Phoenix Solar TectoFlat User manual

TECTOFLAT INSTALLATION INSTRUCTIONS
Status 09/11 – Subject to errors and technical modifications
Phoenix Solar AG, Hirschbergstrasse 8, 85254 Sulzemoos, Germany, Phone [phone] - 130, Fax [phone] -
198
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Installation Instructions
Phoenix TectoFlat

The special features at a glance:
Variability:
- Suitable for all common framed modules (width between 800 and 1050 mm)
- Suitable for MiaSolé and First Solar modules
- May be used on all common types of flat roof: concrete, membranes, bituminous
sheeting, gravel, profiled metal decking for roof pitches of up to 10°
- Module tilt angle between 15° and 29°, incrementally adjustable
Weight optimisation:
- Low point loads due to even load distribution on the roof and aerodynamic
design
- Particularly suited for roofs with low load reserves
Installation:
- Fast installation thanks to pre-assembly and low number of individual parts
- No roof penetrations (except with profiled metal sheet roofs)
Quality and price:
- Low costs thanks to the use of innovative and proven materials
- Wind tunnel and structural tests by independent institutes confirm secure
stability
- Material guarantee: 10 years
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CONTENTS
PAGE
1. Safety instructions..............................................................................................................4
2. Tools required.....................................................................................................................5
3. Required documents ..........................................................................................................5
4. Overview of the components..............................................................................................5
5. Pre-assembly......................................................................................................................7
6. Adjusting the tilt angle ........................................................................................................8
7. Installation instructions.......................................................................................................9
8. Lightning protection..........................................................................................................15
9. Standards and regulations................................................................................................18
Appendix A Installation of MiaSolé and First Solar modules ................................................17
Appendix B Installation on trapezoidal sheet metal..............................................................23
Appendix C Installation of wind detector shield……………………….…………………………27
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1. Safety instructions
A PV system increases the structural load on a building.Therefore, the building to be covered must
be checked for sufficient load reserves.
For membrane roofs, follow the membrane manufacturer's special instructions.
For roofs with insulation under the waterproofing or for inverted roofs, the maximum permissible
point load on the insulation material must be observed.
All work on solar modules is work on live electrical components. The full open-circuit voltage of th
solar modules can be generated
e
as soon as light shines on them. The only way to achieve zero
ge range. In these cases, please
three metres, appropriate safety mechanisms must be installed to
verters and the public mains grid must be performed by a
qualified and approved electrician.
hoenix Solar AG is not liable for services provided by third parties, in particular planning and other services.
voltage is to cover the modules.
The maximum permissible system voltage of the solar system must never be exceeded.
When working in the vicinity of electrical overhead lines, or with string open-circuit voltages
exceeding 120 V DC, you are no longer within the safe low volta
be sure to observe the special accident prevention regulations.
Electrical work must always be performed using insulated tools.
When working at heights above
prevent personnel from falling.
The electrical installation between in
LIABILITY NOTICE:
P
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2. Tools required
Tape measure / folding ruler
Tension string
Hexagon key with spherical head (size 6)
Spanner (size 13)
Ballast plan
t in all cases be checked by an external
ructural engineer. Phoenix Solar AG bears no liability for these services.
of the components
3. Required documents
Roof coverage plan
The roof coverage plan is used to position the modules on the roof. The ballast plan describes the position and
quantity of the weights required to ensure stability. Your personal Phoenix contact will support you in completing
these plans. The implementation of the roof coverage and ballast plan mus
st
4. Overview
Triangular set
with elevation rail 380 (short) with elevation rail 540 (long)
190196 Pre-assembled 190197 Pre-assembled
260266 In individual parts 260279 In individual parts
90150
Wind deflector 380 261119 Wind deflector 540
Wind deflector
1
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Connectors
190140 Connector 280 190148 Connector 750 190148 Connector 1050
260289 Wind deflector fastening set 260295 M8 screw set 260585 Edge clip
Note:
These instructions describe how to install the TectoFlat for framed modules.
Further information for frameless modules by First Solar and MiaSolé is available in Appendix A. The instructions for
the installation on trapezoidal sheet are described in Appendix B.
