Van der valk Valkbox3 User manual

Version 01 |January 2022

Installation manual ValkBox3

Pay attention

• This manual is not project specic.

• This manual is not legally binding.

• No rights may be derived from this installation manual.

• See datasheet ValkCableCare for cable management.

• The system is placed in the middle zone of the roof.

Index

Disclaimer Page 3

Required ballast Page 4

Safety instructions Page 5

Required ballast per country Page 6 - 17

Components Page 18

Mounting the clevis Page 19

Mounting the curved supports Page 19

Mounting panel options Page 20

Placing the rubber tiles Page 21

Position the ballast Page 21

Tighten hinge bolts B1 Page 22

Finish tting the cables Page 22

Position the rows one behind each other Page 22

Installation manual ValkBox3

The ValkBox3 mounting system is a product of:

Van der Valk Solar Systems BV

Netherlands Chamber of Commerce: 27355116

www.valksolarsystems.com

Disclaimer

This installation manual composed with the greatest possible care and contains specic information for correct and safe installation of the solar mounting system, including

installation drawings and ballast tables, calculated according to the Eurocode regulations. The standard values used for input of these calculations, always need to be checked

in advance by the installer for correctness. In case values are different, a project case specic calculation needs to be made. Please contact Van der Valk Solar Systems in this

situation.

At all times all currently applicable structural, safety and building regulations must be observed prior to installation of the solar mounting system. The building in question will

be subject to a load as a result of the solar mounting system installed/mounted. Solar mounting systems installed on roofs will be exposed to wind and snow loads. Therefore, you

are at all times responsible to obtain and use a design calculation to establish whether or not the building will be able to withstand the (extra) load at all times. Where necessary,

modications need to be made by you. Van der Valk will not accept any form of liability upon you not having obtained and used such a required design calculation.

Mounting systems for PV-panels placed on at roofs should either be mechanically attached to the roof or need to be supported by ballast, to make sure that the solar mounting

system is unable to be lifted, tipped over or slide. The required ballast weight per system shown in the tables in this manual ensures that the mounting system can be installed

and used safely. In case the inclination of the roofs is 5 degrees or more, the PV-mounting system must always be mechanically xed to the construction of the roof.

The calculations do not take into account obstacles in the near surrounding such as, for example, high buildings, cliffs and mountains. Restrictions also apply for the position of

the solar mounting system on a roof. The solar panels must be installed at a certain distance from the edge of the roof: the middle zone.

The standard warranty is 10 years, which can be extended under certain conditions. The guarantee provided is subject to the guarantee conditions stated in the general terms and

conditions stipulated by Van der Valk Solar Systems B.V. Our terms and conditions shall apply to all our products at all times and can be found on our website:

www.valksolarsystems.com

Van der Valk Solar Systems B.V. does not accept any liability for any direct and/or indirect consequences of any act (or omission) ensuing from the information in or failure to

observe the instructions provided in this installation manual. The use of the installation manual will at all times be subject to Dutch law.

Van der Valk Solar Systems holds the right to amend this document without further notice.

Installation manual ValkBox3

Required ballast

General

The ValkBox3 mounting system must be weighted down by tiles, which will be

placed at positions G1 and G2. Start by choosing the wind area in which the system

will be installed from the overview below. Next, look at the table for the panel length

in question. In this table, you will choose the relevant type of roof covering. Bitumen

and EPDM have a higher skin friction and it will be possible to use less ballast for this

type of roof covering. Next, choose the table for the wind area in question and the row

for the building height applicable. This will show you the number of tiles necessary for

positions G1 and G2.

The number of tiles calculated in the tables below are based on standard tiles

measuring 30 x 30 x 4.5 cm and weighing 9 kg. If you are using tiles with

different dimensions and, because of this, a different weight, you will need to

add tiles until you have reached the weight required.

