Qcells Q.MOUNT User manual

Q.MOUNT INSTALLATION INSTRUCTIONS Tiled Roofs
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Q.MOUNT
INSTALLATION INSTRUCTIONS
TILED ROOFS

Q.MOUNT INSTALLATION INSTRUCTIONS Tiled Roofs
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The design and planning of the mounting system should be carried out using
the Q CELLS ROOFTOP PLANNER software. Please refer to the project
report you receive from Q CELLS ROOFTOP PLANNER or from your
Q CELLS Q.PARTNER for details of the required materials,positions and the
arrangement of the individual components. This data is statically calculated
and is of great importance for the safe and proper functioning of the system.
Before installation, the manufacturer of the photovoltaic system must ensure
that the given roof substructure is designed for the additional loads that will
occur. To check this, contact structural engineers directly on site.
Each photovoltaic system must be installed in accordance with the structural
requirements of the location and the installation situation, taking into account
the specifications of the existing installation recommendation.
These installation instructions explain the installation procedures for the
Q.MOUNT corrugated sheet metal bridges, their attachment to the roof
substructure and the installation of the girder profiles and modules.
SAFETY INFORMATION
The corrugated sheet metal bridges must always be fixed to the stable roof
substructure.
Normally, the PV modules are mounted in portrait format so that the mounting
profiles are parallel to the ridge. Two mounting profiles per module row are used
as standard. In strong wind and/or snow loads, a third mounting profile may have
to be used.
The Q.MOUNT corrugated sheet metal bridge system is exclusively designed
for PV modules. Any other use is considered improper.
The installation may only be carried out by trained specialists. In particular,
work on the roofing should be carried out by a roofer.
If you have any further questions, take advantage of the professional and
comprehensive consulting service offered by Q CELLS. Our expert civil
engineers and construction technicians will be pleased to help you.
Please carefully read the safety information contained in these installation instructions before starting the installation.
Ensure that you are using the current installation instructions before starting the installation.

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SAFETY AND WARNING INFORMATION
You should follow these instructions exactly for all work on the PV system. Installation,
commissioning, maintenance and repair may only be carried out by appropriately qualified
and authorised personnel.
Please observe the valid regulations and safety instructions.
You must comply with these accident prevention regulations:
BGV A 1 –General regulations
BGV A 3 –Electrical installations and equipment
BGV C 22 –Construction work (personal protective equipment against falls from a height)
BGV D 36 –Ladders and steps
Employer's liability insurance association rules for safety and health at work BGR 203
(roof work) and DIN EN 516 Equipment for walking on roofs
Work clothing and work safety regulations in accordance with the regulations
of the professional association
You must comply with the following DIN standards:
DIN 18299 –General regulations for construction works of any kind
DIN 18338 –Roofing and roof sealing works
DIN 18360 –Metal construction work, locksmith work
DIN 4102 –Fire behaviour of building materials and components
Work on the systems may only be carried out by authorised personnel. The operator of the system
has the following safety-related obligations:
We assume that at least once a year an inspection and maintenance of the installed pitched roof
system components and the roof cladding is carried out.
At least the following points should be checked:
all mechanical connections for correct fit and strength
the position of the system on the roof and the system itself with regard to deformations
the cabling must be checked for integrity
the PV modules must be checked for damage
The assembly of the frame may only be carried out by personnel with appropriate qualifications,
manual skills and basic knowledge of mechanics.
It must be ensured that the assigned personnel are able to assess the work assigned to them
and identify possible hazards.
The installation instructions are part of the product and must be available during assembly.
It must be ensured that the installation instructions –and in particular the safety instructions –
are read and understood by the assigned personnel prior to assembly.
The regulations of the employer's liability insurance association, the local industrial safety
regulations and the rules of technology must be observed.
Suitable lifting equipment and ladders must be used for the installation. No lean-to ladders
may be used.
It is necessary to have the existing building statics checked by a competent civil engineer
with regard to the additional loads from a PV system.
Possible general load limitations imposed by Hanwha Q CELLS GmbH (e.g. the necessity
of snow removal to limit the snow load) must be taken into account.

