Solfex SOLAR CANOPY User manual

INSTALLATION MANUAL
SOLAR CANOPY PV MOUNTING SYSTEM

2 |
Contents
1 Introduction 3
1.1 Short description 3
1.2 Intended use 3
1.3 Standards and technical directives 3
1.4 About this manual 3
2 Safety 4
2.1 Basic safety instructions 4
2.2 Working on roofs 4
2.3 Warnings 4
2.4 Operator‘s responsibilities 5
3 Technical description 6
3.1 System overview 6
3.2 Scope of delivery 7
3.3 Technical specications 8
3.4 Operating conditions 8
4 Planning of the module eld 8
4.1 Dimensions 8
5 Important mounting information 10
5.1 Mounting aids and required tools 10
5.2 Additionally required materials 10
6 Installation 10
6.1 Preparation work 10
6.2 Installing the system 11
6.3 Installing the modules 14
6.3.1 Portrait installation 14
6.3.2 Landscape installation 15
Solar canopy — for universal use on flat roofs

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Introduction
1.1 Short description
The SolarFrame at roof system is a robust mounting
system for PV modules on at roofs. It consists of alumin-
ium triangles, aluminium support rails and all necessary
accessories for attaching the modules to the rails and
connecting the components to one another. Further com-
ponents such as roof xation kits or back plates are also
available. With SolarFrame, both portrait and landscape
module mounting are possible.
1.2 Intended use
The SolarFrame at roof system is to be used for the roof
installation of PV modules only. Any other use is consid-
ered improper.
The observance of the information in these assembly
instructions is a part of proper use. Mounting Systems
GmbH is not liable for damage that results from the
non-observance of assembly instructions, in particular
the safety information, or from the improper use of the
product.
1.3 Standards and technical directives
When planned correctly, SolarFrame fullls the following
standards and technical directives:
Eurocode 9 — DIN V ENV 1999-1-1: Design of aluminium
structures
DIN 1055 — Actions on structures: Basis of design,
safety concept and design rules
1.4 About this manual
Subject
This manual details the installation and assembly of
the SolarFrame at roof system. The illustrations in the
manual show the portrait mounting procedure for framed
modules. Should landscape mounting differ from portrait
mounting, this will be clearly emphasised. Some ad-
ditional components that are repeatedly used are also
indicated. No description is included for materials for spe-
cial substructures that may be required to accommodate
the constructional conditions of the building in addition to
standard materials. These are always specially manufac-
tured and documented separately.
User group
This manual is intended for qualied personnel with a
basic knowledge of mechanics, hand tools and mechani-
cal skills.

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Safety
2.1 Basic safety instructions
The following basic safety instructions and the warning
notes are an essential part of this manual and are of
fundamental importance for handling the product.
• Ensure that the product corresponds to the static
requirements on-site prior to every assembly and
installation.
• Ensure that the building corresponds to the increased
static requirements due to the PV unit, prior to every
mounting and installation.
• Observe occupational health and safety regulations
of the employer‘s liability insurance association.
• Wear a hard hat, protective gloves and safety shoes.
• A second person must be present during the entire
installation process, to give assistance in the event
of an accident.
• A copy of this installation manual must be kept in
the direct vicinity of the unit.
2.2 Working on roofs
When working on roofs, note the following instructions:
• Pay attention to accident prevention regulations for
working on roofs. If appropriate, use a barrier to protect
against falling parts.
• In line with accident prevention regulations, work on
roofs should be carried out using safety harnesses
for individuals or safety scaffolding.
• Observe the relevant local safety regulations.
• Before stepping on to the roof, check the load-bearing
capability of all parts which are under stress.
• Use fall protection.
• Use protective equipment to guard against falling
even when carrying out short jobs.
• Do not carry materials on to the roof via ladders,
but rather use suitable lifting gear.
2.3 Warnings
The warning notes used in this manual identify safety
related information. They consist of:
• Warning symbol (pictograph)
• Indicator word to denote the danger level
• Information about type and source of the danger
• Information about possible consequences if the
danger is not observed
• Measures for avoiding the danger and for preventing
injuries or property damages
The heading of the warning notes identies one of the
following danger levels:
Denotes a potential risk which may
lead to physical injury and property
damage.
CAUTION
Denotes a potentially dangerous
situation which may lead to moder-
ate to serious physical injury and
property damage.
WARNING
Denotes a major risk, failure to
observe which could lead to serious
injury or death.
DANGER

