Schletter FS DUO User manual

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FS DUO
INSTALLATION MANUAL

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Table of contents
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Mounting..........................................................................................................................................................4
1. GENERAL INFORMATION.............................................................................................................4
1.1 Short description of the system.............................................................................................4
1.2 Scope of the installation manual............................................................................................4
1.3 Appropriate use............................................................................................................................4
1.4 Copyrights and property rights...............................................................................................4
1.5 Safety Instructions......................................................................................................................5
1.6 Obligation of the Operator........................................................................................................7
1.7 Obligation of the personnel......................................................................................................7
1.8 Qualification of the personnel.................................................................................................8
1.9 Additional assembly-relevant documents...........................................................................8
2. TRANSPORT, LOADING AND UNLOADING................................................................................9
2.1 Delivery of the components.....................................................................................................9
2.2 Preparation of delivery...............................................................................................................9
2.3 Providing forklifts and lifting equipment...........................................................................10
2.4 Inspection of the scope of delivery.....................................................................................10
2. 5 Storage of the components..................................................................................................11
3. TECHNICAL SPECIFICATIONS......................................................................................................12
3.1 System designation and specifications..............................................................................12
3.2 Mounting Tolerances.................................................................................................................13
4. SYSTEM OVERVIEW.........................................................................................................................14
4.1 System overview for system with portrait module arrangement
and combined clamping...................................................................................................................14
4.1.1 Components.............................................................................................................................14
4.2 System overview for system with portrait module arrangement
and quarter-point clamping...........................................................................................................15
4.2.1 Components.............................................................................................................................15
4.3 System overview for system with landscape module arrangement
and rafters with module clamp.....................................................................................................16
4.3.1 Components.............................................................................................................................16

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5. COMPONENT OVERVIEW................................................................................................................17
6. ASSEMBLY INSTRUCTIONS...........................................................................................................19
6.1 Building ground...........................................................................................................................19
7. FOUNDATION.....................................................................................................................................20
7.1 Verification of the GPS-Points...............................................................................................20
7.2 Pile-driving tolerances..............................................................................................................21
7.3 Pile-driving obstacles and concrete-embedding of the posts...................................21
7.4 Tools................................................................................................................................................22
7.5 Positioning and staking of the foundation posts............................................................22
7.6 Pile driving....................................................................................................................................23
7.7 Rack Mounting.............................................................................................................................23
7.8 Module mounting........................................................................................................................24
7.9 Torque specifications................................................................................................................24
8. INSTALLATION STEPS.....................................................................................................................25
8.1 Pile driving and application of corrosion protection......................................................25
9. RACK MOUNTING - GIRDERS & PURLINS...............................................................................27
9.1 Fastening of the girders on the foundation posts.........................................................27
9.2 Mounting of the purlins..........................................................................................................28
10. INSTALLING THE PURLIN CONNECTOR.................................................................................29
11. INSTALLING THE RAFTERS (FOR LANDSCAPE INSTALLATION)..................................29
12. MODULE INSTALLATION (¼ POINT LANDSCAPE INSTALLATION)..............................31
13. MODULE INSTALLATION (PORTRAIT MOUNTING)...........................................................33
13.1 Special case combined clamping.......................................................................................35
14. MAINTENANCE AND CARE..........................................................................................................36
15. DISASSEMBLY AND DISPOSAL.................................................................................................37
15.1 Safe disposal of individual parts........................................................................................38
16. WARRANTY AND LIABILITY........................................................................................................38
16.1 Disclaimer...................................................................................................................................38
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Mounting
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1. GENERAL INFORMATION
1.1 Short description of the system
The FS Duo is a material optimised steel-system for the mounting of photovoltaic modules in
open areas. The support structure is made of zinc-magnesium coated or continuously hot-dip
coated steel, the fastening elements and screws consist of zinc-flake coated steel or stainless
steel and the rafters (module-bearing profiles) are made of aluminium. Depending on the module
orientation, the FS Duo is installed with or without rafters.
Accessories for the cable management or components for the potential equalization in the
mounting system can be installed additionally. The cable duct is already integrated in the purlin.
1.2 Scope of the installation manual
These mounting instructions explicitly only provide instructions for the mechanical mounting of
the FS Duo. They expressly do not give instructions for working procedures in connection with
electrical or electronic components! Please note that any work in connection with electrical or
electronic components may only be carried out by appropriately qualified personnel.
1.3 Appropriate use
The FS Duo serves as a substructure for the installation of photovoltaic modules. Any other
and/or additional use or incorrect assembly (e.g. use of third-party components) or non-
observance of tolerance specifications are considered as improper use and exclude any liability of
the manufacturer. Any use under conditions other than those assumed in the planning is also
considered as improper use and leads to the loss of any liability claims against the manufacturer.
This applies in particular if the system is used under other load conditions, under other soil
conditions, under other climatic conditions and/or under other corrosion conditions than originally
assumed. Schletter Solar GmbH is in no case responsible for damages to the product itself or
consequential damages caused by the product which are the result of an inappropriate handling
of the product.
Schletter Solar GmbH is in particular not responsible for outages or faults resulting from
modifications made by the customer or other persons. There is no entitlement to the availability
of previous versions or to the re-fitting of delivered components to the current series status.
1.4 Copyrights and property rights
The entire content of these mounting instructions is the intellectual property of Schletter Solar
GmbH and is subjected to the German copyright law. Any multiplication, modification,
distribution, surrender to third parties - even in excerpts - and any kind of use exceeding the
limits of the copyright law require the written consent of the Schletter Solar GmbH.
Schletter Solar GmbH explicitly reserves the right to take legal steps in the case of violation.
These assembly instructions are subject to change without notice. Any product names mentioned
in these assembly instructions are trademarks of the Schletter Solar GmbH and are herewith
acknowledged.

