Schweizer Solrif XL User manual

Ernst Schweizer AG, Metallbau, CH-8908 Hedingen, Telefon [phone], Telefax [phone], www.schweizer-metallbau.ch
Solar Energy Systems of Schweizer:
Installation Manual
Solrif®XL / D
September 2009
Solrif®XL / D
Mounting Directions for In-Roof Photovoltaic Systems

Ernst Schweizer AG, Metallbau, CH-8908 Hedingen, Telefon [phone], Telefax [phone], www.schweizer-metallbau.ch
Contents
1 About this Installation Manual 4
1.1Revisions 4
1.2Validity 4
1.3TargetGroup 4
1.4Warnings,Symbols,Displays 4
1.4.1 Warnings in this Document 4
1.4.2 Symbols and Displays 5
2SafetyInstructions 5
2.1 Use According to Regulations 5
2.2 Safety Regulations 6
2.3 Personnel Qualifications 5
2.4 Changes and Alterations 6
2.5 Sources of Danger 6
2.5.1 Electrical Installation 7
2.5.2 Working on the Roof 7
3Instructions 7
3.1Overview 8
3.2 Solrif®-framed Photovoltaic Modules 8
3.3Substructure 9
3.5 Required Components for In-Roof Mounting / Flashing 12
3.5.1 Flashing profiles 13
3.5.2 Flashings 15
3.5.3 Eaves Skirting, Sealing Tape for Seams and Clamps for the Lower Seam 18
4 Mounting 20
4.1 Tools, Auxiliary Material 20
4.2PreliminarySteps 21
4.2.1 Structure Statics in Accordance with DIN 1055/Eurocode 1 21
4.2.2 General Planning 21
4.3Wiring 24
4.4 In-Roof Mounting 25
4.4.1 Installing the Photovoltaic Modules 25
4.4.2 Roof Seams 32
4.5 Potential Equalization and Lightning Protection 40
6 Dismounting 40
7Control 41
8Disposal 41
9ListofParts 41
9.1 Accessories for Solrif®XL 41
9.2 Accessories for Solrif®D 42

Solar Energy Systems 01.09.2009 Page 3
Mounting Directions for In-Roof Photovoltaic Systems
Ernst Schweizer AG, Metallbau, CH-8908 Hedingen, Telefon [phone], Telefax [phone], www.schweizer-metallbau.ch
1 About this Installation Manual
These instructions describe a quick and reliable in-roof installation of the photovoltaic system.
Read this manual carefully before starting with the installation.
Keep this manual for as long as the photovoltaic system is in use.
Be sure that this manual can be made available to the operator at all times.
Hand this manual on to all subsequent owners or users of the photovoltaic system.
Insert all supplemental information received from the producer.
Heed all other applicable documents.
1.1 Revisions
Date Version What’s new?
12 Feb. 2009 1 complete update
20 April 2009 1.1 potential equalization supplement
Table 1-1: Revisions
1.2 Validity
This manual is valid exclusively for the installation of Ernst Schweizer AG photovoltaic modules Solrif®XL and
Solrif®D.
1.3 Target Group
This manual is intended for installers of photovoltaic systems as well as for qualified technicians specializing in the
mounting, operating and maintenance of photovoltaic systems.
1.4 Warnings, Symbols, Displays
1.4.1 Warnings in this document
In this instruction manual warning signs are used in order to prevent injuries and damages.
Read and always heed these warning signs.
Warnings are marked by the following symbols and terms:
DANGER
Imminent Danger.
Negligence could lead to death or serious injury.
WARNING
Impending Danger.
Negligence could lead to death or serious injury.

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Mounting Directions for In-Roof Photovoltaic Systems
Ernst Schweizer AG, Metallbau, CH-8908 Hedingen, Telefon [phone], Telefax [phone], www.schweizer-metallbau.ch
CAUTION
Dangerous Situation.
Negligence could lead to injury.
CAUTION
Critical Situation.
Negligence could lead to material damage.
1.4.2 Symbols and Displays
In this installation manual symbols and displays are used to facilitate comprehension.
Symbol Meaning
Prerequisite to this specific stage of
installation.
Installation stage with one or more
steps, the order of which is not
important.
1.
2.
3. ...
Installation stage with several steps, the
order of which is relevant and therefore
listed.

– Listing at the first level
Listing at the second level, including
stage instructions
(cf. chapter) Cross reference within this installation
manual
Table 1-2: Symbols and Displays
TIP
Important information towards understanding or towards optimizing the process of installation.