Selection table:

Minimum number of tiles per position G1 and G2 based on:

• Tile dimensions: 30 x 30 x 4,5 cm

• Tile weight: 9 kg

• Terrain category: town (sites more than 1 km inside town boundary - area where at

least 15% of the surface is covered with buildings with an average height above 15m)

• Distance to shoreline: >10km

• Maximum height above sea level: <100m

21,5 m/s

0-5 meter 5 kg 61 kg 9 kg 70 kg

5-10 meter 13 kg 83 kg 17 kg 83 kg

22 m/s

0-5 meter 7 kg 65 kg 11 kg 65 kg

5-10 meter 14 kg 88 kg 19 kg 88 kg

23 m/s

0-5 meter 9 kg 72 kg 13 kg 72 kg

5-10 meter 17 kg 97 kg 22 kg 97 kg

24 m/s

0-5 meter 12 kg 79 kg 16 kg 95 kg

5-10 meter 20 kg 107 kg 26 kg 107 kg

Building heightWind speed

Panel height approx. 180 cm

(width 100 - 110 cm)

Bitumen + EPDM Concrete

Position Position

Total G1 Total G2 Total G1 Total G2

Installation manual ValkBox3

Safety instructions

The ValkBox3 mounting system is installed on roofs and will be exposed to wind and

snow. The building in question will be subject to a greater load as a result of the PV

system. A design calculation must be used to establish whether or not the building in

question will be able to withstand the extra load. Where necessary, modications will

then need to be made.

When installing the ValkBox3 mounting system, the instructions provided in this

user manual must be observed at all times. Read this manual carefully and keep it in

a safe place. Also follow the instructions stated in the manuals for the other system

components that form part of the overall PV system. All current structural, safety and

building regulations must be observed. Van der Valk Solar Systems B.V. will never be

liable for any direct and/or indirect intangible or consequential loss ensuing from or

connected to the failure to observe the instructions provided in this manual.

Starting points

The following starting points apply for the ValkBox3 mounting system:

The standards applied (if applicable for specic solar mounting system)

NEN-EN 1990: Eurocode – Basis of structural design

NEN-EN 1991-1-4: Eurocode 1: Actions on structures - Part 1-4: General actions –

Wind actions

NVN7250: Solar energy systems – Integration in roofs and facades –

Constructional aspects

BS EN 1991-1-4: British Standard

Type of solar panel

The ValkBox3 mounting system is a universal mounting system for solar panels. The

following starting points apply:

Design panels: Standard solar panels with an aluminium frame, with

mounting holes for M6 bolts.

Length panels: approx. 180 cm

Width panels: 100 - 110 cm

Weight panels: approx. 20 kg (length approx. 180 cm)

Type of roofs

The ValkBox3 mounting system can be used to mount panels on at roofs. The following

starting points apply:

Type of roof covering: bitumen, EPDM and concrete

Before installing the ValkBox3 mounting system, make sure that you carefully

sweep the roof area. The ballast calculation for the ValkBox3 mounting

system (see later in this manual) only applies for at roofs and roofs with a

slight pitch of up to 5°. Above this roof pitch, the system should be attached to

the roof securely.

Ballast

The ValkBox3 mounting system needs to be supported by ballast, to make sure that

the system is unable to move, lift or tip over. See later in this manual details of which

ballast should be used for each type of solar panel, each country, each type of roof

covering and for each building height (subject to a maximum of 10 m). The number of

tiles specied (30 x 30 x 4.5 cm) per position will be vital to ensure that the mounting

system can be used safely.

To achieve this, follow the required ballast instructions later in this manual.

Position

Restrictions also apply for the position of the system on a roof. The solar panels must be

installed at a certain distance from the edge of the roof.

According to the current standard, NEN-EN 1991-1-4, this free edge zone is 1/5

of the height of the roof. So, if a roof is 6 meters high, a free edge zone of 120 cm

will be necessary.