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Schletter Solar GmbH has made significant efforts to ensure that these assembly instructions are
free of errors and omissions. Should nevertheless doubts arise as to the correctness and/or
completeness of the instructions, the installer is obliged to consult the manufacturer. No liability
or responsibility is assumed by Schletter Solar GmbH for potential errors contained in these
assembly instructions or for incidental, concrete or consequential damages resulting from the
provision of these assembly instructions.
1.5 Safety Instructions
Read these assembly instructions carefully before starting the assembly and keep them safely at
hand! Comply with all regional and national valid standards, building regulations and accident
prevention regulations!
Make sure to read and understand the safety and warning instructions in these assembly
instructions and apply them in any case, depending on the conditions and working tasks!
This manual contains instructions that must be followed for your personal safety and to avoid
personal injury or property damage. These are marked by a warning triangle. Depending on the
type and degree of danger, warning notices are illustrated as follows:
DANGER
indicates that death or serious physical injury will occur if the required safety measures are not
taken.
WARNING
indicates that death or serious physical injury may occur if the required safety measures are not
taken.
CAUTION
indicates that minor physical injury may occur if the required safety measures are not taken.
DANGER
by handling of electric current.This can lead to severe accidents and cause major injuries.
Appropriate safety precautions must be taken.
SECURING OF THE WORKING AREA
Prior to the beginning of the mounting operations, the construction site must be inspected by a
supervising person by visual inspection or by means of plans showing all supply lines. For this
purpose, the location of all types of underground supply lines must be identified with marking
paint or barriers and non-load-bearing ground or fall-risk zones must be blocked by stable
barriers or warning boards.
Important information and advice
concerning the product and its handling and assembly are marked by this symbol.

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ATTENTION
warns you of situations that can lead to material damage and disturbance in the workflow if the
instructions are not observed.
REFERENCES
Assembly-related documents that are not part of these mounting instructions are indicated by
this symbol.
By all means the following personal protective equipment must be worn for the installation of FS
Duo:
Wear high visibility
vest and safety shoes
at any time
Wear ear protection
during noisy activities
Wear a safety helmet
when working with falling
loads or risk of impact
Wear protective gloves
when working with sharp-
edged parts
Wear respiratory
protection for all dusty
activities
Wear safety glasses
at grinding and cutting
activities, as well as
activities where eyes are
endangered by flying
parts/liquids
Wear safety shoes
at any time
Furthermore, please observe the rules and regulations for accident prevention and environmental
protection valid for the place of installation, as well as any work and operating instructions of the
operator and the premises. 