Solar Energy Systems 01.09.2009 Page 5
Mounting Directions for In-Roof Photovoltaic Systems
Ernst Schweizer AG, Metallbau, CH-8908 Hedingen, Telefon [phone], Telefax [phone], www.schweizer-metallbau.ch
2 Safety Instructions
2.1 Use According to Regulations
The photovoltaic system is intended solely for the generation of solar power. Mounting is to occur only upon roof
constructions in accordance with the present installation manual.
There is no guarantee for alternative applications, even if analogous. Categorically any such application is not in
accordance with regulations.
2.2 Safety Regulations
The operator of the photovoltaic system is responsible for seeing that all relevant legal regulations and guides are
adhered to.
Start, operate and maintain the photovoltaic system only in accordance with the following regulations and
standards.
Installation manual
Warning labels and tips on the photovoltaic module
Further applicable documents
System specific regulations and requirements
Valid international, national and regional specifications, especially as pertaining to the installation of electrical
appliances and systems, to working with direct current and to the regulations of the local power company
applicable to parallel operation of solar power system
Regulations of the construction employers’ liability insurance association
Regulations concerning accident prevention
2.3 Personnel Qualifications
The operator and the installer are responsible for engaging only trained and schooled specialists to carry out
installation, maintenance, initial operation and dismounting.
Ensure all personnel have understood this manual and are capable of implementing the instructions.
Ensure all personnel are familiar with and adheres to the pertinent accident prevention and safety regulations.
Ensure all personnel uses appropriate protective clothing and equipment.
2.4 Changes and Alterations
Changes and alterations to the installation system can damage the photovoltaic module or impair its proper
functioning.
Refrain from making changes or reconstructions during the process of installation, excepting for the steps
described in this manual.
2.5 Sources of Danger
The photovoltaic module is a product made of glass and should be handled as such.
Do not place against bare edging.
Do not step on or burden improperly.

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Mounting Directions for In-Roof Photovoltaic Systems
Ernst Schweizer AG, Metallbau, CH-8908 Hedingen, Telefon [phone], Telefax [phone], www.schweizer-metallbau.ch
2.5.1 Electrical Installation
Ensure that the electrical installation and initial operation is carried out by a licensed electrician.
See that the entire off-circuit voltage is hooked up even by minimal sunshine.
Do not exceed the maximum permissible system voltage of the photovoltaic modules even by low
temperatures.
Electric Arcs on Direct Current Conductors!
Simultaneous contact to both poles causes fatal injury.
Do not sever live cables.
Bare cable ends should be connected or insulated.
Voltage Higher than Safety Extra-Low Voltage (SELV)!
Injury to persons due to summation of voltage during series connection
Observe proper safety and security measures.
Dampness During Electrical Installation!
Injury to persons, damage to the system
Carry out work on the system only on a dry undersurface.
During installation see that photovoltaic modules, wiring, etc., are dry.
2.5.2 Working on the Roof
TIP
Safety regulations state that work higher than 3 meters (eaves height) requires scaffolding with safety nets.
If it is not possible to put up scaffolding or if the roof is very steep:
Put on a safety harness and attach it to a stable structure.
Use a proper safety rail when working on the roof.
Arrange for a suitable work surface for tools and material.
Arrange for cordoned off areas to protect against falling objects.
Heed all relevant regulations for working on a roof.

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Mounting Directions for In-Roof Photovoltaic Systems
Ernst Schweizer AG, Metallbau, CH-8908 Hedingen, Telefon [phone], Telefax [phone], www.schweizer-metallbau.ch
3 Instructions
3.1 Overview
Image 3-1: Exploded drawing of the photovoltaic system
1 Eaves-side skirting and sealing tape 8 Batten for roof tiles
2 Sheet grips 9 Side flashing upper left
3 Mounting clamp 10 Ridge-side flashing left corner
4 Cylinder-head screw (5 x 35) 11 Solrif®-framed photovoltaic module
5 Flashing (left side) 12 Join capping piece
6 Flashing profile (left) 13 Flashing ridge middle
7 Mounting board 100 x 30

Solar Energy Systems 01.09.2009 Page 8
Mounting Directions for In-Roof Photovoltaic Systems
Ernst Schweizer AG, Metallbau, CH-8908 Hedingen, Telefon [phone], Telefax [phone], www.schweizer-metallbau.ch
3.2 Solrif®-framed photovoltaic modules
Solrif®-framed modules consist of standard modules mounted with special Solrif® profile frames and sealed
watertight.
The profile frames of adjoining modules fit neatly together, thus forming the water runoff level of the roof. Along the
sides impermeability between the overlapping module edges is guaranteed by means of an additional rubber lip.
By roof slopes >10° the rainproof integration of the modules into the roofing is thereby possible in accordance with
guidelines set by the German Roofers’ Association (ZVDH).
Ready to mount Solrif®-framed photovoltaic modules for in-roof installation can be obtained by various means:
Solrif®frame kit with framing from Schweizer
Module manufacturers, wholesalers or partners of the Ernst Schweizer AG.
The modules have the following measurements:
Measurement Lamination
measurement L x W
Framed module (mm) (L+50) x (W+32)
Laying measurements
(mm) (L+31) x W
Thickness (mm) Ca. 34
Mass (kg) Lamination + ca. 1.5 -
2.5
Table 3-1: Measurements of the photovoltaic modules
TIP
Please always consult the current data sheets for the exact specifications of framed modules.