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2.4 Operator‘s responsibilities
The system operator has the following safety-relevant
responsibilities:
• Ensure that the installation of the system is only
performed by persons with manual skills and basic
knowledge of mechanics.
• Ensure that the assigned installation personnel can
evaluate the work assigned to them and can recognize
possible dangers.
• Ensure that the persons commissioned are familiar
with the system components.
• Ensure that the installation manual is accessible
during the assembly. The mounting instructions are
an integral part of this product.
• Ensure that the mounting instructions and in
particular the warnings have been read and understood
by the authorized installation personnel prior to
assembly.
• Ensure that the permissible conditions of use
(see chapter 3.4, page 8) have been upheld.
for damage which results from a violation of these
conditions.
• Ensure that the roof construction has the required
load-bearing capacity, in particular in the vicinity of
the force transmission points.
• Ensure that the durability of the mounted connections
and the root atachments are guaranteed.
• Ensure that any necessary roof penetrations are
professionally sealed.
• Ensure that the appropriate lifting equipment is used
for the mounting process.
used, also in case of replacement.
Otherwise the warranty claim is void.
Solfex Ltd will not be held liable
• Ensure that only Solfex Ltd components are

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Technical description
3.1 System overview
All system components are described below. The design
of the individual system components may vary.
They are dependent on:
• Type of roof,
• Type of module,
• Number of modules and
• The conditions on site.
Components:
a Triangle (shown here with foot brackets)
b Triangle (shown here with ground rail)
c X-Stone
d Base rail 13/58
e Splice 13/58 (not visible)
f Telescoping end piece 13/58
g Diagonal strut
h SolRec base plate (optional accessory)
i Module end clamp for landscape installation
j Module clamp
k Module end clamp for portrait installation
a
c
d
g
j
f
k
e
Portrait installation
b
i
h
Landscape installation

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3.2 Scope of delivery
All system parts and requisite small parts
which are required for installation are
included in the delivery. The precise scope
of supply will depend on the size and
number of PV modules which you specify
when ordering. No description is included
for materials for special substructures that
may be required in addition to standard
materials to accommodate the construc-
tional conditions of the building.
a Triangle (shown here with foot brackets)
b Triangle (shown here with ground rail)
c X-Stone*
d Base rail 13/58
e Splice 13/58
f Telescoping end piece 13/58
g Diagonal strut
h SolRec base plate (optional accessory)
i Module end clamp* for landscape
installation, module frames between
32 and 56 mm
j Module clamp*
k Module end clamp* for portrait
installation for frame heights of
35, 43, 46 and 50 mm
l Module end clamp* for portrait
installations for frame heights of
24.5 - 51mm
m Laminate clamp*
n Laminate end clamp*
o Back plate (optional accessory)
p Concrete anchor (optional xation
material)
q Hanger bolt (optional xation material)
r Bolt connection, consisting of Allen
bolt M8 x 20, self-locking nut M8 and
2 washers
s Anti-slip device for modules, consisting
of nut M6 and Allen bolt M6 x 20
t Quickstone prole nut (not an individual
component, but pre-assembled on the
components marked*)
* with Quickstone
b
c
d
a
e f
g h
i j k
m n
o
l
p q
rst

8 |
b
g
h
a
j
f
e
Planning of the module field
3.3 Technical specifications Depth of the frame unit: see table A below
3.4 Operating conditions
Portrait installation
i
4.1 Dimensions
In the following, the dimensions of the mounting system
will be given. The exact spacing between the triangles is
project-specic and must be individually dened in the
planning phase. Width of the unit: Number of horizontal
modules x (module width + 19) + 31mm; maximum 12 m
Notice: The material expansion of a 12 m-row
can be approx. 2 cm. Therefore, a minimum
distance of 10 cm between the rows is recom-
mended. Furthermore, for large systems, it is
wise to leave more space at regular intervals
as maintenance paths.
Application range Flat roof
Roof pitch 0 — 5°, greater pitch subject to prior verification
PV module Framed, unframed
Roof construction The suitability of the entire roof construction, in particular at the load transfer points of
the mounting system, must be examined for static, insulation, leak tightness, and fire
protection requirements prior to installation of the PV system.
Permissible roof load Must be specifically checked for each project.
Attachment method Must be specifically checked for each project.
Triangle and support rails Up to 1,900 PA for a 2.5 m2 surface per triangle and a roof pitch up to 5°
Max. row length 12 m
Distance between the triangles Depending on project planning, portrait installation up to approx. 1.5 m,
landscape installation up to approx. 1.8 m
Support profile, base rails Extruded aluminium (EN AW 6063 T66)
All other profiles Aluminium (EN AW 6060 T6)
Accessories Stainless steel (V2A)
Back plate Aluminium (EN AW 5005)
SolRec base plate PE

