Mounting Systems Theta Bedienungsanleitung

In-roof system Theta

Installation manual

December 2009

Table of contents

ENGLISH

Theta Installation manual 3

12.2009 Theta-MA-ENG-0912

Table of contents

1Introduction 4

1.1 Overview 4

1.2 Intended use 4

1.3 Standards and technical directives 4

1.4 About this manual 4

2Safety 5

2.1 Basic safety instructions 5

2.2 Working on roofs 5

2.3 Warnings 5

2.4 Responsibilities of the operator 6

3Technical description 7

3.1 System overview 7

3.2 Scope of delivery 7

3.3 Technical specifications 7

4Planning the module field 8

4.1 Operating conditions 8

4.2 Landscape installation 9

4.3 Portrait installation 10

5Important installation information 11

5.1 Preparation work 11

5.2 Installation aids and required tools 11

5.3 Additionally required material 11

6Installation 12

6.1 Roof preparation 12

6.2 Installing the substructure 13

Laying the sealing strip 13

Installing the lower profile filler 14

Option A: Foam profile filler with

short lower adapter and narrow sealing strip 14

Option B: Comb profile filler with

intermediate adapter and wide sealing strip 14

Laying the corrugated metal sheets 15

6.3 Installing the adapter (landsacpe installation) 16

Installing of the short or intermediate

landscape adapters 16

Using the steps (for landscape installation) 17

Installing the short or long lateral adapters 17

6.4 Installing the adapter (portrait installation) 18

6.5 Installing the lateral flashings 18

6.6 Installing the top flashing 19

6.7 Installing the PV modules 20

Attaching the PV modules to the outer edge of

the module field (portrait and landscape

installation) 20

Inserting the Quickstone 20

Attaching the PV modules within the module

field (portrait and landscape installation) 20

6.8 Retiling the roof 21

1 Introduction

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1Introduction

1.1 Overview

Theta is an in-roof system for PV modules. It enables

direct integration of PV modules (framed or unframed)

into the roof cladding independently of the type of roof

covering. All components are pre-assembled on the

basis of your order and replace the previous roof cove-

ring. Theta is mounted on the existing or on new battens

of the roof construction. The roof can thus be completely

or partially covered with PV modules.

1.2 Intended use

The Theta in-roof system is to be used only for the roof

installation of PV modules. Any other use is considered

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 particu-

lar the safety information, or from the improper use of

the product.

1.3 Standards and technical directives

When planned correctly, Theta fulfils the following norms

and technical directives:

| Eurocode 1: Actions on structures – Part 1-3:

General actions, snow loads; German version EN

1991-1-3: 2003

| Eurocode 1: Actions on structures – Part 1-4:

General actions, wind actions; German version EN

1991-1-4: 2005

| Eurocode 9 – DIN V ENV 1999-1-1:

Design of aluminium structures

| DIN 1055 Actions on structures, section 100:

Basis of design, safety concept and design rules

| DIN 1055 Actions on structures, Part 4:

Wind actions

| DIN 1055 Actions on structures, Part 5:

Snow and ice loads

1.4 About this manual

Subject

These instructions describe the installation of the Theta

in-roof system.

The drawings in this manual illustrate the mounting of PV

modules on a tile roof (Frankfurter Pfanne, roofing tile).

Please note the specifications for mounting on other roof

types.

User group

This manual is intended for qualified personnel with

a basic knowledge of mechanics, hand tools and

mechanical skills.

Orientation aids

The following aids will improve orientation when using

these instructions:

Position numbers

The illustrations show the individual components with

position numbers referred to in the text. The position

numbers are shown as (1) and (2).

Headers

The headers give the current chapter overview.

Footers

The footers display the product name, the document title

and the page number.

2 Safety

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2Safety

2.1 Basic safety instructions

The following basic safety information and warnings are

an essential part of these instructions and have funda-

mental importance for handling of this product:

| Ensure that the product corresponds to the static

requirements on-site prior to every assembly and

installation.

| Observe occupational health and safety regulations

of the employer's liability insurance association.

| Wear a hard hat, protective gloves and safety shoes.

| Wear sunglasses in the event of glare from the sun

during the installation.

| A second person must be present during the entire

installation process to assist in the event of an acci-

dent.

| 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 identifies one of the

following danger levels:

Denotes a major risk, failure to observe which

could lead to serious injury or death.

Denotes a potentially dangerous situation

which may lead to moderate to serious physical

injury and property damage.

Denotes a potential risk which may lead to

physical injury and property damage.

DANGER

WARNING

CAUTION

2 Safety

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2.4 Responsibilities of the operator

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 commissioned 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 installation manual and in particular

the warnings have been read and understood by the

autorized installation personnel prior to assembly.

| Ensure that the permissible operating conditions

(see chapter 4.1, page 6) have been upheld. Moun-

ting Systems GmbH will not be held liable for

damage which results from a violation of these con-

ditions.

| 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 connec-

tions and roof attachments are guaranteed.

| Ensure that the appropriate lifting equipment is used

for the mounting process.

| Ensure that the water tightness of the mounted roof

installation is guaranteed.

| Ensure that only Mounting Systems components are

used, also in case of replacement.

Otherwise the warranty claim is void.

3 Technical description

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3 Technical description

3.1 System overview

(1) Lateral flashing

(2) Top flashing

(3) Corrugated metal sheet

(4) PV module

(5) Long adapter with module clamp (option A)

(6) Short adapter with module end clamp (option A)

(7) Short adapter with module clamp (option B)

(8) Intermediate adapter with module end clamp (option B)

(9) Sealing strip

Note:

This illustration shows the landscape mounting position

of the PV module. Other adapters must be used for por-

trait installation. The required calottes necessary for

attaching the corrugated sheets to the roof are not

shown here.