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5. Pre-assembly
Screw the components tight by hand (tightening torque 1 Nm) using three M8 x 16 screws and three M8 nuts as
shown in the following figure. Slide inner and outer cross beams together. For pre-assembly with rigid cross beams,
see Appendix A.
190142 380 elevation rail or
190143 540 elevation rail
3x M8 screw set
190144 Inner cross beam
190145 Outer cross
beam
190152 Rear ground joint
190141 Bottom rail
190152 Front ground joint
Figure 1: Pre-assembly of framed TectoFlat triangular set
The front ground joint should always be attached to the third hole of the series of three holes in the bottom rail (see
Figure 1). Make sure the ground joints are oriented correctly: the ground joints are correctly installed when the upper
ends of the elongated hole point outwards.
The hole you need to use from the right hole pattern in the bottom rail will depend on the desired tilt angle. For more
information, see Table 1 in the next chapter "Adjusting the tilt angle".
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6. Adjusting the tilt angle
The tilt angle of the module can be adjusted in two ways:by adjusting the distance between the ground joints and
using elevation rails of varying lengths. The elevation rail is available in two variants: 380 and 540. They vary in
length. See dimension A in Figure 2 and Table 1. Several different module tilt angles are possible for each elevation
(see Table 1).
Figure 2: Dimensions and tilt angle
Module width W [mm] 800 1,000 1,000
Elevation rail A [mm] 540 540 380
Hole spacing X [mm]
1,100 28.3° 29.1° 20.2°
1,150 25.7° 28.0° 19.1°
1,200 22.7° 26.7° 17.6°
1,250 25.1° 15.7°
1,300 23.3°
Tilt angle α[°]
1,350 21.3°
Table 1: Possible module tilt angles of framed modules
In case of strongly differing module widths, the tilt angle can generally be calculated using the law of cosines:










)30(2 )30(
arccos 222
WX AWX

Note: Framed modules with a width of between 800 and 1,050 mm can be installed.
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7. Installation instructions
7.1 Preparation
Two triangular sets are required for each module. The TectoFlat mounting system is first connected to the solar
module before it is put in its final position on the roof. It is recommended that you use a workbench allowing you to
work in a comfortable posture.
Note: The workbench should be made of wood or plastic so the PV module does not become scratched.
Two blocks of wood can also serve as a workbench.
Important: Protection mats and large-sized formwork panels should be placed under and around the workbench
and over frequently used roof areas to protect the roof membrane and insulation. This applies, in particular, to
membrane roofs (with insulation under the waterproofing) and inverted roofs.
Place the solar module with the reverse side facing upwards on the workbench and attach it to two triangular sets
each with two M8 screw sets (tightening torque 12 Nm).
2
1
Figure 3: Module assembly on workbench
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Unfold the triangular set and first fasten the screw to what will later be the top edge of the module (1). Then fasten
another screw to what will later be the bottom edge of the module (2) (see Figure 3). To improve accessibility of the
screw, lift the ground joint to one side (see Figure 4).
Figure 4: Lifted ground joint for attaching the module
Important: Make sure the connection socket is in the correct position in order to guarantee problem-free module
wiring at a later stage (see Figure 5).
Figure 5: Position of the connection socket
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Attention: When hole diameters in the module frame are too small, an M6 screw set (Art. no. 260296) should be
used instead of an M8 screw set. In this case, use the smaller hole in the cross beam.
Now tighten all screws in the triangular sets firmly with a tightening torque of 12 Nm. It is important to ensure that the
contact surface of the ground joints runs parallel to the bottom rail. The parallel position is achieved by itself when
the ground joint is set to the lowest position on the height adjustment.
Then lift the module off the workbench and place it in its final position according to the roof coverage plan.
Note: A plumb line can help you position the modules precisely.
1.5 m
1.5 m
10 mm
Figure 6: Clearance and minimum distance to roof edge
A clearance of at least 10 mm should be kept between two modules. You should ensure a minimum distance to the
roof edge of 1.5 m (see Figure 6).
In the event that a ground joint is not in contact with the roof surface due to uneven roof surfaces, loosen the screw
attached to the ground joint and adjust the position of the screw by moving the elongated hole in the ground joint
(see Figure 7). This can compensate for a height difference of up to 30 mm.