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a Height of the frame unit: see table B below
b Pitch: 20°, 25°, 30°
c Distance between the rows: according to project plan
d Distance to ground: at least 8 cm, depending on
module positioning
e Distance between the triangles: according to plan,
portrait mounting up to approx. 1.5 m,
landscape mounting up to approx. 1.8m
f Distance between the foot brackets of the triangle:
955 mm / 1260 mm, depending on selected triangle
type (model A/B)
g Drill hole size in the foot brackets: 11 mm or 13 mm,
depending on selection
h Ground rail, hole pattern for triangle models A and B:
see illustration I below
i Distance between the base rails for portrait installation:
Distance of the clamp points as recommended by the
module manufacturer (usually marked by the drill holes
in the module frame, approx. ½ the module length).
j Distance between the base rails for landscape
installation: Distance of the outer edges of the rails =
module width
a
c
k
I
B
A
20 20
2021820 545
1.110 1.457
327
327 436 327 20 20327 545 545
ø 6,1 mm ø 6,1 mm
b
i
d
Landscape installation
Pitch Landscape installation Portrait installation
20°
995 mm
module length x 0.94; at least 995 mm
25° module length x 0.91; at least 995 mm
30° module length x 0.87; at least 995 mm
Pitch Landscape installation Portrait installation
20° 534 mm (module length x 0.34) + 80 mm; at least 534 mm
25° 615 mm (module length x 0.42) + 80 mm; at least 615 mm
30° 692 mm (module length x 0.50) + 80 mm; at least 692 mm
All dimensions in mm
Hole pattern: Ground rail A Hole pattern: Ground rail B
Depth of the unit, including module
Height of the frame unit, including module
2032720 545 545

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Important mounting information
5.1 Mounting aids and required tools
You will need the following tools to install the system:
• 6 mm Allen key
• Combination wrenches 13
• Folding rule / tape measure
• 9 mm metal drill bit
Appropriate tools for the respective roof mounting
variations, e.g.:
• For riveting onto SolRec oor plates:
6.1 mm drill bit, rivet gun
• For attachment with x anchors into concrete:
12.5 mm concrete drill bit, hammer
5.2 Additionally required materials
Depending on the system plan, the following additional
materials may be necessary:
• Suitable xation material for roof
Material for weighting as ballast, for example gravel,
concrete slabs or other
• Suitable protective mats to protect the roof surface.
Installation
6.1 Preparation work
20˚ 25˚ 30˚
1 2
Preparing the fixation points
• Dene and mark the xation
points, and/or the planned
substructure according to plans,
and prepare for installing the
triangles.
Mounting the anti-slip protection (only for portrait installation)
• Attach one bolt with M6 nut in each of the lower drill holes of the module
frame as an anti-slip protection, and tighten them by hand.
Preparing the triangles
• Unfold the triangles and
pre-mount both of the support
elements with 2 bolts each (self-
locking nut M8, 2 washers and
M8 x 20 Allen bolt) at the desired
angle (tightening torque 8 Nm).
• Tighten all of the screw
connections on the triangle
(tightening torque 8 Nm).
Potentially mortal danger from
falls and falling objects
• Protect yourself against falling.
• Do not remain in the danger
zone.
• Wear a hard hat.
• After the assembly is
complete, ensure secure
positioning of the mounting
system and the modules.
Material damage from improper mounting. Improperly fastened triangles can bend or collapse.
• Carry out all new bolted connections using the abovementioned materials (bolts, washers and nuts).
• After installation, ensure that all bolted connections are tight.
DANGER
CAUTION
3

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6.2 Installing the system
Mounting the triangles
• While maintaining the planned
spacing, arrange the triangles so
they are parallel, and x them
with the designated connecting
materials.
Fixing the X-stones
• Fix two X-stones per triangle
(see point 4.1 Dimensions) to the
support rail of the triangle at the
specied points. Take care to
observe the differing alignment of
the X-stones for portrait or
landscape installation (see
illustration on the right).
• Insert the Quickstone into the
prole channel so that the form
of the Quickstone ts perfectly
into the prole. The bolt may not
protrude beyond the lower edge
of the Quickstone.
• Fasten the Quickstone loosely
with 2 bolt turns.
• Put the X-stone in the desired
position and line it up
transversely to the support rail.
• Tighten the bolt just enough
so that the X-stone does not slide
down. Do not tighten completely.
Material damage due to improper mounting
Improperly fastened X-stones may slip or rip out.
• All Quickstone connections must be mounted according
to instructions.
• After mounting, check that the bolted connections are tight.
CAUTION
Portrait installation Landscape installation
Material damage due to inappropriate material selection
Inappropriate xation material can cause the triangles to rip out, roof damage and leakage.
• Select appropriate xation material according to the location, roof state, and system design.
Material damage from improper mounting
Improperly xed triangles can rip out and result in leaks.
• All attachments should be of professional quality.
• After mounting, ensure that the xation is correct.
WARNING
WARNING
1
2

