Qcells Q.FLAT-G6 Flat User manual

INSTALLATION AND
OPERATION MANUAL
Q.FLAT-G6 Flat roof system for south orientation

2INSTALLATION AND OPERATION MANUAL FOR FLAT ROOF SYSTEM Q.FLAT-G6 – Q CELLS
1 CONTENT
1 GENERAL SAFETY INFORMATION 3
2 REQUIRED MATERIAL 4
3 REQUIRED TOOLS 5
4 ASSEMBLY 6
4.1 LAY OUT BASE PROFILES A AND B;
CONNECT AND ERECT 7
4.2 ASSEMBLE THE CENTRE COMPONENTS
TOWER C AND THE REAR PANEL TOWER H. 8
4.3 MOUNT CONNECTING COMPONENT CROSS
BRACE AND BALLAST BRACE D 9
4.4 OPTIONAL STEP 10
4.4.1 CABLE DUCT COVER O110
4.4.2 BALLAST BLOCK O211
4.4.3 BALLAST TROUGH TYP V01 O413
4.4.4 BALLAST TROUGH TYP V02 O414
4.5 FIT MIDDLE AND END CLAMPS F AND
SCREW MODULES TOGETHER 15
4.6 REAR PANEL 16
4.7 OPTIONAL STEP 17
4.7.5 MOUNTING THE SIDE COVER O517
5 FINAL INSPECTION 18

3INSTALLATION AND OPERATION MANUAL FOR FLAT ROOF SYSTEM Q.FLAT-G6 – Q CELLS
Please note that our general safety information must be observed. First read through the general safety instructions
and the assembly instructions.
1 GENERAL SAFETY INFORMATION
ÎThe current project report must be used for all information regarding ballasting, dimensions of the module area and the roof
area, etc.!
ÎThe building data specified in the project must be compared with the actual building data. In the event of deviations, this
must be agreed with Hanwha Q CELLS GmbH and the planning adjusted. Hanwha Q CELLS GmbH reserves the right to
exclude liability in the event of non-compliance.
ÎBefore installation, the compatibility of the system with the roof must be checked.
ÎSystems may only be installed and commissioned by persons who, due to their professional qualification (e.g. training or
activity) or experience, can guarantee that they are carried out in accordance with the regulations.
ÎBefore installation, it must be checked whether the product meets the static requirements on site. In the case of roof sys-
tems, the load-bearing capacity of the roof on site must also be checked. National and local building regulations, standards
and environmental protection regulations must be observed.
ÎFor roof pitches greater than 2.5°, we strongly recommended connecting the system to the roof structure in order to prevent
a “bead effect” caused by thermal linear expansion.
ÎOccupational safety and accident prevention regulations, corresponding standards and regulations of the employers' liability
insurance association must be observed.
ÎThe Q CELLS installation instructions for the solar modules must be observed.
ÎIn the event of non-observance of our general safety instructions, installation instructions and non-use of all system com-
ponents as well as the installation and removal of components that were not purchased from us, we accept no liability for
any resulting defects and damage. The warranty is excluded to this extent.
Intended use
ÎThe Q.FLAT-G6 flat roof system is only permitted for use on flat roofs.
ÎThe Q.FLAT-G6 may only be used with Q CELLS solar modules with the dimensions 1673 mm × 1030 mm × 32 mm (e.g.
Q.PEAK DUO BLK-G9), 1840mm × 1030 mm × 32 mm (e.g. Q.PEAK DUO ML-G9) and 1740mm × 1030 mm × 32mm (e.g.
Q.PEAK DUO-G6), including frame.
ÎIf the Q.FLAT-G6 is not to be installed or operated according to the specifications in these installation and operating instructions,
please contact a certified sales partner or employee appointed by Hanwha Q CELLS GmbH.