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1.6 Obligation of the Operator
It is the obligation of the operator to ensure that all parts of the mounting instructions are kept
within easy reach on the PV-plant for the fitters at any time.
The operator is obligated to only allow persons to work on and in the area of the plant
who:
 are qualified for the respective activity and have read and understood the relevant parts of
the mounting instructions
 are aware of the essential regulations on work safety, accident prevention and environment
protection
 have been briefed on the safe handling of the installation (instruction)
Prior to the beginning of the installation, the operator defines a supervising person and
ensures that
 the building site is inspected and secured with the help of plans showing all supply lines and
that the location of all types of underground supply lines and non-load-bearing grounds are
marked in a suitable way or blocked by barriers.
1.7 Obligation of the personnel
As personnel, only persons who can be expected to carry out their work reliably can be admitted.
Persons whose responsiveness is affected, e.g. by narcotics, alcohol or medication, are NOT
permitted.
 Any person involved in the installation of the FS Duo must have read and understood these
mounting instructions, especially the chapter "1.5. safety instructions", as well as all relevant
chapters relating to the respective activity.
 These mounting instructions must be kept accessible and at hand for all persons involved at
any time.
 Only trained and instructed personnel may perform the activities specified in this document.
 Auxiliary personnel may only work on the installation of the FS Duo under the supervision of
an experienced person.
It is recommended to the operator to have each of these confirmed in writing.
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1.8 Qualification of the personnel
These mounting instructions are intended for qualified personnel for the sections transport and
loading, mounting, dismounting and disposal with the following qualifications:
 Based on their professional training, experience, knowledge and the knowledge of the
applicable regulations, the qualified personnel are able to carry out the work assigned to
them and to independently recognize and avoid potential risks.
 The qualified personnel have the necessary knowledge of the safety, accident prevention and
environmental protection guidelines applicable at the relevant construction site, as well as the
regulations for loading and unloading.
 The qualified personnel hold the required driving licences to drive the construction site
vehicles and building machinery at the construction site.
 The qualified personnel is sufficiently trained for the respective tasks.
1.9 Additional assembly-relevant documents
In addition to these mounting instructions, the following documents are required for the
installation of the FS Duo:
 Pile-driving plan & dimensional chain
 Overview drawing, if necessary plan showing all supply lines
 Material list
 Delivery note, packing lists
 DIS unloading guideline for delivery via sea containers
 General terms of sale and delivery of Schletter Solar GmbH
 Regulations for accident prevention and environmental protection
 if necessary, work and operating instructions of the operator / the operating site.
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2. TRANSPORT, LOADING AND UNLOADING
WARNUNG
 Always wear your personal protective equipment (safety shoes, safety helmet, safety glasses,
protective gloves and safety vest) while loading or transporting FS Duo components on the
construction site. (See section 1.5. Safety Instructions).
 Furthermore, wear the personal protective equipment specified in your factory regulations for
the specific task.
 The monitoring of the entire unloading process is mandatory.
 Never step below lifted loads.
 Make sure that there are no unauthorized persons in the danger zone.
 Only use certified and undamaged lifting- and auxiliary equipment.
Make sure to observe all country-specific regulations and standards of the destination country as
well as your work instructions!
2.1 Delivery of the components
The components for FS Duo are delivered with a suitable vehicle, e.g.
 lorries (trucks) or
 overseas containers (observe DIS unloading guideline)
2.2 Preparation of delivery
 Prepare a solid and passable surface for the delivery.
 Ensure that all access roads, manoeuvering areas and unloading areas are accessible for
trucks (up to 40 tons) and can be used by forklifts and lifting equipment.
 Only provide qualified technical personnel for the loading and transport works.
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2.3 Providing forklifts and lifting equipment
 Organise appropriate forklifts and lifting equipment for the delivery date.
 Choose suitable forklifts and lifting equipment in consultation with the responsible site management.
 Make sure that the components, pallets and long items can be unloaded duly.
 Provide forklifts and lifting equipment with different fork spacing or with adjustable forks.
 Please observe the DIS unloading guideline!
2.4 Inspection of the scope of delivery
The following accompanying documents must be checked upon delivery:
 delivery note
 packing lists
We recommend that you pay attention to the following points at receipt of the goods:
 Visual inspection of the delivered material
 Verification of conformity with the supply contract
 Delivered quantity / comparison with packing lists and delivery note
 General condition of the material
 Damage to the delivery
 Delivery documents
Warranty claims of the customer presuppose that he has complied with his obligations of
examination and notification of defects according to §§ 377, 381 HGBIn the event that a defect is
discovered during the incoming goods inspection or later, this must be reported to Schletter Solar
GmbH immediately in writing. The report is considered as immediate if it is made within two
weeks, the timely dispatch of the report being sufficient to meet the deadline. Regardless of this
obligation to inspect and give notice of defects, the customer must report any obvious defects
(including false and incomplete deliveries) in writing within two weeks of delivery, the timely
dispatch of the report also being sufficient to meet the deadline. There is no general right of
return.
Excerpt from the general sales and delivery conditions of Schletter Solar GmbH - available for download on
https://schletter-group.com/downloads/?lang=en