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WARRANTY AND NOTES
WARRANTY/PRODUCT LIABILITY (EXCLUSION)
The dimensioning notes contained in this manual are merely practical tips. Binding assembly
rack statics can be created using the program Q CELLS ROOFTOP PLANNER.
As an installation company, you are responsible for the correct execution of the installation.
Hanwha Q CELLS GmbH is not liable for the dimensioning information contained in
commercial plant quotations.
As an installation company, you are responsible for the mechanical durability of the mounted
interface connections on the building envelope, and especially for their tightness.
The components supplied by Hanwha Q CELLS GmbH are designed for this purpose
in accordance with the expected loads and the current state of the art. In this context,
you must specify all general technical conditions in writing in the project registration form
(details of the supporting structure, snow load zone, building heights, wind loads, etc.)
within the framework of the inquiry/order sent to Hanwha Q CELLS GmbH.
Hanwha Q CELLS GmbH is not liable for improper handling of the installed parts.
Use of the components near the sea is not permitted due to the risk of corrosion.
If handled properly and dimensioned in accordance with the static framework conditions and
normal environmental and ambient conditions, Hanwha Q CELLS GmbH provides a 2-year
product warranty for the service life and durability of its mounting systems. This applies in the
context of the generally prevailing weather and environmental conditions.
Material and processing warranty: Hanwha Q CELLS GmbH provides a material and
processing warranty of 10 years for the materials used. For more detailed information,
please refer to the separate warranty conditions.
NOTES ON ELECTRICAL INSTALLATION
You may only carry out electrical work if you are a qualified electrician. The applicable
DIN standards, VDE regulations, VDEW guidelines, VDN guidelines, accident prevention
regulations and the regulations of the local electricity supply companies (EVU) are decisive
in this context.
DIN VDE 0100 (Erection of power installations with nominal voltages up to 1000 V)
VDEW guideline for the parallel operation of in-house generation plants on the low-
voltage grid of the power supply company
VDI 6012 Guideline for decentralised energy systems in buildings: Photovoltaics
Leaflet on the VDEW Guideline "Distributed power generating plants connected to the
low-voltage grid"
VDN guideline "Distributed power generating plants connected to the low-voltage grid"
DIN/VDE regulations, DIN/VDE 0100 "Erection of power installations with rated voltages
up to 1000 V", in particular VDE 0100 Part 410 "Protection against direct and indirect
contact" (DC voltages > 120 V, < 1000 V DC) and the "Accident prevention regulations of
the industrial employers' liability insurance associations" VBG4 "Electrical installations and
operating equipment"
DIN VDE 0100-540 Selection and installation –Earthing, protective conductors and
equipotential bonding conductors
VDE 0185 Establishment of a lightning protection system and VDS 2010

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IMPORTANT WARNINGS
Solar modules generate electricity as soon as they are exposed to light, so they are always
live. Although the fully insulated plug contacts provide protection against accidental contact,
you must pay attention to the following when handling the solar modules:
Do not insert electrically conductive parts into the plugs and sockets.
Do not mount solar modules and cables with wet plugs and sockets.
Perform all work on the lines with extreme caution.
Do not carry out any electrical installation work in damp conditions.
Even with low illumination, very high direct voltages are generated at the series connection
of solar modules, which are life-threatening if touched. Pay particular attention to the
possibility of secondary damage from electric shock. DIN VDE 0100-540 Selection
and erection of electrical equipment -Earthing arrangements and protective conductors.
High contact voltages can occur in the inverter even when it is disconnected:
Be especially careful when working on the inverter and the cables.
After switching off the inverter and carrying out other work, it is essential to observe
the time intervals specified by the manufacturer to allow the high-voltage components
to discharge.
Please also observe the installation instructions provided by the inverter manufacturer.
Opening a closed string (e.g. when disconnecting the DC line from the inverter under load)
can cause a lethal electric arc:
Never disconnect the solar generator from the inverter while it is connected to the grid.
NOTES ON RACK INSTALLATION
For installation in the roof area, you must observe the currently valid rules of construction
engineering, in particular the requirements formulated in the DIN standards and in the
regulations of the German roofing trade ("Regelwerk des Deutschen Dachdeckerhandwerks").
Check that all screw connections are tight.
Observe the specified torques.
Irrespective of verifiable statics, you must ensure in advance of each installation that the
product meets the static requirements on site in accordance with DIN EN 1991.
DIN standard EN 1991 "Actions on structures" –and all related national application documents
Part 1-1: Weights, dead weight and payloads in building construction
Part 1-3: Snow loads
Part 1-4: Wind loads
DIN standard EN 1990: "Basis of structural design" –and all related national application
documents.
The design of the assembly rack is carried out in accordance with DIN EN 1993 "Design of
steel structures" and DIN EN 1999 "Design of aluminium structures«.
Ensure that the substructure is suitable in terms of load-bearing capacity (dimensioning, state of
preservation, suitable material characteristics), load-bearing structure and other layers affected
by this (e.g. insulation layer).
Make sure that the drainage of rainwater is not hindered.
Take into account aspects of building physics (e.g. possible condensation when penetrating
insulation layers).
STANDARDS AND GUIDELINES
All listed standards and guidelines have been issued and are applicable in Germany. They must
be taken into account by referring to the latest valid version as amended. Outside Germany,
please also observe the relevant national standards and guidelines.
PRODUCT LIABILITY
The technical documentation is part of the product. Hanwha Q CELLS GmbH is not liable for
damages resulting from non-observance of the installation instructions, in particular the safety
information, and/or from misuse of the products.

