Schletter PvMax-S SRF User manual

FS DUO | 400224EN | V4 | INSTALLATION MANUAL | 202011 1
SCHLETTER SOLAR GMBH | SUBJECT TO MODIFICATIONS
3Y0D[665)
INSTALLATION MANUAL

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Table of Contents
1. General Information ................................................................................................................................................................. 4
1.1. Short Description ....................................................................................................................................................................................4
1.2. Intended Use.............................................................................................................................................................................................4
1.3. Copyright and Intellectual Property Rights...................................................................................................................................4
1.4. Safety Information..................................................................................................................................................................................5
1.5. Obligation of the Plant Owner / Operating Company...............................................................................................................7
1.6. Commitment of the Personnel...........................................................................................................................................................7
1.7. Training of the Personnel .....................................................................................................................................................................7
1.8. Additional Documents Relevant for the Mounting ....................................................................................................................8
2. Transportation, Loading and Unloading .............................................................................................................................. 8
2.1. Delivery of the components................................................................................................................................................................8
2.2. Preparing the delivery...........................................................................................................................................................................8
2.3. Provide forklift trucks and hoisting equipment...........................................................................................................................9
2.4. Check the scope of delivery ................................................................................................................................................................9
2.5. Storage of the components.................................................................................................................................................................9
3. Technical data...........................................................................................................................................................................10
3.1. System description and properties ............................................................................................................................................... 10
3.2. Rack tolerances ..................................................................................................................................................................................... 10
3.3. Systems overview................................................................................................................................................................................. 11
3.4. Components .......................................................................................................................................................................................... 12
3.4.1. PvMax foundation and components............................................................................................................................... 12
3.4.2. Module-bearing rails and connection elements......................................................................................................... 12
3.4.3. Girder assemblies and components................................................................................................................................ 13
3.4.4. Module clamps for vertical module mounting............................................................................................................ 14
3.4.5. Module clamps for horizontal module mounting...................................................................................................... 15
3.4.6. Module clamp adapter and connection elements for module clamps .............................................................. 15
3.4.7. Screws/bolts for Standard module clamps ................................................................................................................... 16
3.4.8. Auxiliary equipment / accessories.................................................................................................................................... 16
4. Mounting information............................................................................................................................................................17
4.1. Terrain....................................................................................................................................................................................................... 17
4.2. Foundation ............................................................................................................................................................................................. 17
4.2.1. Pre-cast strip foundations .................................................................................................................................................... 18
4.2.2. Dimensioning and reinforcement..................................................................................................................................... 18
4.2.3. Preparation of the terrain and positioning of the foundations .............................................................................. 18
4.2.4. Tolerances regarding inclination and distortion (twist) ............................................................................................ 19
4.3. Tools .......................................................................................................................................................................................................... 20
4.3.1. Surveying, staking and aligning the foundations....................................................................................................... 20
4.3.2. Rack mounting ........................................................................................................................................................................ 20
4.3.4. Module mounting .................................................................................................................................................................. 21
4.4. Torque specications .......................................................................................................................................................................... 21
4.4.1. Bolted connections in the substructure......................................................................................................................... 21
4.4.2. Fastening of the module clamps ...................................................................................................................................... 21
5. Assembly steps ........................................................................................................................................................................22
5.1. Pre-drilling the concrete foundation and inserting the dowels/screw anchors.......................................................... 22
5.2. Fastening the base bracket and foundation rail ...................................................................................................................... 24
5.3. Mounting the girder assembly....................................................................................................................................................... 25
5.4. Mounting the module-bearing rail (purlin)............................................................................................................................... 26
5.5. Mounting the purlin connectors (optional) .............................................................................................................................. 27
5.6. Mounting the module clamp adapter (optional) .................................................................................................................... 27
6. Module mounting and module clamping ..........................................................................................................................29
6.1. Module mounting and clamping in the case of vertical module bearing....................................................................... 30
6.2. Module mounting and clamping in the case of horizontal module bearing................................................................. 31
6.3. Module mounting and clamping in case of combined module bearing ........................................................................ 32
7. Disassembly and disposal......................................................................................................................................................33
8. Maintenance and care ............................................................................................................................................................34
9. Warranty and liability .............................................................................................................................................................34