4INSTALLATION AND OPERATION MANUAL FOR FLAT ROOF SYSTEM Q.FLAT-G6 – Q CELLS
2 REQUIRED MATERIAL
REQUIRED
A
Start, end
and connection profile
H
Rear panel tower
B
Main base profile
I
10° base
C
10° tower OPTIONAL
D
Cross brace and
ballast brace
O1
Cable duct cover
E
Cross brace connector
O2
Ballast block 40 × 40 × 4
not included in the scope of delivery
F
Module and ballast clamp as
middle and end clamps
O4
Ballast trough V01 / V02
V01: Assembly after adding the bulk material
V02: Assembly before adding the bulk material
G
Rear panel
O5
Side cover 10°

5INSTALLATION AND OPERATION MANUAL FOR FLAT ROOF SYSTEM Q.FLAT-G6 – Q CELLS
REQUIRED OPTIONAL
Tape measure Rubber hammer
Chalk line
Torque spanner
with SW5 hexagon socket attachment
3 REQUIRED TOOLS

6INSTALLATION AND OPERATION MANUAL FOR FLAT ROOF SYSTEM Q.FLAT-G6 – Q CELLS
Just
5 steps
to the finished system
Optional
Required
4 ASSEMBLY

7INSTALLATION AND OPERATION MANUAL FOR FLAT ROOF SYSTEM Q.FLAT-G6 – Q CELLS
Preliminary work:
ÎClean the roof surface and remove any obstructions;
ÎMeasure roof surface and compare with planning documents;
ÎMark system corner dimensions.
Procedure:
ÎLay out the components start and end profile A, base I,main base profile B, one behind the other according to the planning
documents. The order here is starting from south to north: AIBIBIB… B. The sequence is the same in
every row and always ends at the end of the row with the component B.
ÎPush the profiles A, Iand Binto each other until the click latch engages with an audible noise (see Detail Figure 3).
ÎThe snap-in connection is to be checked for clean form fit and strength.
ÎThe base profile rows are now to be set up at the spacing specified in the planning documents (see ).
ATTENTION: The base Imust always face away from the main base profile B!
TIP: The marking at the ends of the cross brace and ballast brace Dindicates the exact removal of the main base profiles B.
A
B
B
x = 1840 / 1673 / 1740
+ 20 mm
− 115 mm
All Q CELLS base profiles are fitted with 11mm thick high-tech protective mats. The gaps between the protective mats ensure
free water drainage. The protective mats prevent damage to the roof covering due to mechanical impact and long-term damage
due to plasticiser migration. Furthermore, all profiles are equipped with drainage holes on the undersides to prevent water build-up
and frost damage.
INFO i
4 ASSEMBLY
4.1 LAY OUT BASE PROFILES A AND B;
CONNECT AND ERECT
B
x
I
I
I
4
3
CLICK!
A
B
2
A
B
I
1

8INSTALLATION AND OPERATION MANUAL FOR FLAT ROOF SYSTEM Q.FLAT-G6 – Q CELLS
4 ASSEMBLY
4.2 ASSEMBLE THE CENTRE COMPONENTS
TOWER C AND THE REAR PANEL TOWER H.
Procedure:
ÎPlace the tower middle section Con the two narrow recesses 1(towards the long end of the rail) on the base profile with the
latching nose pointing away from the base.
ÎPress the tower Cvertically into the base profile Band push it towards the end of the rail until the click latch engages with an
audible noise.
ÎPress the rear wall tower Hvertically into the two recesses 2with the inclination pointing away from the tower Cand push it
towards the tower until the click latch engages with an audible noise.
CORRECT INCORRECT
C
H
The component towers serve as upper support elements for the modules in all Q CELLS systems, the rear panel towers serve as
support elements for the rear panel.
INFO i
ATTENTION !
Always ensure that the click latch is correctly seated and “locked”.
B
C
H
1
2