The guarantee provided is subject to the guarantee conditions stated in the general

terms and conditions stipulated by Van der Valk Solar Systems BV. Our terms and

conditions can be found on our website: www.valksolarsystems.com.

Panel: maximum dimensions 1800x1100 mm (21 kg) Panel: maximum dimensions 2100x1100 mm (24 kg)

Windmap The Netherlands

Required ballast | The Netherlands

General

The ValkBox3 mounting system must be reinforced by means of tiles, which must be placed on the

indicated ballast foundations. In three steps you can easily calculate the required ballast;

• determine the wind area on the windmap

• choose the wind area and building height in the table

• you can now read the number of tiles / kg

Note 1: Min. extra ballast in G1 & G2 has to be 2 x 1 tile (2 x 9 kg).

Note 2: The ballast in G1 & G2 must be equally divided over the rubber ballast carriers.

Note 3: The max. of 20 tiles (4 in G1 and 16 in G2) can be placed for extra ballast (180 kg).

Building height 0 - 5

meter

5 - 7

meter

7 - 9

meter

9 - 12

meter

12 - 15

meter

Wind area G1 G2 G1 G2 G1 G2 G1 G2 G1 G2

I (29,5 m/s) 36,0 92,0 36,0 92,0 36,0 106,0 XXXXkg

4,0 10,5 4,0 10,5 4,0 12,0 XXXXtiles

II (27 m/s) 36,0 73,0 36,0 73,0 36,0 85,0 36,0 98,0 36,0 Xkg

4,0 8,5 4,0 8,5 4,0 9,5 4,0 11,0 4,0 Xtiles

III (24,5 m/s) 36,0 56,0 36,0 56,0 36,0 65,0 36,0 76,0 36,0 85,0 kg

4,0 6,5 4,0 6,5 4,0 7,5 4,0 8,5 4,0 9,5 tiles

Building height 0 - 5

meter

5 - 7

meter

7 - 9

meter

9 - 12

meter

12 - 15

meter

Wind area G1 G2 G1 G2 G1 G2 G1 G2 G1 G2

I (29,5 m/s) XXXXXXXXXXkg

XXXXXXXXXXtiles

II (27 m/s) 36,0 88,0 36,0 88,0 36,0 101,0 XXXXkg

4,0 10,0 4,0 10,0 4,0 11,5 XXXXtiles

III (24,5 m/s) 36,0 67,0 36,0 67,0 36,0 78,0 36,0 91,0 36,0 102,0 kg

4,0 7,5 4,0 7,5 4,0 9,0 4,0 10,5 4,0 11,5 tiles

Environmental factors

Position Middle zone roof

Terrain category Builded environment

Roong materials Bitumen

X= the required ballast is higher than will t under the system. The system must be mechanically attached to the roof. Please contact Van der Valk Solar Systems.

* If you use tiles of different sizes and thus another weight, you need to adjust the number of tiles to get the right weight.

Ballast foundations

Panel: maximum dimensions 1800x1100 mm (21 kg) Panel: maximum dimensions 2100x1100 mm (24 kg)

Windmap Belgium

Required ballast | Belgium

General

The ValkBox3 mounting system must be reinforced by means of tiles, which must be placed on the

indicated ballast foundations. In three steps you can easily calculate the required ballast;

• determine the wind area on the windmap

• choose the wind area and building height in the table

• you can now read the number of tiles / kg

Note 1: Min. extra ballast in G1 & G2 has to be 2 x 1 tile (2 x 9 kg).

Note 2: The ballast in G1 & G2 must be equally divided over the rubber ballast carriers.

Note 3: The max. of 20 tiles (4 in G1 and 16 in G2) can be placed for extra ballast (180 kg).