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1. General Information
1.1. Short Description
PvMax-S is a modular unit assembly system for the installation of ground-mount substructures in high-quality and ecient
steel design. As the individual components have been optimized and structurally synchronized, a minimum system price
is achieved. The dimensioning is intended in such a manner that continuous module rows are created simply by stringing
together individual units of standardized lengths. Due to the individual units, thermal tensions within the system are
avoided. If the lengths of the rows are determined by the boundaries of the terrain, the rows are made out of as many equal
units as possible, then completed by a unit shortened to obtain the required length.
It is also possible to assembly additional accessories for the cable management or components for the internal potential
equalization.
1.2. Intended Use
PvMax-S is a substructure for the mounting of photovoltaic modules. Any kind of dierent use that is not mentioned in
these Mounting Instructions or an incorrect mounting (e.g. the utilization of components made by other producers or non-
observance of tolerances specied here and/or exceeding the indicated loads) are considered as non-intended use and, thus,
exclude any liability of the manufacturer.
The manufacturer accepts no liability for damage caused by failure to observe these Mounting Instructions.
1.3. Copyright and Intellectual Property Rights
The entire content of these Mounting Instructions is the intellectual property of Schletter GmbH and is subject to the
German copyright law.
Any reproduction, editing, propagation, transfer to third parties - also in excerpts - and any kind of utilization beyond the
limits of the copyright law must be approved in writing by Schletter GmbH.
Schletter GmbH reserves the right to take legal action in case of infringements.
These Mounting Instructions are subject to change without notice.
All names of products stated in these Mounting Instructions are trademarks of Schletter GmbH and are herewith recognized
and acknowledged.
Schletter GmbH is not liable for any damage of a product or consequential damage caused by the product that are due to
improper handling.
First and foremost, Schletter GmbH is not responsible or liable for failures and faults that are caused by modications made
by the customer or other persons.
There is no claim for availability of previous designs and for the ability to retrot delivered components to the respective
latest state of the series.
Schletter Solar GmbH has made considerable efforts to make sure that these Mounting Instructions are
free of errors and omissions.
Schletter Solar GmbH does not assume any responsibility or liability for possible errors included in these
Mounting Instructions and/or incidental, concrete or consequential damages arising from the publication
of these Mounting Instructions.
Mounting instruction PvMax-S SRF | 2016.07 V.002
Schletter Solar GmbH – Alustraße 1 – 83527 Kirchdorf

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1.4. Safety Information
Please read these Mounting Instructions carefully before starting the assembly and keep it in a safe place for further
reference. Please observe and abide by the regional and national applicable standards, building regulations and accident
prevention regulations.
This instruction manual contains guidelines and notices you have to observe in order to ensure your personal safety and
to prevent physical injuries or damage to property. Such safety and warning notes are marked with a warning triangle.
Depending on the kind and degree of danger, warning notices are displayed as follows:
DANGER
indicates that death or serious personal injury will result, if proper safety precautions are not taken.
WARNING
indicates that death or serious personal injury can result, if proper safety precautions are not taken.
CAUTION
indicates that minor personal injury may result, if proper safety precautions are not taken.
DANGER
due to operations with electricity. Electric power can lead to serious accidents and can cause serious
injuries. Appropriate safety precautions are to be taken by all means.
Securing the working area
Before the start of construction, the building site must be inspected by a supervising person by sight check
or using plans showing all supply lines (water, electricity, gas) in the relevant area. For this purpose, the
position of all supply lines (water, gas, electricity, etc.) must be marked using marking paint and unstable
ground and areas that are landslide-prone must be sealed o with stable barriers or warning signs.
Read and make sure you understand the safety and warning notes in these Mounting Instructions and
always apply them according to the relevant conditions and type of operation!
Schletter Solar GmbH – Alustraße 1 – 83527 Kirchdorf
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We absolutely recommend to observe the following protective measures when mounting PvMax-S system:
Always wear ear protection
when carrying out noisy work
Remember to wear high-
visibility vests and safety shoes
all the time
Always wear a hard hat when
there might be falling objects or if
you could hurt your head in some
other way
Wear protective gloves when
working with sharp-edged com-
ponents
When carrying out dusty work,
always wear breathing protection
Wear safety glasses when
carrying out grinding and
abrasive cutting operations in
order to avoid any danger to your
eyes caused by ying liquids or
parts (sparks, splinters)
Apart from that, please consider the applicable rules and regulations on accident prevention and environmental protection
that apply at the respective installation site as well as the work instructions and directives by the plant owner/operating
company or at the place of operation.
PLEASE NOTE
warns about situations that can lead to material damage and disturbances during the operating procedure,
if the instructions are not observed.
Important information and notices
regarding the product and its handling and/or mounting of the product are characterized by the
following symbol.
REFERENCES
All documents relevant for the mounting that are not included in these Mounting Instructions,
are marked with this symbol.
Schletter Solar GmbH – Alustraße 1 – 83527 Kirchdorf
Mounting instruction PvMax-S SRF | 2016.07 V.002

