assembly
3.1 Universal central and end support 8
3.2 Front support 9
3.3 Rear support 10
3.4 Connecting rails 11
3.5 End of the rail connection 12
3.6 Rail layout 13
3.7 Ballast tray 14
3.8 Adapter wind deflector 16
3.9 Assembly of modules and side covers 17
3.10 End clamp 18
3.11 Middle clamp 19
3.12 Wind deflector 20
3.13 Top rail cover 21
2023-08-03 FD3-S Installation Manual

3
FD3-S Premium Line
1. Introduction
1.1 Short description
The FD3-S flat roof system is a heavy-duty frame
solution designed for mounting PV modules on flat
roofs. Several rows of modules in an south orientation
can be connected with the FD3-S system. The system
is tilted by 10° or 15° as standard. The FD3-S system is
built in connection with the total area of modules of at
least 10 m2. This solution has been specially developed
for applications on flat roofs with a low permissible
load. All elements have been designed as easy to
assemble. The elements used are made from aluminum
and stainless steel. The selected materials used for the
system guarantees a high resistance to corrosion, while
at the same time oering the possibility of full disposal.
1.2 About these instructions
Subject of instructions
These instructions describe the installation of the
FD3-S system for flat roofs and contain all the
information for this solution in terms of planning,
components and safety instructions. The pictures
in the first part of the manual show installation with
frame modules locked in the corners.
Co-binding documents
In addition to this document, each delivery includes
the ‘Montageanleitung allgemein’ [General Assembly
Instructions], which can be found at www.mounting-
systems.com, this document provides general
information on standards, safety, transportation,
maintenance, disassembly, and disposal for systems.
Both these instructions and the aforementioned
document comprise a permanent part of the FD3-S
assembly system and must be observed during all
assembly work.
Please read both, this installation manual and the
above mentioned documents carefully prior to any
installation, maintenance or disassembly work. You will
be provided with all information for safe and complete
installation, maintenance and disassembly. However,
if you have any questions after having read these
documents, please contact Mounting Systems GmbH.
User group
These installation instructions are intended
for the following persons (user group):
· Skilled stu
· Instructed stu
Skilled stu
Are persons who, on the basis of their professional
training, are able to execute installation, maintenance
and disassembly work properly.
Instructed stu
Are persons who have been instructed and taught
appropriately regarding the assigned tasks and the
possible risks in the event of improper conduct. An
instructed person must have received instructions
regarding the required safety devices, precautions,
relevant regulations, accident prevention regulations
as well as operating conditions and must have
demonstrated their competence.
The implemented work must be inspected and
accepted by skilled personnel.
Guidance notes
The following guidance notes enhance the orientation
when handling this installation manual:
Pictograms:
This symbol indicates important
information and useful tips.
This symbol indicates ways and means
to make the installation process easier.


1.3 Warnings
The following warnings are used in these Installation
Instructions to indicate safety-related information.
They include:
· Warning symbols (pictograms)
· Signal words which identify the hazard level
· Information about the type and source
of the hazard
· Information about the potential consequences
if the hazard is disregarded
· Measures for the prevention of hazards and the
prevention of injuries or damage to property.
The signal words of the warnings respectively
indicate one of the following hazard levels:
1.4 Safety
All universally valid safety instructions for products of
Mounting Systems GmbH are listed in the document
‘Montageanleitung für PV-Gestellsysteme: allgemeiner
Teil’ [“Installation manual for PV mounting systems –
general part”. Please read this document carefully and
observe the instructions given therein: Do not use
the product in a manner other than intended, please
comply with the obligations of the owner and observe
all general and specific safety instructions.
In addition, please observe the specific safety
instructions given in this installation manual for all
installation work. The specific safety instructions are
positioned in each case directly with the respective
installation step.
Danger!
Indicates a potentially mortal danger,
disregard for which may result in
death or serious injury.
Attention!
Indicates a potentially dangerous
situation which may result in serious
injury or damage to property.
1.5 Tools
1 Tape measure
2 String
3 Torque wrench with Allen socket
4 Measure of distance (optional)
5 Sheet metal shears
   

FD-South x
°






5
FD3-S Premium Line
2. Basic information about the system
FD-S °
Modulsize
Max. width: mm
Max. length: mm
Distance between the rows: mm
FD-S °
Modulsize
Max. width: mm
Max. length: mm
Distance between the rows: mm











Installation manual
2.1 Elements and components
Base rail
° mm (-)
° mm (-)



Locking front support 250mm (600-0365)
Connecting profil south 585mm (600-0371)
Connecting rail 1025mm (600-0370)
Connecting rail 1475mm (600-0374)
Connecting rail 1293mm (600-0375)
Front support (814-0703) Rear support (711-0260)
Ballast tray
1831mm, max. 120kg (801-0373)
2037mm, max. 120kg (801-0374)
2171mm, max. 120kg (801-0375)
2327mm, max. 100kg (801-0384)
Adapter wind deflector
40mm (600-0361)
Ball locking pin
x (807-0351)