9INSTALLATION AND OPERATION MANUAL FOR FLAT ROOF SYSTEM Q.FLAT-G6 – Q CELLS
4 ASSEMBLY
4.3 MOUNT CONNECTING COMPONENT CROSS
BRACE AND BALLAST BRACE D
The bracing has two functions. In the single version, it increases the static bond of the system and facilitates further work such
as pulling the cables and laying the modules, as it is more difficult for the base profiles to slip. In the double version, it serves to
accommodate additional ballast (see Option 2). With a continuous bracing of the main base profile rows, the potential equalisation
of the system is carried out.
Procedure:
Insert the cross brace and ballast brace Din the centre of the tower Cand push them in as far as the marking. Screw the cross brace
and ballast brace Dtogether as far as they will go using the two M8x30 screws. Observe the tightening torque of 10 Nm. (Please observe
the note MAINTENANCE.)
CROSS BRACE AND BALLAST BRACE
The cross brace connector Emust be installed according to the planning documents. This is to be inserted into a cross brace and ballast
brace Das far as the centre. Slide the following cross brace and ballast brace Dover the cross brace connector E. The component
combination must be fixed to the tower Cwith two M8x30 screws. Observe the tightening torque of 10 Nm. (Please observe the note
MAINTENANCE.)
CROSS BRACE CONNECTOR
CORRECT POSITION
INCORRECT POSITION
C
C
D
INFO i
Note: The cross brace must always be mounted on the tower. The cross brace and ballast brace Dmust always be inserted on
the tower Cas far as the marking.
Marking
POTENTIAL EQUALISATION

10INSTALLATION AND OPERATION MANUAL FOR FLAT ROOF SYSTEM Q.FLAT-G6 – Q CELLS
In order to protect the string lines from permanent and damaging environmental influences, especially UV radiation, all Q CELLS
base profiles have cable duct cover receptacles. The installation of the cable duct covers is possible after each work step of the
system assembly.
4 ASSEMBLY
4.4 OPTIONAL STEP
4.4.1 CABLE DUCT COVER O1
Preliminary work:
Check clean position of string lines; check permanent and secure fastening of string lines so as to avoid damage to lines due to movements
(wind).
Optionally, additional fastening by means of edge clips to the base profile is to be carried out in order to ensure secure positioning of
the cables.
Procedure:
Place the cable duct cover O1in the lower guide groove on the base profile B; tilt the cable duct cover O1onto the upper guide groove;
load the cable duct cover O1centrally until the click latch engages with an audible noise.
When attaching the cable duct, take care not to damage the lines.
INFO i
ATTENTION !

11INSTALLATION AND OPERATION MANUAL FOR FLAT ROOF SYSTEM Q.FLAT-G6 – Q CELLS
The amount of additional weighting of the system depends on many parameters such as building height, location, environment,
type of roofing and many more.
4 ASSEMBLY
4.4 OPTIONAL STEP
4.4.2 BALLAST BLOCK O2
Preliminary work:
Fit the cross brace and ballast brace Das described under step 3 to the tower Cand rear panel tower H.
Procedure:
Place ballast blocks O2evenly distributed on the ballast braces D; maximum weight per ballast brace arrangement: 135kg
The position of the ballasting must always be carried out strictly in accordance with the planning documents. A different distribution
or the omission of ballast elements can impair the positional safety of the entire installation and represent an enormous risk. The
system is planned as standard with ballast blocks with the dimensions 40 × 40 × 4cm; if the dimensions of the blocks differ, manual
adjustment may be necessary on site. Deviations from the planning must always be agreed with Q CELLS and only carried out after
written approval. The position of the ballasting elements must be selected in such a way that slipping down, tilting or wobbling is
permanently prevented. The ballast must be fully supported, leaning on the ballast is not sufficient.
INFO i
ATTENTION !