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1.6. Commitment of the Personnel
Only people who give reason to expect that they will reliably do their job are allowed. Persons whose ability to react is
aected, for example by drugs, alcohol or medication, are NOT allowed.
• Every person that is involved in the mounting of PvMax-S must have read and understood these Mounting Instructions,
especially chapter "1.4.
Safety Information", as well as all relevant chapters regarding the corresponding operations.
• These Mounting Instructions should always be kept available and easily accessible for all persons involved.
• Only trained and instructed qualied and certied personnel are allowed to execute the operations mentioned in this
instruction manual.
• Personnel that still is to be trained may only mount the PvMax-S system under the supervision of an experienced person.
1.7. Training of the Personnel
These Mounting Instructions are addressed to certied personnel qualied in the areas of transportation and loading,
mounting, disassembly and disposal, having the following qualications:
• The certied professionals must be capable of fullling the tasks they have been assigned with and must be able
to realize and avoid dangers on the basis of their professional formation, experience, expertise and their specic
knowledge of the relevant regulations.
• The certied sta members must have the required knowledge of the guidelines regarding safety, accident prevention and
environmental protection, as well as of loading and unloading regulations that apply at the respective construction site.
• The certied professionals have the driving licenses required at the specic construction site to be able to drive site
vehicles and operate construction machines.
We recommend the operator to insist on a conrmation in writing in each case.
1.5. Obligation of the Plant Owner / Operating Company
The plant owner ensures that all parts of these Mounting Instructions are readily available and handy at the plant.
The plant owner/operating company undertakes to only let people work at and in the striking distance of the plant who
• have read and understood the parts of the mounting instruction that are relevant for the respective operations,
• are familiar with the fundamental regulations on work safety, accident prevention and protection of the environment
• and have been instructed in the safe handling of the plant (training course).
Before starting any mounting works, the plant owner/operating company designates
• a supervising person and ensures that
• the construction site is inspected using plans showing all supply lines (water, electricity, gas) and thus
• the position of all underground supply lines and unstable ground without sucient load-bearing capacities are marked
properly or sealed o with barriers.
Schletter Solar GmbH – Alustraße 1 – 83527 Kirchdorf
Mounting instruction PvMax-S SRF | 2016.07 V.002