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2. 5 Storage of the components
The components are partly delivered in cardboard boxes on pallets. Among the components there
are breakable and fragile parts.Laden Sie die Komponenten nur auf festem und tragfähigem
Untergrund ab.
 Only unload the components on solid and stable ground.
 Protect all sensitive components from rain, snow, humidity and other weather influences.
 Store all sensitive components in dry and well-ventilated storage facilities or tents.
 Never store the sensitive components outdoors or covered only with a foil.
Thereby you prevent damage before installation.
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3. TECHNICAL SPECIFICATIONS
3.1 System designation and specifications
System designation  FS Duo - two-support steel system for open
areas
Material  Foundation posts: steel, continuously hot-dip
coated according to DIN EN 10327
 Girders/ Purlins: Steel coated with zinc
magnesium alloy, alternatively continuously hot-
dip coated according to DIN EN 10327
 Rafters: Aluminium / steel
 Module clamps: Aluminium
 Fasteners and screws: Steel, zinc flake coated or
stainless steel
 Structural analysis of the terrain based on an
external soil expertise
Structural
dimensioning  Individual system structural analysis based on regional data and guidelines
 Load assumptions according to DIN1055, part 4
(03/2006), part 5 (06/2005), part 100
(03/2001), Eurocode 1 (06/2002), DIN4113,
DIN18800, Eurocode 9 and further or
corresponding national standards.
 Verification of all structural components on the
basis of FEM calculations or verification
according to structural test setup.
Characteristics of the
design  Quick and easy mounting  Highly efficient and material-economic profile
geometries
 Available in individual parts or, upon request,
maximally pre-assembled
Delivery and service  Individual structural analysis based on regional
data
 Supply of the structural components
 Delivery of structural components or pick-up
from manufacturing facility
Module types  Framed modules with a frame height between
30 mm and 50 mm
 Frameless modules upon request

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3.2 Mounting Tolerances
The FS Duo is always explicitly designed for the wind and snow loads of the specific location. In
favour of economic efficiency, the subcomponents are typically utilised to their maximum load-
bearing capacity. Thus the mounting racks must be installed with high precisionIn case of
significant deviations from the assembly plans, static overstressing and can occur. For these and
their consequences, Schletter Solar GmbH does not assume any liability. Therefore, compliance
with the tolerances listed below is essential for the structural safety of the rack.
Embedment depth of the foundation post ± 100 mm
Field span ± 150 mm
Lateral cantilever ± 100 mm
Lower girder connection ± 100 mm
Upper girder connection ± 100 mm
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Lateral cantilever
Seitliche Auskragung
Upper girder
connection
Lower girder
connection
Field span

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4. SYSTEM OVERVIEW
According to the requirements, the system can be designed in different variations. For portrait
mounting with a girder-purlin construction on the one hand and with additional rafters for
landscape mounting on the other.
4.1 System overview for system with portrait module arrangement and combined
clamping
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4.1.1 Components
Foundation post
Hexagon head screw M12x30
FS girder
FS UNO/DUO connector purlin-girder
Hexagon head screw M10x50
Purlin LC/LT/Zeta
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
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

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

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4.2 System overview for system with portrait module arrangement and quarter-point
clamping
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4.2.1 Components
Foundation post
Hexagon head screw M12x30
FS girder
FS UNO/DUO connector purlin-girder
Hexagon head screw M10x50
Purlin LC/LT/Zeta
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

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


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4.3 System overview for system with landscape module arrangement and rafters with
module clamp
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4.3.1 Components
Foundation post
Hexagon head screw M12x30
FS girder
FS UNO/DUO connector purlin-girder
Hexagon head screw M10x50
Purlin LC/LT/Zeta
FS Uno/Duo purlin claw
Screw M10x25 square
Module bearing rail aluminium/steel
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







