00MK-MA0190-EN00

Universal Light system with locking brackets, for sloped roof

ASSEMBLY INSTRUCTIONS

Rev.02 – February 2014

Table of contents General instructions

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General safety instructions

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Universal Light system with locking brackets, for sloped roof

4

Regulations

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Components required

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Tools required

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Assembly instructions

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Notes

Table of contents

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General instructions Ensure you observe the general fitting and maintenance prescriptions. If you need any clarifications, please call immediately our customer service at number +39 011 19870791. • The Around You fitting system is constantly evolving and may therefore be subject to changes; before starting, check the version of the assembly instructions in your possession and, if it is not up to date, send a request for an updated version to [email protected]. All personnel on work site must have a copy of the assembly instructions. • The 12-year warranty is assured by our warranty certificate subject to compliance with assembly instructions, general instructions and general safety prescriptions provided by Thesan S.p.A. • In case of non-compliance with the assembly instructions, or are not used the parts listed, the warranty is void and Thesan declines all liability. • To disassemble the system, perform the assembly steps in reverse sequence.

General instructions

• Follow the instructions of the manufacturer of PV modules and the manufacturer of inverters. • Is necessary to provide routine maintenance on all parts of the plant, on a regular basis (maximum each 6 months).

Visual inspections: • Atmospheric events • Dirt, musk and other deposits • Corrosion of metal parts • Stability of the structure • Sealing of the roof cover

Mechanical inspections: • Check the tightness of nuts and, if necessary, retighten the nuts to the torque given in the assembly instructions The areas under the modules are more prone to becoming dirty, so remove all the deposits during the routine maintenance.

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General safety instructions Ensure you observe the general safety fitting and maintenance prescriptions. If you need any clarifications, please call immediately our customer service at number +39 011 19870791. • Fitting and commissioning of the systems must be carried out exclusively by skilled personnel who, thanks to their specific training or professional experience, are able to ensure that the work is performed correctly and to high standards. • The existing structures on which the system is to be fitted must be checked to ensure that the loading capacity of the building/structures is adequate. • Observe all regulations and local and national building regulations, and provisions relating to the environment. • Observe all regulations and national laws and local regulations regarding health and safety, accident prevention and the requirements of professional associations. In particular, it is necessary : • Wear personal protective equipment: safety helmet, safety gloves , safety shoes, etc. • If the system is to be fitted on an elevated surface comply with safety regulations for work at heights by using

General safety instructions

safety harnesses, falling objects signs, etc. • At least two people must be on the work site during the fitting procedures, so that one person can provide first aid or call emergency services in case of accident • Efficient earthing system is essential. If necessary, use the lightening protection devices. • If you need to cut the mounting rails to the installation location, you must make sure to remove the burrs on the surfaces affected by the cut in order to eliminate any possible risk of injury. Also you need to make sure that the cutted rails are not curvy. • The electrical installation must be carried out exclusively by skilled personnel who, thanks to their specific training or professional experience, are able to ensure that the work is performed correctly and to high standards. The wiring of the photovoltaic modules must be made to avoid the possible creation of loops.

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Universal Light system with locking brackets, for sloped roof

FEATURES OF THE SYSTEM • Thanks to the significant reduction in the number of components, the Around You system allows a reduction of approximately 57% in the amount of time required to fit the photovoltaic panels, compared to similar mounting systems of key competitors. • Robustness, practicality, and reliability over time are key characteristics of the system.. • Suitable for photovoltaic modules with and without frame. • Around You is leader in guaranteeing, on request, a reliable and efficient after -sales service, which is at customers’ disposal for any requirements.

The Universal Light system with locking brackets, for sloped roof, is a not preassembled mounting system for photovoltaic modules. In order to ensure safe and proper fitting of the system, each step described in these instructions must be carefully and accurately followed. At each step, necessary materials and equipment are listed. For any inconvenience or misunderstandings please call immediately our customer service at number +39 011 19870791. Universal Light system with locking brackets, for sloped roof

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Regulations The installation of the system have to be performed in accordance to the following regulations, or similar standards which are being used in the region of installation. The quality level of the standards need to be equal or higher as the standards which are mentioned.

BGV A1

Accident prevention regulations – General rules

BGV A3

Power system and equipment

BGV C22

Construction work

DIN EN 62305

Lighting protection

DIN VDE 0185

Lighting protection Components

DIN VDE 0100 part 410

Grounding

DIN VDE 0100 part 712

Electrical installations of buildings

DIN VDE 0105

Operation of electrical installation

DIN VDE 0298

Application of cables and cords in power installations

DIN 18338

Roofing work

DIN 18451

Scaffolding work

DIN 4102

Fire behavior of building materials and building components

DIN 18015

Electrical installations in residential buildings

DIN 18531

Waterproofing of roofs

VDS 2023

Electrical installations in structural works with mainly flammable materials

Eurocode 1

Wind loads

Eurocode 1

Snow loads

Eurocode 3

Design of steel structures

Eurocode 9

Design of aluminum structures

Regulations

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CLAMP SETS

FASTENERS

RAILS

Components Required

Components Required

Universal Light Aluminium

Alternatives available: SO-AYP05L3-0000 (3,1 m) SO-AYP05L6A3-0000 (6,2 m)

Locking bracket.