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1.8. Additional Documents Relevant for the Mounting
In addition to these Mounting Instructions, the following documents are required for the mounting of PvMax-S:
2. Transportation, Loading and Unloading
2.1. Delivery of the components
The delivery of the components for PvMax-S is carried out with an appropriate vehicle, for example
• truck/lorry or
• overseas container.
2.2. Preparing the delivery
• Provide a stable and drivable surface for the delivery.
• Please make sure that all access roads, manoeuvring and unloading areas are suitable for trucks (up to 40 tons)
and can be used by forklift trucks and hoisting equipments.
• Ensure that loading/unloading and transport activities are carried out by trained and certied personnel only.
WARNING
• Always wear protective equipment (safety shoes, hard hat, safety glasses, protective gloves and
high-visibility vest) when unloading the components of the PvMax-S system.
• Besides also wear the personal protective equipment that is specied in your intra-company
regulations for the respective activity.
• It is compulsory to monitor and supervise the complete unloading process.
• Do not step under suspended loads!
• Please make sure that there are no unauthorized persons in the danger area.
• Reinforcement plan (optional)
• Blueprint drawing / general layout drawing
• Bill of materials / parts list
• Delivery note
• DIS unloading guidelines for transport in maritime containers
• General Terms and Conditions of Sale and Supply of Schletter GmbH
Please observe all country-specic regulations and standards of the country of
destination and its work instructions!
Schletter Solar GmbH – Alustraße 1 – 83527 Kirchdorf
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2.3. Provide forklift trucks and hoisting equipment
• Organize suitable forklift trucks and hoisting equipment to be available at the moment of delivery.
• Choose the suitable forklift trucks and hoisting equipment in cooperation with the site manager in charge.
• Make sure that the components, pallets and long items can properly be unloaded.
• Provide forklifts and hoisting equipment with dierent fork intervals or with adjustable forks.
2.5. Storage of the components
We recommend to observe the following points when receiving the goods:
• Visual inspection of the delivered goods
• Check whether the supplied goods correspond to the delivery order
• Delivered quantity / comparison with packing lists and delivery note
• General condition of the goods
• Damages of the delivery
• Delivery documents
The following shipping documents need to be veried on delivery:
• Delivery note
• Packing lists
Claims as to defects by the customer shall require that he has complied with his duties of examination and
notication of complaint contained in
Sections377, 381 of the German Commercial Code [HGB]. Defects discovered during incoming goods
inspection or later shall be notied to Schletter GmbH in writing without undue delay. A notication shall
not be unduly delayed if it has been made within two weeks; the timely dispatch of this notication shall
be deemed sucient to meet the deadline. Regardless of the obligation to inspect and notify, the customer
shall notify Schletter of obvious defects (including delivery of the wrong product or in not enough quantity)
within two weeks of delivery in writing; the timely dispatch of this notication shall also be deemed
sucient in this case to meet the deadline. A general right to return purchased goods is not granted.
Extract from the General Terms and Conditions of Sale and Supply of Schletter GmbH - download available at www.schletter.de/AGB_en
2.4. Check the scope of delivery
The components will also be delivered in cardboard boxes on pallets. And there also are fragile and sensitive items among
those components.
• Unload the items on rm and stable ground only.
• Protect all components against rain, snow, moisture and other weather conditions.
• Store the items in dry and well-ventilated storage buildings or tents.
• Never store components outdoors or covered by a plastic sheet only.
If you adhere to the hints above, you can prevent the goods from being damaged already before mounting.
Schletter Solar GmbH – Alustraße 1 – 83527 Kirchdorf
Mounting instruction PvMax-S SRF | 2016.07 V.002

©Schletter GmbH as of 07/2016
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System description PvMax-S, steel ground mount system with concrete foundation
Material • Foundation posts: Steel, hot-dip galvanized
• Proles / rails: Steel, hot-dip galvanized
• Fastening elements and screws/bolts: Steel, hot-dip galvanized or high-grade steel
(fastening device, bolts)
Construction • Quick and easy installation
• Highly ecient and material-saving rail geometries
Foundation • Cast-in-place concrete provided by the customer on site according to our specications
• Pre-cast concrete foundations according to data taken from the system structural analysis
Delivery and services • Delivery of single components as well as a maximum level of pre-assembly possible
• Transport to the installation site in accordance with the mounting progress
• Delivery of the complete mounting material
• Structural analysis of the soil and calculation of the foundation including screw anchor
(dowel) recommendation
• Site-specic structural analysis based on local loading data
• Optional: Rack mounting
• Optional: Complete module assembly
Structural analysis • Individual system structural analysis based on regional load values
• Load assumptions according to DIN EN 1990 (Eurocode 0), DIN EN 1991 (Eurocode 1), DIN EN 1993
(Eurocode 3), DIN EN 1999 (Eurocode 9) and further resp. corresponding national standards
• Structural verication of all construction components based on FEM calculation
Module types • Framed modules with a frame thickness of up to 50 mm
• Unframed modules on request
3. Technical data
3.1. System description and properties
3.2. Rack tolerances
PvMax-S is always congured specically for the wind and snow loads at the respective installation site. In the interest of
economic eciency, usually the maximum load-bearing capacity of the individual component is exploited. To achieve this,
however, the racks must be mounted with the utmost precision. If there are signicant deviations from the mounting plans,
this can lead to structural overstress which in turn can lead to damage cases. Schletter GmbH will not assume any liability for
such damages nor for any consequences thereof. Adherence to the specied tolerances is therefore essential to the structural
safety of the rack.
Field span / support width Lateral cantilever
Upper girder
connection
Lower girder
connection
Support width ± 150 mm
Lateral cantilever of purlins ± 100 mm
Lower girder connection ± 100 mm
Upper girder connection ± 100 mm
Clearance between module and clamp 0.5 to 2 mm
Fig. 3.2.-1 (eld span / support width)
Fig. 3.2.-2 (girder connections)
Schletter Solar GmbH – Alustraße 1 – 83527 Kirchdorf
Mounting instruction PvMax-S SRF | 2016.07 V.002