Building height 0 - 5

meter

5 - 7

meter

7 - 9

meter

9 - 12

meter

12 - 15

meter

Wind area G1 G2 G1 G2 G1 G2 G1 G2 G1 G2

23 m/s 36,0 38,0 36,0 47,0 36,0 54,0 36,0 63,0 36,0 69,0 kg

4,0 4,5 4,0 5,5 4,0 6,0 4,0 7,0 4,0 8,0 tiles

24 m/s 36,0 43,0 36,0 53,0 36,0 61,0 36,0 70,0 36,0 77,0 kg

4,0 5,0 4,0 6,0 4,0 7,0 4,0 8,0 4,0 9,0 tiles

25 m/s 36,0 48,0 36,0 59,0 36,0 67,0 36,0 78,0 36,0 86,0 kg

4,0 5,5 4,0 7,0 4,0 7,5 4,0 9,0 4,0 10,0 tiles

26 m/s 36,0 54,0 36,0 65,0 36,0 75,0 36,0 85,0 36,0 94,0 kg

4,0 6,0 4,0 7,5 4,0 8,5 4,0 9,5 4,0 10,5 tiles

Building height 0 - 5

meter

5 - 7

meter

7 - 9

meter

9 - 12

meter

12 - 15

meter

Wind area G1 G2 G1 G2 G1 G2 G1 G2 G1 G2

23 m/s 36,0 46,0 36,0 57,0 36,0 65,0 36,0 75,0 36,0 83,0 kg

4,0 5,5 4,0 6,5 4,0 7,5 4,0 8,5 4,0 9,5 tiles

24 m/s 36,0 52,0 36,0 64,0 36,0 73,0 36,0 84,0 36,0 93,0 kg

4,0 6,0 4,0 7,5 4,0 8,5 4,0 9,5 4,0 10,5 tiles

25 m/s 36,0 59,0 36,0 71,0 36,0 81,0 36,0 93,0 36,0 102,0 kg

4,0 7,0 4,0 8,0 4,0 9,0 4,0 10,5 4,0 11,5 tiles

26 m/s 36,0 65,0 36,0 79,0 36,0 89,0 36,0 102,0 X X kg

4,0 7,5 4,0 9,0 4,0 10,0 4,0 11,5 X X tiles

X= the required ballast is higher than will t under the system. The system must be mechanically attached to the roof. Please contact Van der Valk Solar Systems.

* If you use tiles of different sizes and thus another weight, you need to adjust the number of tiles to get the right weight.

Environmental factors

Position Middle zone roof

Terrain category III (villages, suburban terrain, permanent forest)

Roong materials Bitumen

Ballast foundations

Panel: maximum dimensions 1800x1100 mm (21 kg) Panel: maximum dimensions 2100x1100 mm (24 kg)

Windmap Germany

Required ballast | Germany

General

The ValkBox3 mounting system must be reinforced by means of tiles, which must be placed on the

indicated ballast foundations. In three steps you can easily calculate the required ballast;

• determine the wind area on the windmap

• choose the wind area and building height in the table

• you can now read the number of tiles / kg

Note 1: Min. extra ballast in G1 & G2 has to be 2 x 1 tile (2 x 9 kg).

Note 2: The ballast in G1 & G2 must be equally divided over the rubber ballast carriers.

Note 3: The max. of 20 tiles (4 in G1 and 16 in G2) can be placed for extra ballast (180 kg).