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5. COMPONENT OVERVIEW
RAFTER
120012-111 Mod. bear. rail R1 - project length
120013-111 Mod. bear. rail R2 - project length
120014-111 Mod. bear. rail R3 - project length
144502-047 FS Rafter A47
PURLIN
144901-001 FS Uno/FS Duo purlin 5 project length
144901-017 FS Purlini LC90SH project length
144901-018 FS Purlin LT100SH project length
000014-577 FS Uno/FS Duo purlin connector Galv. Gen2
144999-085 FS Purlin Connector LT/LC
GIRDER
144099-009 FS Girder SH P1 project length
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ARTICLE NUMBER ITEM NAME
GIRDER-PURLIN CONNECTOR
144999-086 FS UNO/DUO connector purlin LC Girder
144999-088 FS UNO/DUO connector purlin-girder galv
PURLIN RAFTER CONNECTION
144999-021 FS Uno/Duo purlin claw VA
MODULE CLAMPS
131121-002 Middle clamp Rapid16 40 – 50
131101-002 End clamp Rapid16 40 - 50
131121-001 Middle clamp Rapid16 30 - 40
131101-001 End clamp Rapid16 30 - 40
131101-003 End clamp Rapid16 H 30 - 40
131121-112 Middle clamp Rapid16 40 – 50 L
131121-111 Middle clamp Rapid16 30 - 40 L
131101-101 End clamp Rapid16 30 - 40 L
131101-102 End clamp Rapid16 40 - 50 L
131101-103 End clamp Rapid16 H 30 - 40 L

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FOUNDATION POSTS
143006-200 Steel foundation post SRF6 cust. Size
143007-200 Steel foundation post SRF7 cust. Size
143012-010 Foundation post SRF6 extens.L1000mm galv
143012-020 Foundation post SRF7 extens.L1000mm galv
SMALL MATERIAL
942000-880 Nut M10 hexagon ISO 4032 ZFC
942000-881 Nut M12 hexagon ISO 4032 ZFC
942000-872 Flat washer M10 ISO 7089 200HV zfc
942000-873 Flat washer M12 ISO 7089 200HV zfc
942000-874 Screw M10x30 hexagon ISO 4017 st.8.8 zfc
942610-050 Screw M10x50 hexagon ISO4017 8.8 ZFC
942000-882 Screw M12x30 hex. DIN933 8.8 zfc
943912-010 M10 Flange nut serrated DIN6923 A4
943912-012 M12 Flange Nut serrated DIN6923 A4
943922-010 M10 Large Washer DIN9021 A2
943922-012 M12 Large Washer DIN9021 A2
943410-025 Screw M10x25 square A2 GMB
943610-030 Bolt M10x30 hexagonal DIN933 A2 GMB
943610-050 M10x50 Hexagon head bolt DIN933 A2 GMX
943612-030 Anti-Seize Coated M12x30 Bolt DIN933 A2
000016-673 FS steel locking plate
964000-176 Paint zinc dust silver gray satin-gloss
149023-001 Fastening retainer 1.0-3.0mm upper guide (Zeta purlin)
129012-011 FSAS Cable clip (LC/LT Purlin)
144504-015 FS-Gen3 SRF6 Tilt Head
144504-016 FS-Gen3 SRF7 Tilt Head
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6. ASSEMBLY INSTRUCTIONS
The FS Duo is planned individually for the specific location. The following information is
required already in the planning stage:
 Property lines
 Rights of way, the property must be accessible at any time
 Obstacles in the building ground (pipelines, underground cables, etc.)
 Weather conditions (wind, rain, snow, etc.)
 Conditions that may have an impact on the building ground (seismic events, risk of erosion,
etc.)
 Geotechnical reports on the topology of the site and the soil composition
For the mounting of the racks we recommend
 to keep a clear and detailed site report in which all daily work steps, personnel deployment
and assembled material are recorded.
 to carefully compare the delivery notes with the delivered material on the construction site
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6.1 Building ground
Consider the admissible ground slope already at the planning stage of the ground mount system.
The following guide values provide the basis for the structural safety of the system:
Maximum admissible
ground slope east-
west: 10°
Maximum admissible
ground slope north-
south: 35°
(depending on the slope
properties, soil composition, rocks,
etc.)
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FS DUO | 400224EN | V4 | INSTALLATION MANUAL | 202011 20
SCHLETTER SOLAR GMBH | SUBJECT TO MODIFICATIONS
The Schletter mounting systems do not follow the terrain topgraphy within one rack. Height
differences of the ground within one rack can be compensated by the foundation posts.
Therefore, align the foundation posts with a cord regarding their height already at the pile-driving
operations. The tolerance of the embedment depth is ± 100 mm.
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7. FOUNDATION
7.1 Verification of the GPS-Points
A verification of the measuring points is of particular importance on very uneven terrain. If the
measuring points have been determined with the help of GPS devices, the foundation posts can
often be offset in a north-south direction. This can make the rack mounting more difficult.
Therefore, check the GPS points with try square and cord, as shown in the following diagram,
before starting the pile driving
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200 mm 100 mm
100 mm
Cord in alignment
. Winkel
GPS-Point (Verification of GPS-Points)