SO-AY036-0001

Self-drilling wood screw or Self-drilling screw or Concrete screw anchor.

Depending on the type of module, refer to general catalogue.

Adhesive and structural tape.

SOST-V501-003M (25mmx33m)

Aluminium clamp sets for glass-glass modules.

Depending on the type of module, refer to general catalogue.

Aluminium clamp sets for modules with standard frame.

Depending on the type of module, refer to general catalogue.

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CLAMPS OPTIONAL

Aluminium clamps for modules with standard frame.

Depending on the type of module, refer to general catalogue.

Nut with safety fit, M8, stainless steel. (DIN6923)

Alternatives available: SOST-V209-00TH (M8X30mm) SOST-V206-00TH (M8X36mm) SOST-V210-00TH (M8X42mm)

Protective Neoprene tape Width 120 mm, thickness 5 mm, roll 20 m

0042-80500-0000

Other accessories available on request. Consult the general catalogue.

For the possible use of alternative components contact Thesan S.p.a. technical department at [email protected] Components required

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Tools Required

Wireless screwdriver.

Torque wrench.

Mark line cord.

Metric tape measure.

Tools Required

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Assembly instructions

Step 1 Preliminary checks a. Check the design measurements on the roof on which the system is to be fitted. b. Provide a minimum distance of the rails from the edge of the roof of 500 mm. This system is highly versatile, hence it is ideal for installation on different types of roofs and surfaces,

such as:

- Corrugated sheet metal roofs;



- Wooden porch roofs;



- Metal porch roofs;



- Pitched roofs with counter batten

Step 2 Alignment a Use the line marker cord to trace the positions where to apply the adhesive and structural tape. The distance will be determined by Thesan Technical Dept. (or Thesan configurator software) depending on the specific project to be carried out. In case of different assembly solutions the warranty is void.

Step 3 Applying the adhesive and structural tapes a. Make sure that the metal surface where the tapes are to be applied is clean. If there are traces of dirt, remove any residual particles with a rag soaked in an oil-free cleaner. b. Cut the tape into lengths of approx. 10 cm.. c. Remove the protective film from the tape and apply the latter, with a slight pressure, to the support surface.

Assembly instructions

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Step 4 Positioning the Universal mounting rail the tape, taking into account the trace previously made with the line marker cord in order to ensure correct alignment of the rails. c. Place a couple of brackets, one on the left side and one on the right side of the rail, close to the previously applied tapes. d. Fasten the

brackets

to the support surface. Use

suitable fasteners depending on the support surface:

- Wood surfaces use stainless steel torx drive self- drilling screws, flat head



- Metal surface use galvanized steel hex head self- drilling screws



- Concrete surfaces use concrete wall plugs The type of fastener will be determined by Thesan

a.

Technical Dept. (or Thesan configurator software) de-

Remove the protective film from the upper side of structural adhesive tape, previously applied on the corrugated metal sheet.

e. Space each profile from the next by at least 1 cm in order

b. Position the Universal Light mounting rail aligned with

to allow a safety margin in the case of thermalexpansion.

pending on the specific project to be carried out.

Step 5 Positioning and fixing the photovoltaic modules

If the clamps you are using are not preassembled, insert the hammer head screw in the specific opening in the upper side of the mounting rail, turn the screw of 90° clockwise, position the clamp and partially tighten the nut with safety fit.

b. If the PV module is mounted landscape, the long side of the clamp must be in longitudinal position respect the mounting rail, if instead the PV module is mounted portrait, the long side of the clamp must be in orthogonal position respect the mounting rail. c. Position the photovoltaic module and fully tighten the nut with safety fit to a torque of 14Nm. d. Ensure the correct position of the clamp compared to the frame of PV module. The vertical walls of the clamp must adhere perfectly to the frame of the module:

Note : Follow the instructions of the manufacturer of the PV modules.



Upper side

a. If pre-assembled clamp sets are used, insert the hammer head screw into the specific opening in Lower side the upper side of the mounting rail, press the clamp gently to turn the screw of 90° clockwise. Make sure that hammer head screw is in an orthogonal position respect to the rail, and that the spring of the clamp makes completely adhere the hammer head screw to the rail.

End clamp for PV module with frame

Pre-assembled end clamp for PV module with frame

Module Rail

Module Rail



Assembly instructions

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Step 6 Earthing system a. Efficient earthing system is essential. b. Fastened with a screw the ground wire at any point on the aluminium rail.

Assembly instructions

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Notes

Notes

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SOLUZIONI CHE INNOVANO. ENERGIE CHE SI RINNOVANO. INNOVATING SOLUTIONS. RENEWING ENERGY.

www.thesan.com

Thesan S.p.A. - Via Torino 25 - 10050 Chiusa di San Michele (TO) Italy - tel. +39 011 19870791 - [email protected]

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