Building height 0 - 5

meter

5 - 7

meter

7 - 9

meter

9 - 12

meter

12 - 15

meter

Wind area G1 G2 G1 G2 G1 G2 G1 G2 G1 G2

1 (22,5 m/s) 36,0 39,0 36,0 39,0 36,0 39,0 36,0 39,0 36,0 39,0 kg

4,0 8,7 4,0 4,5 4,0 4,5 4,0 4,5 4,0 4,5 tiles

2 (25 m/s) 36,0 53,0 36,0 53,0 36,0 53,0 36,0 53,0 36,0 53,0 kg

4,0 6,0 4,0 6,0 4,0 6,0 4,0 6,0 4,0 6,0 tiles

3 (27,5 m/s) 36,0 68,0 36,0 68,0 36,0 68,0 36,0 68,0 36,0 68,0 kg

4,0 8,0 4,0 8,0 4,0 8,0 4,0 8,0 4,0 8,0 tiles

4 (30 m/s) 36,0 84,0 36,0 84,0 36,0 84,0 36,0 84,0 36,0 84,0 kg

4,0 9,5 4,0 9,5 4,0 9,5 4,0 9,5 4,0 9,5 tiles

Building height 0 - 5

meter

5 - 7

meter

7 - 9

meter

9 - 12

meter

12 - 15

meter

Wind area G1 G2 G1 G2 G1 G2 G1 G2 G1 G2

1 (22,5 m/s) 36,0 48,0 36,0 48,0 36,0 48,0 36,0 48,0 36,0 48,0 kg

4,0 5,5 4,0 5,5 4,0 5,5 4,0 5,5 4,0 5,5 tiles

2 (25 m/s) 36,0 64,0 36,0 64,0 36,0 64,0 36,0 64,0 36,0 64,0 kg

4,0 7,5 4,0 7,5 4,0 7,5 4,0 7,5 4,0 7,5 tiles

3 (27,5 m/s) 36,0 81,0 36,0 81,0 36,0 81,0 36,0 81,0 36,0 81,0 kg

4,0 9,0 4,0 9,0 4,0 9,0 4,0 9,0 4,0 9,0 tiles

4 (30 m/s) 36,0 100,0 36,0 100,0 36,0 100,0 36,0 100,0 36,0 100,0 kg

4,0 11,5 4,0 11,5 4,0 11,5 4,0 11,5 4,0 11,5 tiles

X= the required ballast is higher than will t under the system. The system must be mechanically attached to the roof. Please contact Van der Valk Solar Systems.

* If you use tiles of different sizes and thus another weight, you need to adjust the number of tiles to get the right weight.

Environmental factors

Position Middle zone roof

Terrain category IV (city)

Height above sea level 350 m

Exclusief North German Lowland

Roof materials Bitumen

Ballast foundations

Panel: maximum dimensions 1800x1100 mm (21 kg) Panel: maximum dimensions 2100x1100 mm (24 kg)

Windmap United Kingdom

Required ballast | United Kingdom

General

The ValkBox3 mounting system must be reinforced by means of tiles, which must be placed on the

indicated ballast foundations. In three steps you can easily calculate the required ballast;

• determine the wind area on the windmap

• choose the wind area and building height in the table

• you can now read the number of tiles / kg

Note 1: Min. extra ballast in G1 & G2 has to be 2 x 1 tile (2 x 9 kg).

Note 2: The ballast in G1 & G2 must be equally divided over the rubber ballast carriers.

Note 3: The max. of 20 tiles (4 in G1 and 16 in G2) can be placed for extra ballast (180 kg).