12INSTALLATION AND OPERATION MANUAL FOR FLAT ROOF SYSTEM Q.FLAT-G6 – Q CELLS
Place the ballast block in the middle of the rail, push it up to the
base Cand secure it with the end clamp F.
Place the ballast blocks in the centre of the rail and secure them
with the middle clamp.
Secure ballast block 1 + 2 as described in point 2, apply the third
and, if necessary, the fourth block and push it up to the module
frame in the direction of the base Cto secure it.
If the ballast stones are placed on the double cross brace, distribute
the blocks evenly on the cross brace as described on page 11 and
push them up to the rear panel.
The number and weight of the ballast blocks required can always be found in the current project report.
The position of the ballasting must always be carried out strictly in accordance with the planning documents. A different distri-
bution or the omission of ballast elements can impair the positional safety of the entire installation and represent an enormous risk.
Deviations from the planning must always be agreed with Q CELLS and only carried out after written approval. The position of the
ballasting elements must be selected in such a way that slipping down, tilting or wobbling is permanently prevented. The ballast
must be fully supported, leaning on the ballast is not sufficient.
1 ballast block per rail
2 ballast blocks per rail
3 – 4 ballast blocks per rail
9 – 17 ballast blocks on the double cross brace
Positioning of the ballast blocks O2
4 ASSEMBLY
4.4 OPTIONAL STEP
4.4.2 BALLAST BLOCK O2
ATTENTION !

13INSTALLATION AND OPERATION MANUAL FOR FLAT ROOF SYSTEM Q.FLAT-G6 – Q CELLS
Not all roof surfaces have additional load reserves for the required layer ballast. Especially roofs with additional fill through gravel
or substrate are often not able to take additional loads. The ballast trough is utilised to make these roofs usable.
4 ASSEMBLY
4.4 OPTIONAL STEP
4.4.3 BALLAST TROUGH TYP V01 O4
INFO i
Procedure:
Remove gravel / substrate fill up to the inner edges of the base profiles Bin the area between the base and tower C. The depth of the
excavation should be 50mm from the top edge of the fill over the entire area in order to ensure a flat support of the trough O4on the
residual fill or the roof surface. When placing the trough O4directly on the roof covering, make sure that the surface is clean in order to
avoid long-term damage caused by objects lying between the ballast trough O4and the roof covering.
Place the trough O4between the tower Cand base in the middle of the base profile B. Then screw the trough O4to the base profile B
using self-drilling screws. Six screws per trough are to be inserted centrally, evenly distributed. Observe the maximum torque of 5 Nm!
Put the fill back into the trough O4. Ensure even coverage in the trough O4.
Ensure minimum cover in the trough according to the planning documents! The maximum fill height must not exceed 70 mm.
B
C
E
ATTENTION !

14INSTALLATION AND OPERATION MANUAL FOR FLAT ROOF SYSTEM Q.FLAT-G6 – Q CELLS
Not all roof surfaces have additional load reserves for the required layer ballast. Especially roofs with additional fill through gravel
or substrate are often not able to take additional loads. The ballast trough is utilised to make these roofs usable.
4 ASSEMBLY
4.4 OPTIONAL STEP
4.4.4 BALLAST TROUGH TYP V02 O4
INFO i
Procedure:
The substructure is built directly onto the roof cladding. Then position the troughs O4at the locations indicated in the project report.
When placing the trough on the roof covering, make sure that the surface is clean in order to avoid long-term damage caused by objects
lying between the trough O4and the roof covering.
Place the trough O4between the tower Cand base in the middle of the base profile B. Then screw the trough O4to the base profile B
using self-drilling screws. Six screws per trough are to be inserted centrally, evenly distributed. Observe the maximum torque of 5 Nm!
Ensure minimum cover in the trough according to the planning documents! The maximum fill height must not exceed 70 mm.
E
B
C
ATTENTION !

15INSTALLATION AND OPERATION MANUAL FOR FLAT ROOF SYSTEM Q.FLAT-G6 – Q CELLS
The assembly can be started with the module as well as with the clamp. The order is freely selectable here.
4 ASSEMBLY
4.5 FIT MIDDLE AND END CLAMPS F AND
SCREW MODULES TOGETHER
INFO i
Procedure:
Place the middle and end clamps Fon the inside of the tower C
(side facing away from base) on the lower guide groove and press
them onto the opposite guide groove until the click latch engages
with an audible noise. Ensure that the clamps Fare securely and
seated flush in the guide grooves!
Place the middle and end clamps Fon the outside of the base (side
facing away from the tower) on the upper guide groove and press
them onto the opposite guide groove until the click latch engages
with an audible noise. Ensure that the clamps Fare securely and
seated flush in the guide grooves!
Place the modules and ensure that they are centred on the tower C
and base . Ensure that the middle and end clamps Fare flush and
clean with the module. Tighten the locking screws. The installation
instructions of the module manufacturers must be strictly observed.
Observe the tightening torque of 10Nm. (Please observe the note
MAINTENANCE.)
NOTE:
Care must be taken not to excessively press the clamps too far and thus bend them.
CORRECT INCORRECT