30 mm
25 - 55 mm
Figure 7: Compensating for uneven surfaces
The clearance between the roof covering and the bottom rail is between 25 and 55 mm.
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7.2 Module wiring
Cable the modules immediately after mounting them. Wire the module according to the wiring diagram. Cable ties
with clips are available to bundle the strings in a west-east direction. They can be attached either to the module
frame or the inner cross beam.
Note: Measure the open-circuit voltage and insulation resistance of every string immediately after installation. This
allows potential mistakes and their sources to be quickly identified.
7.3 Mounting the ballast
Note: Concrete paving stones are required as ballast. These are not included in the TectoFlat scope of delivery.
All types of concrete paving stone may be used which are frost resistant in accordance with DIN EN 1338 class 3
(D).
The quantity and position of the weights can be taken from the ballast plan. The ballast plan should be checked for
accuracy by an independent structural engineer. In order to affix the ballast, place two 1050 connectors over the
bottom rail and cover them with paving stones in such a way that they are framed by the two profile rails.
Two connectors together should not bear more than 30 kg in weight. Use two additional connectors if you have
higher ballast requirements. For loads of over 50 kg per module, the bottom rails should be supported with protection
mats, so that they only bend to a maximum degree of 5 mm.
Clamp edge clips to the bottom rail on the outside next to the connectors, in order to prevent the connectors from
sliding apart (see figure).
Figure 8: Affixing the ballast with 2 x 21.6 kg
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7.4 Attaching the wind deflectors
Please see appendix C for installation of wind deflector set 540 (art. no. 261119)
In addition to its aerodynamics effect, the wind deflector is used to connect the modules to each other in a west-east
direction. Start at the end of a row by placing a wind deflector in the notches of the elevation rail, flush against the
edge of the module. Affix the wind deflector to the upper end of each triangular set using a wind deflector attachment
set by clamping it in place.
Figure 9: Wind deflector attachment
The wind deflector is 2.08 m long, i.e. it is higher than a standard module (about 1.65 m long). In the event that the
wind deflector extends beyond the elevation rail of the adjacent module, the next wind deflector can be attached
overlapping that elevation rail and the two wind deflectors can be connected together by clamping (see Figure
10).
Figure 10: “Overlapping” option Figure 11: “Screwing” option
Another way to connect the wind deflectors together is to screw them together using the holes in the corners of the
wind deflectors (see Figure 11).
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7.5 Connecting the module rows together
In order to connect the modules to each other, a connector and two M8 screw sets are required. The distance
between the rows can be adjusted using the holes in the bottom rail.
Figure 12: Attaching the connector
The bottom rail of the modules in the corner of the roof (red area in
Figure 13) should all be connected to connectors. In the edge area (yellow area in
Figure 13), one bottom rail for each module should be installed. In the remaining roof area, connecting every fourth
bottom rail is sufficient.
Figure 13: Overview of attachment of connectors
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8. Lightning protection
8.1 External lightning protection and grounding
If the building is equipped with an external lightning protection system then the solar system must be connected to it
over the shortest possible path (according to DIN VDE 0185 Lightning Protection System). If this is not possible then
(with reference to the regulations for antenna systems) this conductor can be connected internally through the
building – but not through rooms and areas containing inflammable or explosive materials. To avoid flashover and
induction dangers, the conductor must be kept away from other electrical circuits.
To avoid lightning flashovers, make sure to maintain a separation distance between the solar energy system and the
lightning conductor.
Calculation of the separation distance:
S = ki* (kc / Km)* i (m)
S = separation distance
kc = coefficient, dependent on the geometric arrangement
ki = coefficient, dependent on the selected lightning protection class
Km = coefficient, dependent on the material in the separation
If the building does not possess a lightning protection system then it is currently a matter of contention as to whether
the DIN VDE 0855 standard can be applied to solar systems. If this standard is used, the mounting system and the
module frames must be grounded. If the DIN VDE 0855 standard is not used then the solar generator does not need
to be grounded. However, connection to the building grounding is always recommended. Conversely, when using
transformerless inverters (e.g. with all SMA inverters with a "TL" suffix in the product name) all conducting parts of
the solar system and the mounting system must be grounded. If the system is not grounded then this can result in
capacitive voltages that are dangerous to humans. The grounding can be achieved (e.g.) via the system connection
to the equipotential bonding bar of the house or via an external grounding stake.. Type NYM-J or NYY-Y grounding
cables with a minimum cross section of 16 mm² satisfy the current regulatory requirements. The grounding device to
which the solar system is connected must be tested for correct operation.
werden. The results of this test should be recorded in a test or commissioning log for the system.