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ROOF HOOK INSTALLATION -TILE, PLAIN TILE, SLATE
Note:
The clamping ranges and the resulting loads are specified in the installation instructions for the modules used.
Do not use the roof hooks and girder profiles as climbing aids or ladders!

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REQUIRED TOOLS
Cordless screwdriver with
bits, WS8, hexagon 6
Torque wrench Measuring tape Chalk line Allen key WS6Spirit level

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ROOF REQUIREMENTS
•Use: Tile; plain tile, slate
•Module type: framed modules
•Module orientation vertical/horizontal
•Max. module field length: 12 m
•Roof pitch: 10°-65 °
•Connection: Plate-head screws
•Material: Aluminium EN AW-6063/stainless steel
•Surface: plate-finished
•Torque: 15 Nm (M8)
30 Nm (M10)
Additional required documents

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VERTICAL MODULE MOUNTING -SINGLE LAYER
End clamp
Middle clamp
Roof hook
AL13/ALS13
Girder profile 37/45/65
Profile connector 37/45/65

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TILED ROOF COMPONENTS
Q.MOUNT
Roof hook
AL 13/ALS13/ AL12
Q.MOUNT
Girder profile
37/45/65
Q.MOUNT
profile connector
37/45/65
Q.MOUNT
Click middle clamp
Q.MOUNT
Click end clamp
Q.MOUNT
Click middle clamp
with PIN
Q.MOUNT
Click end clamp
with PIN
Q.MOUNT
shim
Q.MOUNT
Sheet metal tile
Q.MOUNT
Roof hook
AL13 X
Q.MOUNT
Plate-head screw
Q.MOUNT
Cross connector
Q.MOUNT
roof hook for plain tile
with quick assembly
Q.MOUNT
Sheet metal plain tile
Q.MOUNT
Roof hook for slate
Q.MOUNT
Edge clip KC1 incl.
cable clip
Q.MOUNT
wire clamp 8-10
Q.MOUNT
Round wire (8 mm)
Q.MOUNT
End cap QC

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REMOVE ROOF TILES AND FIX ROOF HOOKS
•Measure and mark the roof tiles to be removed according to the ROOFTOP PLANNER
and the corresponding module clamping areas
•Enlist the help of a roofer for roof work.
•Remove the corresponding roof tiles above the rafter.
•Place the roof hook on the rafter so that the roof hook is in the valley of the corrugation
of the tile underneath with the appropriate spacing.
•The roof hook must never rest directly on the tile surface (3-5 mm distance).
•Keep a distance in horizontal and vertical direction to the roof tile of 3-5 mm each.
•The roof hook must never rest directly on the tile surface (3-5 mm distance).
•To maintain the correct distance, use the adjustment possibilities of the bracket. To do this,
loosen the screw between the bracket and the base plate, position it correctly and tighten
the screw again accordingly (15 Nm).
In each area 3-5 mm
•If necessary, parts of the lip of the roof tile underneath or above must be removed with an angle grinder
(diamond blade).
•Always ensure that the roof is watertight.
•Never grind into the tile itself, this will invalidate the roof tile manufacturer's warranty and increase the risk
of roof leaks.
•Always check an alternative use of metal roof tiles in our portfolio.

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FASTEN ROOF HOOKS TO RAFTERS
•Screw the roof hook into the rafter according to the following requirements with 2 plate-head screws.
•If necessary, use the shim to ensure full contact with the rafter.
•Align the roof hooks and the quick-mounting adapter with the help of a cord.
•Minimum rafter width: 60 mm
•Min. distance of the screws to the rafter end: 24 mm
•Minimum distance between the screws: 10 mm
•Minimum screw-in depth into the rafters: 60 mm
•Ensure that the base plate of the roof hook is fully supported.
•Level out any unevenness with the spacer plate.
•Use additional rafters or counter battens or wooden boards to ensure a full
surface of the base plate (option 1, 2, 3).
•Ensure that the base plate of the roof hook is fully supported.
•Level out any unevenness with the spacer plate.
•Use additional rafters or counter battens or wooden boards to ensure a full.
surface of the base plate (option 1, 2, 3).
Plate head screw
Rafter
Min. rafter width 60 mm
Min. 10 mm distance between screws
Min. distance of screw to rafter
end 24 mm
Minimum screw depth
60 mm
Roof hook AL 13
Option 1Option 2Option 3
AL13
AL13
AL13
AL13
AL13
AL13
Rafter Additional
rafter Rafter
Rafter
Wooden
substructure Counter
batten Vapour barrier
additional
counter batten

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FASTENING ROOF HOOKS TO RAFTERS
In the case of above-rafter insulation, wood screws with upper thread must be provided and used on
site. The length of the wood screw is calculated by the sum of the thickness of the roof hook green
plate of the roof hook, the thickness of the counter-battening, the height of the thermal insulation and
the 60 mm anchoring depth in the rafter.
Length of the wood screw (incl. upper thread):
Thickness of DH base batten
+Height of the counter-battening
+Height of the thermal insulation
+60 mm anchorage depth in the rafters
•Reposition the removed and processed roof tiles or used sheet metal tiles.
•Properly again.
•Make sure that the roof is watertight.