16INSTALLATION AND OPERATION MANUAL FOR FLAT ROOF SYSTEM Q.FLAT-G6 – Q CELLS
4 ASSEMBLY
4.6 REAR PANEL
The rear panel is an aerodynamically system-relevant component and must be mounted behind each module.
Disregarding this rule leads to exclusion of liability!
INFO i
Procedure:
Slide the back panels Ginto the rear panel tower Hwith the long
leg facing downwards. When assembling, insert the rear panels
into the tower from left to right, starting with 1 2 3 4… and
screw them tightly into the rear panel tower with an M8x16 screw.
Observe the tightening torque of 10Nm.
The direction of work from east to west must be adhered to 1 2 3 4…
2
1
ATTENTION !

17INSTALLATION AND OPERATION MANUAL FOR FLAT ROOF SYSTEM Q.FLAT-G6 – Q CELLS
The construction of the system with the side covers causes an improvement of the cp value, which has a positive influence on the
required layer ballast, as well as can lead to a lower additional ballast.
INFO i
The side cover is a component relevant to stability. Omission of the side covers specified in the project report will inevitably lead
to an exclusion of liability by Hanwha Q CELLS GmbH.
Note:
The side covers O5are an optional component and are not necessarily planned. This information can always be found in the cor-
responding project report. Place the side covers O5with the screw holes over the screw positions on the tower Cand base and
fix them with three M8x20 screws. Observe the tightening torque of 10 Nm.
C
O5
B
H
4 ASSEMBLY
4.7 OPTIONAL STEP
4.7.5 MOUNTING THE SIDE COVER O5
ATTENTION !

18INSTALLATION AND OPERATION MANUAL FOR FLAT ROOF SYSTEM Q.FLAT-G6 – Q CELLS
ÎCheck that the entire system and ALL components have been erected according to the planning documents and that there
are no deviations.
ÎCheck whether ALL hexagon socket head screws have been attached at the intended places (cross and ballast braces).
ÎCheck that ALL hexagon socket screws have been tightened to the torque specified in the assembly instructions (middle
clamps, end clamps, cross and ballast braces). ATTENTION! This is relevant to stability and can lead to considerable damage!
ÎCheck whether ALL ballasting elements have been applied with sufficient weight according to the planning documents and
their state is permanent and safe. ATTENTION! This is relevant to stability and can lead to considerable damage!
ÎCheck whether all “click connections” are correctly latched.
FINAL INSPECTION !
Changes and deviations from the planning documents must be agreed in writing with Hanwha Q CELLS GmbH!
ÎThe upper and lower limits of the tightening torque of the locking screws must be checked regularly as part of the mainte-
nance (maintenance interval at least once a year, observe the maintenance log).
MAINTENANCE !
5 FINAL INSPECTION

HANWHA Q CELLS GMBH
OT Thalheim
Sonnenallee 17 – 21
06766 Bitterfeld-Wolfen
Germany
TEL [phone] – 23222
FAX [phone] – 23000
EMAIL [email protected]
WEB www.q-cells.com
Manufacturer
Premium Mounting Technologies GmbH & Co. KG
Industriestraße 25
95346 Stadtsteinach
GERMANY
Subject to change ©Q CELLS Installation_Instructions_South_Orientation_Q.FLAT-G6_2021-01_Rev01_EN
TEL [phone] - 0
FAX [phone] - 999
EMAIL [email protected]
WEB www.pmt.solutions