12 |
Install base rail
• Mount 2 horizontal base rail sections per row of triangles.
• Align and position the rails according to the selected
module dimensions (distance between the rails,
see page 9 point j and k).
• Lay the rails with the smooth side down on the triangles
and fasten them loosely to the vertically-mounted
x-stones on the side.
• Take care to observe the differing alignment of the rails
for portrait or landscape installation (see illustration on
the right).
• Align the rails and subsequently tighten the vertical and
horizontal X-stone bolts nally (tightening torque 8 Nm).
Connecting the individual rails
• The splice should be slid in half-way from the side,
on the back side of the prole rail.
• Slide the next prole rail into the splice.
• Tighten both bolts of the splice (tightening torque 8 Nm).
Mounting the telescoping end piece
(inclusion is dependent on design)
• If intended, slide a telescoping end piece into the base
rail at the end of each rail section, but wait to tighten.
• If applicable, mount the exible element of the
telescoping end piece onto the X-stone of the last triangle.
• After the precise adjustment to the length of the
module surface area, x the telescoping end piece.
This is done by, tightening the bolt on the end of the
telescoping end piece facing the module surface area
(tightening torque 8 Nm).
3
4
5
TIP: It is best not to pre-calculate
and adjust the exact position of the
telescoping end piece, but instead to
do the exact positioning and nal
mounting while xing the last module.
Portrait
installation
Landscape
installation

| 13
Attaching the diagonal struts
• Mount 2 diagonal struts per unit on the left and
right ends of the row.
• Loosely mount one end of the diagonal in the lowest
pre-drilled bore hole of the strut to the outside triangle
with a self-locking nut M8, 2 washers and an allen bolt.
• Point the strut diagonally to the next triangle in the
row and mark the exact position of that triangle’s
upper-most bore hole on the diagonal.
• Drill a hole with diameter of 9 mm at the marked
location.
• Fix the second end of the diagonal.
• Tighten both diagonal connections nally (tightening
torque 8 Nm).
• If necessary, shorten any protruding ends of the
diagonals (purely for appearance purposes).
Attaching the back plate (alternative
to the diagonal struts)
• Hold the back plates against the
triangles from behind, and x them to
the triangle supports with two drill
screws per triangle.
• Allow the back plates to overlap by
5 cm.
6
7

14 |
Material damage due to
improper mounting
• Improperly fastened module
(end) clamps may rip out.
• All Quickstone connections
must be mounted according
to instructions.
• After installation, ensure that
the bolted connections are tight.
6.3 Installing the modules
6.3.1 Portrait installation
Module positioning
• Place the modules on the rails so
that the slip-guard bolts are in
the lowest rail channel.
Attaching the outer modules
• Insert the Quickstone of the
module end clamps in the top
channel of the base rail (the bolt
may not protrude on the under
side of the Quickstone) and
fasten them loosely.
• Before tightening, push the
modules under the module
clamps and align them.
• Tighten the module end clamps
(tightening torque 8 Nm).
Attaching the inner modules
• Insert the Quickstone of the
module clamp into the top rail
channel of the base rail, slide
them on to the previously
mounted module and fasten
loosely.
• Slide the second module onto the
module clamp, align it, and
tighten the bolts (tightening
torque 8 Nm).
1
2
3
CAUTION
i
When installing
laminates, special
laminate end and/
or laminate middle
clamps must be
used. The installa-
tion procedure is
identical. Slide the
laminate between
the rubber lips of the
laminate end clamp
before tightening.

6.3.2 Landscape installation
Mounting the lower module end clamps for landscape
installation
• Fix two module end clamps per module to the lower
base rail.
• Insert the Quickstone of the end clamp into the side
channel of the rail and fasten loosely.
• The distance between the clamps should be based on
the optimal clamping points of the respective module
specied by the manufacturer (usually marked by the
drill holes in the module frame, approx. ¼ of the
module length from the right and the left).
Module positioning
• Place the module in landscape position onto the
loosely mounted lower module end clamps.
• Align the modules. It is not necessary to leave any
space between the individual modules.
• Adjust the height of the lower module end clamp by
means of the slotted hole so that the clamp lies
directly on the module. Finally tighten the clamps in
this position (tightening torque 8 Nm).
Mounting the upper module end clamps
• Make sure that the upper edge of the upper rail row
is ush with the modules and that the side rail
channels and the X-stones point upwards (see
illustration page 12, point 3). If necessary, correct
the positioning of the base rail.
• Mount two end clamps per module to the upper base
rail, parallel to the positioning of the lower end clamps
and tighten nally (tightening torque 8 Nm).
1
2
3Material damage due to improper
mounting
• Improperly mounted module end
clamps may slip or rip out.
• All Quickstone connections must be
mounted according to instructions.
• After installation, ensure that the
bolted connections are tight.
CAUTION
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