©Schletter GmbH as of 07/2016
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



Concrete foundation
Connection to the concrete foundation
Components Connection elements / fasteners
3.3. Systems overview


Detail A
Fig. 3.3-1 (system visualisation)

Girder

Fastening plate

Module-bearing rail (purlin)



Module clamp adapter kit
Detail B Detail C

Fig. 3.3.-2. (detail A) Fig. 3.3.-3. (detail B) Fig. 3.3.-4. (detail C)







SRF foundation
Hexagon bolt M12x30 DIN933, ange nut M12 DIN6923
and washer M12 DIN9021

Fastening device
Drill screw
Detail A
Detail B
Detail C






Schletter Solar GmbH – Alustraße 1 – 83527 Kirchdorf
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3.4. Components
3.4.1. PvMax foundation and components
143006-200 PvMax-S foundation SRF6
143018-001 Base bracket - concrete connection PvMax-S
943612-090 Hexagon head bolt M12x90 DIN933 A2 GMC
943912-012 Flange nut M12 serrated DIN6923 A4
943922-012 Large washer M12 DIN9021 A2
3.4.2. Module-bearing rails and connection elements
144901-001 FS Uno / Duo purlin
144999-003 FS Uno / Duo fastening device
144999-008 FS Uno / Duo purlin connector Gen2 kit
Fig. 3.4.2.-3 (144999-008)
Fig. 3.4.2.-2 (144999-003)
Fig. 3.4.2.-1 (144901-001)
Fig. 3.4.1.-1 (143018-001)
Schletter Solar GmbH – Alustraße 1 – 83527 Kirchdorf
Mounting instruction PvMax-S SRF | 2016.07 V.002

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3.4.3. Girder assemblies and components
144301-000 FS Duo girder assembly 1V custom cut
144302-200 FS Duo girder assembly 2V custom cut
144303-200 FS Duo girder assembly 3V custom cut
144304-200 FS Duo girder assembly 4V custom cut
144305-200 FS Duo girder assembly 5V custom cut
144306-200 FS Duo girder assembly 6V custom cut
144307-200 FS Duo girder assembly 7V custom cut
144308-200 FS Duo girder assembly 8V custom cut
144301-000 FS Duo girder assembly 1H custom cut
144302-100 FS Duo girder assembly 2H custom cut
144303-100 FS Duo girder assembly 3H custom cut
144304-100 FS Duo girder assembly 4H custom cut
144305-100 FS Duo girder assembly 5H custom cut
144306-100 FS Duo girder assembly 6H custom cut
144307-100 FS Duo girder assembly 7H custom cut
144308-100 FS Duo girder assembly 8H custom cut
144999-006 FS Uno / Duo fastening plate galvanized
943612-030 Hexagon head bolt M12x30 DIN933 A2 GMB
943912-012 Flange nut M12 serrated DIN6923 A4
943922-012 Large washer M12 DIN9021 A2
Fig. 3.4.3.-1 (144302-200)
Fig. 3.4.3.-2 (144999-006)
Fig. 3.4.3.-3 (943612-030)
Fig. 3.4.3.-5 (943922-012)
Fig. 3.4.3.-4 (943912-012)
Schletter Solar GmbH – Alustraße 1 – 83527 Kirchdorf
Mounting instruction PvMax-S SRF | 2016.07 V.002