8.2 Internal lightning protection – Overvoltage protection
The internal lightning protection minimises damage caused by overvoltages that may occur. Impermissibly high
voltages at the solar modules can be reduced via simple measures when laying the module cables. In the case of a
lightning strike near to the solar modules the extremely high rate of change of current from the lightning can induce
high induction voltages across the mounted modules and module cables.
Attention: The larger the effective area generated by the modules and cables, the higher the induced voltage.
This type of overvoltage can be reduced through careful consideration when laying the DC cables.
Figure 14 shows an unsuitable cable layout that can result in very high induction voltages capable of destroying the
solar modules and the inverter. Figure 16 shows a correct cable layout that reduces the effective area generated by
the cables and thus reduces the danger to the solar modules and inverter.
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Figure 14: Incorrect cabling without row connectors Figure 15: Correct cabling with row connectors
Surge arresters at the solar generator and the inverter can also help to reduce overvoltages. Inverters usually have a
built-in varistor for limiting overvoltages.
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9. Standards and regulations
The recognized engineering standards and the relevant accident prevention regulations must always be followed
when installing a solar system. The following rules, regulations and standards must be followed:
BGV A1 Accident prevention regulations
BGV A2 Electrical systems and equipment
BGV C22 Construction work
BGV D35 Ladders and steps
DIN VDE 0100 Erection of low voltage plants
DIN VDE 0126 Solar energy systems for domestic use
andards
on work
works
ss
on of photovoltaic power generation systems with the low
TAB Technical connection requirements for connecting to the low volt e grid of the energy supply
companies
ZVDH regulations issued by the Central Association of the German Roofing Trade
DIN VDE 0185 Lightning protection st
DIN 1055 Design loads for buildings
DIN 18299 General rules for all types of constructi
DIN 18338 Roof covering and roof sealing
DIN 18451 Scaffolding work
DIN 18800 Steel construction
DIN EN 60728-11 Safety requirements for cable networks and antennae
DIN EN 516 Installations for roof acce
VDEW guideline for parallel operati
voltage grid of the energy consumer
VDE 0100 section 410 Grounding
VDI 6012 Decentralised energy systems in buildings
ag
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Appendix A: Installation of MiaSolé and First Solar modules
Laminate clamp sets
260291 First Solar end clamp set 260294 First Solar central clamp set
260292 MiaSolé end clamp set 260293 MiaSolé central clamp set
Pre-assembled triangular sets
190198 Triangular set for First Solar with 380 elevation rail
190199 Triangular set for First Solar with 540 elevation rail
190200 Triangular set for MiaSolé with 380 elevation rail
190201 Triangular set for MiaSolé with 380 elevation rail
Non pre-assembled triangular sets
260286 Triangular set for First Solar with 380 elevation rail
260288 Triangular set for First Solar with 540 elevation rail
260282 Triangular set for MiaSolé with 380 elevation rail
260284 Triangular set for MiaSolé with 540 elevation rail
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Pre-assembly
190146 FS (First Solar) cross beam
or 190147 MS (MiaSolé) cross beam
Pre-assembly of frameless TectoFlat
Adjusting the tilt angle
Figure 16: Dimensions and tilt angle
Module type First Solar MiaSolé
Elevation rail A [mm] 380 540 380 540
Hole spacing X [mm]
1,250 17.4 24.8
1,300 17 24.3
1,350 16.3 23.6 15.9
1,400 15.3 22.6 15.7 22.3
1,450 14 21.6 15.2 21.8
Tilt angle α[°]
1,500 12.3 20.3 14.5 21.1
Table 2: Possible module tilt angles of laminate modules
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Installation
For installation purpose, we recommend an installation template which ensures that the specified clamping areas are
maintained (not included in the scope of delivery).You will find drawings of these templates at the end of this
appendix.
Figure 17: Workbench with installation template
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