Solar Energy Systems 01.09.2009 Page 9
Mounting Directions for In-Roof Photovoltaic Systems
Ernst Schweizer AG, Metallbau, CH-8908 Hedingen, Telefon [phone], Telefax [phone], www.schweizer-metallbau.ch
1
2
3
4
Image 3-2: Framed photovoltaic modules (front and backside)
1 Photovoltaic module 3 Socket
2 Solrif®-XL profile frames 4 Connecting cable with patch plug
3.3 Substructure
The substructure is the basis for the in-roof mounting of the modules. It consists of battens and mounting boards
fastened directly to the roof. It is constructed by means of a grid plan (cf. chapter 4.2.2, p. 26).
3.4 Mounting Clamps
Modules framed with Solrif® XL profile frames are braced to the substructure with mounting clamps. Three different
types of clamps can be used:
Number Designation Article Number
1 Mounting clamp “profile” and “frame”
respectively 13318
1.1 Mounting clamp “profile”, black 06497
2 Mounting clamp “glass” and “module”
respectively 13319
2.1 Mounting clamp “glass”, black 06500
3 Mounting clamp “top”, long, for flat
sheet-metal seams 33954
Table 3-2: Overview of mounting clamp types

Solar Energy Systems 01.09.2009 Page 10
Mounting Directions for In-Roof Photovoltaic Systems
Ernst Schweizer AG, Metallbau, CH-8908 Hedingen, Telefon [phone], Telefax [phone], www.schweizer-metallbau.ch
Mounting Clamp „Profile“
The mounting clamp “profile” is used to brace two modules respectively to their frames in the overlapping area.
This clamp is normally necessary.
Clamp width: 16.5 mm
Material gauge: 1,5 + 2,0 mm
Material: Stainless spring steel type 1.4310
Screw type: Cylinder-head screws 5 x 35 high grade (2
screws)
Image 3-3: Mounting clamp “profile”
Mounting Clamp „Glass“
In order to meet the demands of statics, a module can be additionally fastened in the glass area by means of the
mounting clamp “glass”. The necessary number of clamps per module edge is to be determined on the basis of the
grid plan in accordance with the static demands. To protect the glass the front side of the clamp has been coated
with weatherproof plastic.
TIP
The mounting clamp “glass” has been conceived as an additional measure, dependent upon module size and
static demands, not necessary all the time nor in every case.
Clamp width: 16.5 mm
Material gauge: 1,5 + 2,0 mm
Material: Stainless spring steel type 1.4310
Screw type: Cylinder-head screws 5 x 35 high grade (2
screws)

Solar Energy Systems 01.09.2009 Page 11
Mounting Directions for In-Roof Photovoltaic Systems
Ernst Schweizer AG, Metallbau, CH-8908 Hedingen, Telefon [phone], Telefax [phone], www.schweizer-metallbau.ch
Image 3-4: Mounting clamp “glass”
Mounting Clamp „Top“
The mounting clamp “top” for flat sheet-metal seams is for fastening the highest row of modules from the top. This
clamp is only necessary when flat sheet-metal seams other than those provided by Ernst Schweizer AG are used.
If sheet-metal seams are to be laid from the top, mounting clamps “frame” should be used. The necessary number
of clamps per module edge is to be determined on the basis of the grid plan in accordance with the static demands.
Clamp width: 16.5 mm
Material gauge: 2,0 mm
Material: Stainless spring steel type 1.4310
Screw type: Wood or cylinder-head screw 5 x 35 high grade
(2 screws)
Image 3-5: Mounting clamp “top/long flat flashing joins