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3.4.4. Module clamps for vertical module mounting
Steel clamp Rapid clamp* Standard clamp*
Module
height
End clamp
left
Middle
clamp
End clamp
right
End clamp Middle
clamp
End clamp Middle
clamp
20 mm --- --- --- --- --- 130001-020 130002-000
24 mm --- --- --- --- --- 130001-024 130002-000
28 mm --- --- --- --- --- 130001-028 130002-000
30 mm 144912-030 144910-001 144911-030 131001-030 131002-000 130001-030 130002-000
31 mm 144912-031 144910-001 144911-031 131001-031 131002-000 130001-031 130002-001
32 mm 144912-032 144910-001 144911-032 131001-032 131002-000 130001-032 130002-001
33 mm 144912-033 144910-002 144911-033 131001-033 131002-000 --- ---
34 mm 144912-034 144910-002 144911-034 131001-034 131002-000 130001-034 130002-001
35 mm 144912-035 144910-002 144911-035 131001-035 131002-000 130001-035 130002-001
36 mm 144912-036 144910-002 144911-036 131001-036 131002-000 130001-036 130002-001
37 mm 144912-037 144910-002 144911-037 131001-037 131002-000 --- ---
38 mm 144912-038 144910-003 144911-038 131001-038 131002-000 130001-038 130002-001
39 mm 144912-039 144910-003 144911-039 131001-039 131002-000 --- ---
40 mm 144912-040 144910-003 144911-040 131001-040 131002-001 300001-040 130002-001
41 mm 144912-041 144910-003 144911-041 131001-041 131002-001 130001-041 130002-001
42 mm 144912-042 144910-003 144911-042 131001-042 131002-001 130001-042 130002-001
43 mm 144912-043 144910-004 144911-043 131001-043 131002-001 130001-043 130002-001
44 mm 144912-044 144910-004 144911-044 131001-044 131002-001 130001-044 130002-001
45 mm 144912-045 144910-004 144911-045 131004-045 131002-001 130001-045 130002-001
46 mm 144912-046 144910-004 144911-046 131001-046 131002-001 130001-046 130002-001
47 mm 144912-047 144910-004 144911-047 131001-047 131002-001 --- ---
48 mm 144912-048 144910-005 144911-048 131001-048 131002-001 130001-048 130002-001
49 mm 144913-049 144910-005 144913-049 131001-049 131002-001 --- ---
50 mm 144913-050 144910-005 144913-050 131001-050 131002-001 130001-050 130002-001
51 mm --- --- --- --- --- 130001-051 130002-001
* in combination with module clamp adapter
Fig. 3.4.4.-1 (144912-030) Fig. 3.4.4.-2 (131001-030) Fig. 3.4.4.-3 (130001-030)
Schletter Solar GmbH – Alustraße 1 – 83527 Kirchdorf
Mounting instruction PvMax-S SRF | 2016.07 V.002