Building height 0 - 5

meter

5 - 7

meter

7 - 9

meter

9 - 12

meter

12 - 15

meter

Wind area G1 G2 G1 G2 G1 G2 G1 G2 G1 G2

22 m/s 36,0 57,0 36,0 72,0 36,0 78,0 36,0 97,0 36,0 97,0 kg

4,0 6,5 4,0 8,0 4,0 9,0 4,0 11,0 4,0 11,0 tiles

23 m/s 36,0 64,0 36,0 81,0 36,0 87,0 36,0 108,0 36,0 108,0 kg

4,0 7,5 4,0 9,0 4,0 10,0 4,0 12,0 4,0 12,0 tiles

24 m/s 36,0 71,0 36,0 89,0 36,0 97,0 XXXXkg

4,0 8,0 4,0 10,0 4,0 11,0 XXXXtiles

25 m/s 36,0 79,0 36,0 99,0 36,0 107,0 XXXXkg

4,0 9,0 4,0 11,0 4,0 12,0 XXXXtiles

26 m/s 36,0 87,0 36,0 108,0 XXXXXXkg

4,0 10,0 4,0 12,0 XXXXXXtiles

Building height 0 - 5

meter

5 - 7

meter

7 - 9

meter

9 - 12

meter

12 - 15

meter

Wind area G1 G2 G1 G2 G1 G2 G1 G2 G1 G2

22 m/s 36,0 68,0 36,0 86,0 36,0 94,0 XXXXkg

4,0 8,0 4,0 10,0 4,0 10,5 XXXXtiles

23 m/s 36,0 77,0 36,0 96,0 36,0 104,0 XXXXkg

4,0 9,0 4,0 11,0 4,0 12,0 XXXXtiles

24 m/s 36,0 85,0 36,0 107,0 XXXXXXkg

4,0 9,5 4,0 12,0 XXXXXXtiles

25 m/s 36,0 94,0 XXXXXXXXkg

4,0 10,5 XXXXXXXXtiles

26 m/s 36,0 104,0 XXXXXXXXkg

4,0 12,0 XXXXXXXXtiles

X= the required ballast is higher than will t under the system. The system must be mechanically attached to the roof. Please contact Van der Valk Solar Systems.

* If you use tiles of different sizes and thus another weight, you need to adjust the number of tiles to get the right weight.

Environmental factors

Position Middle zone roof

Terrain category Builded environment

Height above sea level 50 m

Distance to coast line 5 km

Distance to city border 5 km

Roof materials Bitumen

Ballast foundations

Panel: maximum dimensions 1800x1100 mm (21 kg) Panel: maximum dimensions 2100x1100 mm (24 kg)

Windmap Ireland

Required ballast | Ireland

General

The ValkBox3 mounting system must be reinforced by means of tiles, which must be placed on the

indicated ballast foundations. In three steps you can easily calculate the required ballast;

• determine the wind area on the windmap

• choose the wind area and building height in the table

• you can now read the number of tiles / kg

Note 1: Min. extra ballast in G1 & G2 has to be 2 x 1 tile (2 x 9 kg).

Note 2: The ballast in G1 & G2 must be equally divided over the rubber ballast carriers.

Note 3: The max. of 20 tiles (4 in G1 and 16 in G2) can be placed for extra ballast (180 kg).

Building height 0 - 5

meter

5 - 7

meter

7 - 9

meter

9 - 12

meter

12 - 15

meter

Wind area G1 G2 G1 G2 G1 G2 G1 G2 G1 G2

25 m/s 36,0 79,0 36,0 99,0 36,0 107,0 36,0 XXXkg

4,0 9,0 4,0 11,0 4,0 12,0 4,0 XXXtiles

26 m/s 36,0 87,0 36,0 108,0 XXXXXXkg

4,0 10,0 4,0 12,0 XXXXXXtiles

27 m/s 36,0 95,0 XXXXXXXXkg

4,0 11,0 XXXXXXXXtiles

28 m/s 36,0 104,0 XXXXXXXXkg

4,0 12,0 XXXXXXXXtiles

Building height 0 - 5

meter

5 - 7

meter

7 - 9

meter

9 - 12

meter

12 - 15

meter

Wind area G1 G2 G1 G2 G1 G2 G1 G2 G1 G2

25 m/s 36,0 94,0 36,0 117,0 XXXXXXkg

4,0 10,5 4,0 13,0 XXXXXXtiles

26 m/s 36,0 104,0 36,0 131,0 XXXXXXkg

4,0 12,0 4,0 15,0 XXXXXXtiles

27 m/s XXXXXXXXXXkg

XXXXXXXXXXtiles

28 m/s XXXXXXXXXXkg

XXXXXXXXXXtiles

X= the required ballast is higher than will t under the system. The system must be mechanically attached to the roof. Please contact Van der Valk Solar Systems.