Solar Energy Systems 01.09.2009 Page 12
Mounting Directions for In-Roof Photovoltaic Systems
Ernst Schweizer AG, Metallbau, CH-8908 Hedingen, Telefon [phone], Telefax [phone], www.schweizer-metallbau.ch
3.5 Required Components for In-Roof Mounting / Flashing
Often the module surface of the system, based upon the grid measure of the modules, does not correspond exactly
with the measurements of the roof itself. In this case, the rest of the roof surface must be integrated into the system
by means of flashing profiles and flashings, which can be delivered.
3.5.1 Flashing profiles
For in-roof mounting, special profiles for flashings on the right and left sides of the system are available as an
option. They compose a uniform transition to the seams.
Flashing profile right
1
2
3
Image 3-6: Flashing profile right
1 Flashing seam right side 3 Photovoltaic module
2 Flashing profile right side

Solar Energy Systems 01.09.2009 Page 13
Mounting Directions for In-Roof Photovoltaic Systems
Ernst Schweizer AG, Metallbau, CH-8908 Hedingen, Telefon [phone], Telefax [phone], www.schweizer-metallbau.ch
Flashing profile left
3
2
1
3-7: Flashing profile left
1 Flashing seam left side 3 Photovoltaic module
2 Flashing profile left side

Solar Energy Systems 01.09.2009 Page 14
Mounting Directions for In-Roof Photovoltaic Systems
Ernst Schweizer AG, Metallbau, CH-8908 Hedingen, Telefon [phone], Telefax [phone], www.schweizer-metallbau.ch
3.5.2 Flashings
Flashings provide a weatherproof seam to the roof tiles. They have been designed to be able to accommodate
most standard types of roof tiles.
The following flashings are available:
Flashing side (left/right)
Flashing side top (left/right)
Flashing ridge (middle/left/right)
1
1
2
7
7
6
3 4
8
5
Image 3-8: Mounting of the flashings
No. Designation Lamination size L x W
1 Flashing side left (W + 110) x 121 mm
2 Flashing side top left 281 x 121 mm
3 Flashing ridge left (W + 54) x 281 mm
4 Flashing ridge middle (W + 29) x 281 mm
5 Flashing ridge right (W + 54) x 279 mm
6 Flashing side top right 281 x 121 mm
7 Flashing side right 773 x 121 mm
8 Photovoltaic modules (laying
measurements) (L + 31) x W mm
Table 3-3: Flashing measurements

Solar Energy Systems 01.09.2009 Page 15
Mounting Directions for In-Roof Photovoltaic Systems
Ernst Schweizer AG, Metallbau, CH-8908 Hedingen, Telefon [phone], Telefax [phone], www.schweizer-metallbau.ch
3.5.2.1 Flashing side right/left
Flashings right/left are attached to the flashing profiles and fastened to the mounting board by means of sheet grips
and nails. The flashings are laid upon the modules’ mounting boards and are thus at the same height.
Flashing right side
2
1
3
Image 3-9: Flashing side/right
1 Flashing right side 3 Flashing profile right side
2 Sheet grips with nails
TIP
Fasten the sheets with as many sheet grips as deemed necessary but at least:
Flashing right side/left side: 2 grips
Flashing topside right/left: 1 grip

Solar Energy Systems 01.09.2009 Page 16
Mounting Directions for In-Roof Photovoltaic Systems
Ernst Schweizer AG, Metallbau, CH-8908 Hedingen, Telefon [phone], Telefax [phone], www.schweizer-metallbau.ch
Flashing left side
3
1
2
Image 3-10: Flashing side/left
3.5.2.2 Flashing upper right/left side
The ridge flashings are laid upon the upper side flashings right/left. They have the same width as the side
flashings. These flashings can be used with all types of modules.
Flashing upper right side
1
2
4
6
5
3
Image 3-11: Flashing side/top/left
1 Sheet grips with nails 4 Flashing ridge left
2 Flashing left side 5 Photovoltaic module
3 Flashing upper left side 6 Flashing profile left side
1 Sheet grips with nails 3 Flashing profile left side
2 Flashing left side

Solar Energy Systems 01.09.2009 Page 17
Mounting Directions for In-Roof Photovoltaic Systems
Ernst Schweizer AG, Metallbau, CH-8908 Hedingen, Telefon [phone], Telefax [phone], www.schweizer-metallbau.ch
Flashing upper left side
1
2
4
6
5
3
Image 3-12: Flashing side/top/left
1 Sheet grips with nails 4 Flashing ridge left
2 Flashing left side 5 Photovoltaic module
3 Flashing upper left side 6 Flashing profile left side
Flashing Ridge
The upper seam consists of individual sheets, each of which is assigned to a module in the upper row.
There are three types of flashings for the upper seam:
Flashing ridge middle
Flashing ridge left side
Flashing ridge right side
1
3
2
8
4
6
5
7
Image 3-13: Flashing ridge