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3.4.5. Module clamps for horizontal module mounting
Rapid clamp* Standard clamp*
Module height End clamp Middle clamp End clamp Middle clamp
20 mm --- --- 130001-020 130002-000
24 mm --- --- 130001-024 130002-000
28 mm --- --- 130001-028 130002-000
30 mm 131001-030 131002-000 130001-030 130002-000
31 mm 131001-031 131002-000 130001-031 130002-001
32 mm 131001-032 131002-000 130001-032 130002-001
33 mm 131001-033 131002-000 --- ---
34 mm 131001-034 131002-000 130001-034 130002-001
35 mm 131001-035 131002-000 130001-035 130002-001
36 mm 131001-036 131002-000 130001-036 130002-001
37 mm 131001-037 131002-000 --- ---
38 mm 131001-038 131002-000 130001-038 130002-001
39 mm 131001-039 131002-000 --- ---
40 mm 131001-040 131002-001 300001-040 130002-001
41 mm 131001-041 131002-001 130001-041 130002-001
42 mm 131001-042 131002-001 130001-042 130002-001
43 mm 131001-043 131002-001 130001-043 130002-001
44 mm 131001-044 131002-001 130001-044 130002-001
45 mm 131004-045 131002-001 130001-045 130002-001
46 mm 131001-046 131002-001 130001-046 130002-001
47 mm 131001-047 131002-001 --- ---
48 mm 131001-048 131002-001 130001-048 130002-001
49 mm 131001-049 131002-001 --- ---
50 mm 131001-050 131002-001 130001-050 130002-001
51 mm --- --- 130001-051 130002-001
* in combination with module clamp adapter
3.4.6. Module clamp adapter and connection elements for module clamps
144919-050 FS Steel Module clamp adapter KIT
129010-008 KlickIn click component for nut M8
943914-008 Square nut M8 DIN557 A4
Fig. 3.4.6.-1 (144919-050)
Schletter Solar GmbH – Alustraße 1 – 83527 Kirchdorf
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©Schletter GmbH as of 07/2016
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3.4.7. Screws/bolts for Standard module clamps
Frame height
in mm
Hexagon socket
bolt in mm Name
943308-125 20 25 Hexagon socket bolt M8x25 serrated DIN912 A3
943308-130 24. 30. Hexagon socket bolt M8x30 serrated DIN912 A3
943308-135 28 - 30 35. Hexagon socket bolt M8x35 serrated DIN912 A3
943308-120 31 - 35 20. Hexagon socket bolt M8x20 serrated DIN912 A3
943308-125 36 - 40 25. Hexagon socket bolt M8x25 serrated DIN912 A3
943308-130 41 - 45 30. Hexagon socket bolt M8x30 serrated DIN912 A3
943308-135 46 - 51 35. Hexagon socket bolt M8x35 serrated DIN912 A3
The nuts and bolts of the Standard clamps are not included in the scope of delivery and must be ordered separately.
With big order quantities, clamps for other module thicknesses can be manufactured on request!
The Standard clamps are not pre-assembled when they are delivered. These clamps are combined with a hexagon socket
head bolt, a KlickIn click component and a square nut. The screws/bolts listed below can be used for that purpose:
3.4.8. Auxiliary equipment / accessories
964000-176 Paint zinc dust silver gray satin-gloss
149023-001 Cable fastening retainer 1.0-3.0mm, guidance at the top
149023-002 Cable fastening retainer 1.0-3.0mm, guidance at the side
149023-003 Cable fastening retainer 3.0 - 6.0 mm
144999-009 FS Uno / Duo cable fastener purlin
144999-010 Empty cable conduit
Fig. 3.4.8.-4 (149023-001)
Fig. 3.4.8.-1 (144999-009)
Fig. 3.4.8.-3 (149023-002)
Fig. 3.4.8.-2 (149023-003)
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4. Mounting information
4.1. Terrain
When planning the ground-mounted system, make sure that the ground slope is within the tolerances. In the following, the
guiding values for a structurally safe solar plant are specied.
Inclination North - South Inclination East - West
Maximum admissible ground slope
East-West: 10°
Regarding the structural calculations, additional measures
may be required (for example reinforcements)
Maximum admissible ground slope
North-South: 10°
(depending on the condition of the slope, soil
composition, rocks, etc.)
Installations on steeper slopes are only
possible if special measures such as
anchoring or excavations of the terrain
are taken!
The PvMax-S system is customized for the respective installation site. The following indications are already needed during the
planning process:
• Site boundaries
• Rights of way / easements (the building site must be accessible for vehicles at any time)
• Obstacles in the subsoil (pipes, subterranean cables, etc.)
• Weather conditions (wind, rain, snow, etc.)
• Conditions that may inuence the building ground (seismic activities, erosion risks, etc.)
• Geotechnical reports about the topology of the site and the composition of the soil
When mounting the ground-mount system, we recommend:
• Keeping a clearly laid out and detailed daily construction report (site journal), where all daily work steps, employment of
personnel and assembled components are exactly specied.
• Accurately checking and comparing the delivery notes with the delivered goods on the site.
Fig. 4.1.-1 (ground slope)
4.2. Foundation
PvMax-S can basically be combined with all kinds of concrete foundations!
Ground-mounted solar plants are often built on re-vegetated landll sites or agricultural terrains of low quality with bad
subsoil conditions. In such cases a foundation using posts at frost penetration depth mostly is not possible or not reasonable.
Thus, a foundation on concrete blocks made of pre-cast concrete or cast-in-place concrete is recommended as a standard
option. This kind of foundation is virtually always possible and easy to carry out.
Other types of foundation on request!
Whether or not the subsoil is suitable for a certain type of foundation generally has to be determined on site in each case.
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4.2.1. Pre-cast strip foundations
4.2.2. Dimensioning and reinforcement
