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.

Solar Energy Systems 01.09.2009 Page 4
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.

Solar Energy Systems 01.09.2009 Page 6
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.

Solar Energy Systems 01.09.2009 Page 7
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)