Solar Energy Systems 01.09.2009 Page 18
Mounting Directions for In-Roof Photovoltaic Systems
Ernst Schweizer AG, Metallbau, CH-8908 Hedingen, Telefon [phone], Telefax [phone], www.schweizer-metallbau.ch
1 Flashing ridge left 5 Flashing upper right side
2 Flashing ridge middle 6 Flashing ridge right
3 Join capping piece 7 Flashing right side
4 Roof tile 8 Photovoltaic module
The ridge flashings left and right have a special construction and lock into the corner flashings and thus ensure a
rainproof junction. The ridge flashings are joined at the upturn, or bevel fold, by means of a capping sheet, which
also guards against the weather.
3.5.3 Eaves skirting, seam sealing strip and bottom mounting clamps
Lower Seam
The photovoltaic modules can be mounted either directly on the eaves or above the tiles.
For the crossover from the lower array edge to the tiles it is normal to use eaves skirting as for other in-roof fixtures,
such as dormer windows (rolled lead sheet 150 mm or Mage flex aluminum roll black 280 mm available as
accessories).
The sealing strips (valley sealing strips) are mounted on the eaves skirting in order to close off the roof hollows for
small animals and insects.
TIP
It is advisable to lay a 17 mm spacing block underneath the mounting clamp “glass” in the lowest row. This is to
prevent the back side of the module from coming into contact with the fold of the mounting clamp by heavy snow
load.
4 Mounting
4.1 Tools, Auxiliary Material
Have the following tools and other material at hand during the mounting process:
Carpenter’s pencil
String / chalk line
Tape measure and measuring stick
Screwdriver set
Nails for sheet grips
Hammer for sheet grip nails
Level
Wood saw
Sheet metal shears and tongs
Knife
Portable electric screwdriver with T25 bit
Angle grinder (diamond grinding wheel) for removing tile nibs
Multimeter
Ultraviolet-resistant cable ties

Solar Energy Systems 01.09.2009 Page 19
Mounting Directions for In-Roof Photovoltaic Systems
Ernst Schweizer AG, Metallbau, CH-8908 Hedingen, Telefon [phone], Telefax [phone], www.schweizer-metallbau.ch
4.2 Preliminary Steps
4.2.1 Structural Calculations in Accordance with DIN 1055/Eurocode 1
TIP
The following specifications should be checked on site by means of the local structural conditions.
Before ordering, determine the structural conditions of the roof with the aid of Schweizer’s dimensioning
program ProSolrif and draw up the parts list, especially the number of mounting clamps.
The “simplified” calculating method is based upon actual tests (maximum clamp load) and load effect in
accordance with DIN 1055 (WLZ 2). This method is appropriate for normal wind and snow conditions.
For higher wind conditions and snow loads the dimensioning must be carried out in accordance with DIN 1055.
4.2.2 General Planning
TIP
The particular design of the generator field should conform with local factors and with the demands of the project.
Size of the Grid
Calculating the size of the grid:
- Grid size horizontal: Rhor [mm] = Lamination Width [mm] + 31 mm (frame profile)
- Grid size vertical: Rver [mm] = Lamination Height [mm]
Generator Panel
1. Multiply the grid measurements by the corresponding number of module columns or module rows:
TIP
When calculating the size of the grid, do not forget the overlapping frame profiles.
TIP
In the case of very large systems it is advisable to calculate by 32 mm in order to allow for tolerances.

Solar Energy Systems 01.09.2009 Page 20
Mounting Directions for In-Roof Photovoltaic Systems
Ernst Schweizer AG, Metallbau, CH-8908 Hedingen, Telefon [phone], Telefax [phone], www.schweizer-metallbau.ch
- Generator width [mm] = Rhor [mm] x number of module columns
- Generator height [mm] = Rver [mm] x number of module rows
2. Include the outer frame profiles, as they have no further overlapping elements:
- Generator width [mm] + 30 mm (15 mm right and left)
- Generator height [mm] + 30 mm (top)
3. Include the flashings, as the case may be.
CAUTION
Misinterpretation of the number of mounting clamps in accordance with DIN 1055!
Damage to the roof structure and to the entire photovoltaic system.
Calculate so that the required number of mounting clamps in direct relationship to the given snow load and
wind zone are used.
Image 4-1: Distance between the mounting clamps
- If the demands of the structural design require it, set the mounting clamps “glass” in center between the
framing clamps (a given number of “glass” clamps will have to be spaced evenly at the corresponding
pitch.
TIP
Contact your Solrif®dealer in order to draw up an individual grid plan for the photovoltaic modules.
Space the mounting clamps 15 mm away from the upper Solrif®profile, so that the modules can be pushed
upwards and removed, if need be, for example for repair work.