The dimensioning of the foundations is carried out according to the structural analysis (by all means do specify the load
parameters - especially the wind loads!) The foundations have to be reinforced by the concrete builder according to the
loads that have to be considered.
As a standard, strip foundations are put under the supports (continuous strips parallel to the module rows are also possible).
The weight of the foundations has to be dimensioned in such a manner that the wind loads are compensated by the founda-
tion weight only.
4.2.3. Preparation of the terrain and positioning of the foundations
Before setting up the PvMax-S system, the terrain must be prepared for the positioning of the concrete foundations. Please
consider that individual sub-racks that are part of one rack are not parallel to the subsoil beneath them. Thus, the founda-
tions have to aligned correctly. This alignment must be maintained for all the racks in order to avoid "terracing" that would
lead to shades on individual racks.
WARNING
• Only use construction machines and site vehicles that comply with local safety requirements and
which ensure protection of health and safety when used as intended.
• Secure the work area by taking appropriate measures and make sure that there are no unauthorized
persons in the work area of the construction machines.
• See to it that persons who are performing earthworks are protected by personal protective
equipment (PPE), such as high-visibility vest, safety shoes and hard hat).
NOTICE
If the terrain structure is too uneven, soil has to be removed and the terrain has to be graded, if necessary.
Fig. 4.2.3.-1 (removing soil and grading the terrain structure)
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NOTICE
The concrete foundations must be aligned ush on a gravel bed. The rack can only be installed properly, if
all foundations are correctly aligned and at the same level.
Maximum height tolerance within the foundations: ± 30 mm.
NOTICE
Also when using a cast-in-place foundation, make sure that the foundations are cast up to the same height.
Fig. 4.2.3.-2 (ush alignment of the concrete foundations)
Fig. 4.2.3.-3 (casting up the concrete foundations to the same height)
Cast-in-place
concreteCasting mold
4.2.4. Tolerances regarding inclination and distortion (twist)
Inclination of the concrete founda-
tion (East-West)
Twist of the support
on the concrete
foundation
± 2° ± 2°
Fig. 4.2.4.-1 (twist / distortion) Fig. 4.2.4.-2 (east-west tilt of the concrete foundation)
Flush height
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4.3. Tools
In the following, the tools that are usually required for mounting the PvMax-S system are listed. Additional tools that are
required for special cases (for example encasing the foundations in concrete) are not listed here.
4.3.1. Surveying, staking and aligning the foundations
4.3.2. Rack mounting
• Measuring tapes (100 m)
• Line pins (about 20 pieces)
• Mason's lacing cord
• Club hammer
• Wooden stakes
• Color spray (for ground marking etc.)
• Permanent marker
• Spirit level
• Shovel
• Chains / straps to lift the foundations
• Torque wrench (30 Nm to 60 Nm)
• Wrench socket size 17
• Wrench socket size 19
• Hammer
• Club hammer (to hold against the connector hook)
• Plastic tip hammer
• Angle meter (goniometer) - spirit level
• Mason's lacing cord
• Cordless screw driver
• Drill hammer with drill
• Air pump for blowing out the drill holes
We recommend using torque wrenches for all bolted connections. With fast rotary motions, there is an
increased danger of "jamming / bolt blocking"!
The fasteners (e.g. dowels/screw anchors) are not included in the scope of delivery!
NOTICE
For the assembly of the PvMax-S system, please exclusively use the tools recommended.
If you use tools that are not intended for this purpose, the rack can be damaged and the structural safety of
the plant could thus be endangered!
T
he selected fasteners (e.g. screw anchors/dowels) must be appropriate for the fastening forces that are specied
in the structural analysis! The customer has to add an accordant structural verication to the documents.
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4.3.4. Module mounting
• Mason's lacing cord
• Measuring tape
• Possibly distance template for distances between the modules
• Cordless screw driver
• Size 8 socket for cordless screwdriver
• Size 6 hexagon socket wrench / 40TX key
• Torque wrench (< 8 Nm)
• Size 6 hexagon socket wrench / 40TX bit for torque wrench
4.4. Torque specications
4.4.1. Bolted connections in the substructure
Name Tightening torque (MA-Nm)
Hexagon head bolt DIN933 M12x30
A2 GMB
Flange nut DIN6923 M12 A4
Washer, large DIN9021 M12 A2
56 Nm
Fig. 4.4.1.-1 (screw connection M12)
4.4.2. Fastening of the module clamps
Name
Tightening
torque (MA-Nm)
Module
arrangement
Hexagon socket bolt DIN4762 M8
(20 - 35 mm)
KlickIn click component for nut M8
Square nut DIN557 M8 A4
14 Nm H and V in com-
bination with
module clamp
adapter
Hexagon socket bolt DIN912 M8 A2
(25 - 45 mm)
8 Nm V
TX stud screw M8 A2 GMC
(42.5 - 55 mm)
14 Nm H and V in com-
bination with
module clamp
adapter
Always fasten the bolted connection by turning the bolt head! When checking
the pre-stress of the bolts, it has to be considered that constraints and frictional
forces can lead to a loss of clamping force. This was taken into consideration when
the tightening torques were determined. When a bolted connection is checked, it
must not loosen when 50% of the specied tightening torque is applied.
Fig. 4.4.2.-1 (Standard module clamp)
Fig. 4.4.2.-2 (steel module clamp)
Fig. 4.4.2.-3 (Rapid2+ module clamp)
Schletter Solar GmbH – Alustraße 1 – 83527 Kirchdorf
Mounting instruction PvMax-S SRF | 2016.07 V.002