 

Side reflector ° right (-)
Side reflector ° right (-)
Side reflector ° left (-)
Side reflector ° left (-)
7
FD3-S Premium Line
 
End clamp
30-40mm (702-0478)
40-50mm (702-0479)
Middle clamp
30-40mm (700-0273)
40-50mm (700-0274)

Back Windreflector mm (-)
Back Windreflector mm (-)
Back Windreflector mm (-)
Back Windreflector mm (-)
Rail cover south ° mm (-)
Rail cover south ° mm (-)
Rail cover south ° mm (-)

Protection mat 250 mm (814-0704)

Washer M (807-0315)

Sheet metal screw
,x (806-0520)
Cylinder head screw
Mx (806-0340)


Installation manual
3. Assembly
3.1 Universal central and end support – 10° & 15°
Fold the feet down and secure with two ball locking pins (7) to desired positions 10° or 15°.
See designation.
CLICK
CLICK


10°
15°

9
FD3-S Premium Line Montage
3.2 Front support

. Install the front support (5) in the cutouts
at the side edge of the base rail (1)
. Lock together with the rail (2). Assembling the protection mat
CLICK
At the beginning of the system
lock with component (2)

 









up to an audible clickPprotection mat beneath the
front and middle support


. Lock the rear support (6) with the connecting rail (3)
up to an audible click
CLICK



assamble protection mat


3.3. Rear support
. Place the rear support (6) in the cutouts
. Place the front support (5) in the cutouts. See page 20.
°°
Front support rotated 180° for back wind deflector for



11
FD3-S Premium Line
3.4 Connecting rails
1. Slide in
Connecting rail
up to an audible click
assamble protection mat
CLICK







 Installation manual
 Lock together with the locking rear support (4)
At the end of the system
lock with component (4)




3.5 End of the rail connection

assamble protection mat
Overview of the rails in a row
 -  -  -  - 
for further rows always put (3) and (1) in a row




  

13
FD3-S Premium Line
3.6 Rail layout
Place the rails parallel to the length of the module.
Rail spacing = Module length Rail spacing = Module length Rail spacing = Module length
Distance gauge
Rail spacing = Module length


3.7.1 Ballast tray for multi-row arrangement tray
Note the maximum weight
per ballast tray
The number, position and weight of the
necessary ballast (stones or gravel) should
always be included in the project information
Order
First, place a narrow
side on the outside



. Insert the ballast tray (8) diagonally
. Slide in
3. Fixing between support
  
schmale: mm
breite: mm

Hole marked
the wide side
Installation manual

15
FD3-S Premium Line
. Press the flap down
For the first and last ballast
tray (8), press the flap to
be locked in the rail.
Place further ballast trays
on and press down only one flap.

. Apply ballast evenly, from the outside to the inside
Cover the openings
with paving slabs
Paving slabs or
cobblestones
Gravel
Note the maximum weight
per ballast tray
Ballast must be put in the ballast tray starting
from both ends in parallel at the same weight
volume. Ballast must be evenly distributed.



3.7.2 Ballast tray for single row arrangement
Note the maximum weight
per ballast tray
The number, position and weight of the
necessary ballast (stones or gravel) should
always be included in the project information
schmale: mm
breite: mm
Installation manual
Order
First, place a narrow
side on the outside
9

Hole marked
the wide side.
The overhang of the
ballast tray depends
on the module width
. For later installation
of the side plate, the ballast tray
must be cut to length
flush with the rail.
. Insert the ballast tray (8) diagonally, see chapter 3.7.1

17
FD3-S Premium Line
. Press the flap down
For the first and last ballast
tray (8), press the flap to
be locked in the rail.
Place further ballast trays
on and press down only one flap.

. Apply ballast evenly, from the outside to the inside
Cover the openings
with paving slabs
Paving slabs or
cobblestones
Gravel
Note the maximum weight
per ballast tray
Ballast must be put in the ballast tray starting
from both ends in parallel at the same weight
volume. Ballast must be evenly distributed.


 Installation manual
3.8 Adapter wind deflector
Mount on the middle support.
For the ° variant, the adapter (9) must be rotated by °.
South °
South °
°
South °
South °



Tighten with a torque of 8Nm.

19
FD3-S Premium Line
°
°
3.9 Assembly of modules and side covers
The side deflector is locked with the
end clamp (17) locked. See next page
. Arrange modules
. Insert in and fix the right (10) and left (11) side deflector


Make sure the noses of the
side deflector have been
placed in the correct position,
to ensure a correct grip.
 
Tighten with a torque of 8Nm.


Make sure that the bottom
of the end clamp (17) is against
the side deflector.
End clamp 30-50mm
3.10 End clamp
Installation manual