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METAL ROOF TILE TYPE CLAY AND CONCRETE
Original underlay plates Marzari –
type clay / type concrete
1. a) Provide support, if necessary insert roof batten
b) Insert metal roof plate
2. Secure with nail if necessary
3. Determine and position for roof hooks
4. If necessary, flatten the edge slightly towards the
bottom
5. Glue the foam wedge and cut it as described in the
separate instructions
6. Fit the roof hooks
7. Cover with tiles
8. Mould in lead apron
* Special note: Make sure that the metal roof plate fits exactly to the
respective building project. Particularly in the case of clay roofs, the
enormous variety and variable installation options of these tiles make
careful suitability testing and processing urgently necessary.

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METAL ROOF TILES TEGALIT AND PLAIN TILE
1. Insert metal roof plate
2. Secure with a nail or screw
3. Bend upstand forward if necessary (water lifting edge
must remain functional)
4. Glue on foam wedge and cut as per separate
instructions
5. Mount roof hooks
6. Cover the roof with tiles
Important note!
Already when taking up the roof, pay attention to the
thickness of the battens and the corresponding selection of
the roof hooks with regard to the leg height.

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FASTENING THE ROOF HOOKS - PLAIN TILE
•Remove the roof tile under the roof hook and replace it with a sheet metal plain tile as shown
on the following page.
•Screw the roof hook into the rafter with 2 wood screws according to the following instructions.
•Replace the roof tile located above the roof hook.
•Make sure that the roof is watertight.
•Fix the girder profiles on the mounting plate with the right side up.
•Screw the support profile tight with the Allen screw to a torque of 15 Nm.
•Measure the positions of the roof hooks according to the ROOFTOP PLANNER
on the roof and remove the roof tiles above the rafters.
•Also pay attention to the corresponding module clamping area.

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METAL ROOFING TILES -PLAIN TILE
1. Insert metal roof plate
2. Secure with a nail or screw
3. Bend upstand forward if necessary (water lifting edge
must remain functional)
4. Glue on foam wedge and cut as per separate
instructions
5. Mount roof hooks
6. Cover the roof with tiles
Important note!
Already when taking up the roof, pay attention to the
thickness of the battens and the corresponding selection of
the roof hooks with regard to the leg height.

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FASTENING THE ROOF HOOKS -SLATE
•Position the roof hooks according to the static requirements of the ROOFTOP PLANNER.
•Align and position slate roof hooks on rafters and fasten to rafter with 2 wood screws Fastening.
•The tightness of the roof must be ensured. Comply with the regulations and rules of the German
roofing trade.
•If necessary, leave out the slate roof tiles and use a titanium zinc sheet to seal the adjacent slate
roof tiles and seal it with a sealing tape to be provided by the customer.
•Fix the adjacent roof tiles and the titanium zinc sheet in accordance with the rules and regulations
of the German roofing trade.
•Fix the girder profiles on the mounting plate with the right side up.
•Screw the support profile tight with the Allen screw to a torque of 15 Nm.

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FASTENING THE GIRDER PROFILES TO THE ROOF HOOK
Connect girder profiles: necessary if the width of the module field is greater than the length
of the girder profile. Insert the profile connector halfway into the first girder profile and
insert the second girder profile onto the profile connector. If necessary, screw the profiles
to the profile connector. Press the end caps into the end of the girder profile by hand.
•Place the girder profile with the correct side on the quick-mounting adapter of the roof hook.
•And fasten the carrier profile with the Allen screw with a torque of 15 Nm.•Press the end caps into the ends of the girder profiles.

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MOUNTING SOLAR MODULES
Click the clamps into the girder profile at a slight angle as shown and push the clamp up to
the module frame. When the clamp and the second module are in the correct position,
tighten the clamp. Tighten the screw on the middle clamp with a torque of 15 Nm.
Click the centre clamps into the girder profile at a slight angle as shown and slide the
end clamp to the module frame. When the clamp is in the correct position, tighten the
clamp. Tighten the screw on the middle clamp with a torque of 15 Nm . Slide the next
modules back to the middle clamp.
Start in the lowest module row by placing the first solar module on the girder profiles and
aligning it. Place the end clamp on the module frame and click it into the girder profile.
When the clamp is in the correct position, tighten the clamp.
Middle/end clamp min. 20 mm
Note: The middle/end clamps must be installed at least 20 mm from the end of the
corresponding girder profiles.
15 Nm
15 Nm