3.2 Scope of delivery

Theta includes all system components and accessory

components which are necessary for installation.The

delivery content corresponds to the configuration of

the PV unit. Additional roof battens and their respective

fixing materials are not included in delivery.

3.3 Technical specifications

(2)

(1)

(3)

(4)

(5)

(6)

(9)

(7)

(8)

Support profiles,

module (end) clamps Extruded aluminium EN AW

6060 T6/6063 T66

Small parts Stainless steel (V2A)

Flashings Aluminium, EN AW 5005

Corrugated metal sheet Aluminium, EN AW 3005

4 Planning the module field

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4 Planning the module field

4.1 Operating conditions

Application range Pitched roof

Roof covering Any

Roof pitch Depending on the regular roof pitch

of the remaining roof covering, min.

of 10°; max 45°

PV module Any size

Roof construction The roof construction must have ade-

quate load-bearing capacity. The roof

structure must comply with national

requirements and standards (for

example, rear ventilation).

Building height Max. 12 m

Snow load Max. 1.44 kN/m²*

Wind load Max. 39 m/s*

Roof batten spacing Max. 320 mm**

Roof batten

thickness Min. 35 mm

Roof batten width Min. 35 mm

* The maximum values may vary, depending on module size, building and

location.

**Applies to installation on existing battens. For installation on new bat-

tens: Position the battens at the quarter points of the modules.

Module field planning is based on:

| Module size (L x W x H)

| Module positioning (portrait, landscape)

| Number of modules

| Roof batten spacing

Additional roof battens

If the existing roof battens do not correspond to the

required points in the module field, additional roof bat-

tens will be necessary at the following points:

| Fixation of upper adapters

| Fixation of the sealing strip

| Fixation of the top flashing.

Additional roof battens and their respective fixing mate-

rials are not included in delivery.

Planning information

The following must be observed for planning the module

field:

| The standard Theta components are designed for

mounting the module field into a tiled roof. Mounting

on other types of roof coverings must always be

done by a professional roofing company.

| There must be a distance of at least three rows of

tiles between the top edge of the module field and

the roof ridge. If this is not the case, the top edge

completion must be performed by a roofing com-

pany to guarantee the water tightness and durability

of Theta. Should the ridge tiles not be fixed, then

there must be a distance of at least one row of tiles

between the top edge of the module field and the

roof ridge.

| Direct connections of the module field to the roof

ridge, roof verge or the eaves must be performed by

a professional roofing company in all cases.

4 Planning the module field 4.2 Landscape installation

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4.2 Landscape installation

The modules can be fixed along the entire length of the

adapters.

(1)

(2)

(3)

(4)

(6)

(7)

(3)

(6)

(7)

(5)

(1) Height of the module field:

Module width x number of modules vertically + ((number of

modules vertically – 1) x 19 mm) + 50 mm

(2) Width of the module field:

Module length x number of modules horizontally + ((num-

ber of modules horizontally – 1) x 19 mm)

(3) Additional roof battens for attaching the sealing strip and

the lower adapter: Distance between new batten (center)

and edge of the below tiles: 120 mm (for the short adapter)

or 220 mm (for the intermediate adapter).

(4) Additional roof battens for fixing the top adapter:

Height of module field – 30 mm (center of batten)

(5) Additional roof battens for fixing the top flashing:

Height of module field + 280 mm (center of batten).

(6) Horizontal distance between adapters:

Approx. at quarter points of the module = ½ module length

(observe the information provided by the module manufac-

turer)

(7) Vertical distance between adapters:

Can be calculated from the module dimensions. Place the

adapter correctly in the inner part of the module field so

that its centre point is located in the 19 mm clearance

space between the modules. A minimum distance of 25

mm between the adapter edge and module field edge must

be kept for the outer top and bottom adapters.

Choosing between short and long adapters

for landscape installation

Should the existing battens be replaced or supplemented

during the course of precise module arrangement planning,

then the short adapters may be used in the inner surface

area. The long adapters facilitate more flexibility in the verti-

cal fixation of the PV modules, so that in some cases, when

installing the mounting system, no further roof battens need

to be added to the roof truss.

For the lower edge of the PV field, short or intermediate

adapters may be used. The intermediate adapters enable (in

connection with a correspondingly wide sealing strip) a lar-

ger overlapping in the sealing strip area. This may be neces-

sary, depending on the national standards.

4 Planning the module field 4.3 Portrait installation

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4.3 Portrait installation

(1) (7)

(6)

(2)

(3)

(5)

(4)

(1) Width of the module field:

Module width x number of modules horizontally +

((number of modules horizontally – 1) x 19 mm) + 50 mm

(2) Heigth of the module field:

Module length x number of modules vertically +

((number of modules vertically – 1) x 19 mm)

(3) Additional roof battens for fixing the sealing strip: Distance

between new batten (center) and edge of the below tiles:

120 mm or 220 mm, depending on the chosen sealing strip.

(4) Additional roof battens for fixing the upper edge of the PV

field: Height of the module field - 30 mm (center of batten).

(5) Additional roof battens for fixing the top flashing:

Height of the module field + 280 mm (center of batten).

(6) Vertical distance between adapters:

Approx. at quarter points of the module = ½ module length

(observe the information provided by the module manufac-

turer). Spacing is based on the roof batten raster. In the

case of a particularly unfortunate batten raster, additional

battens may have to be installed).

(7) Horizontal distance between adapters:

Can be calculated from the module dimensions. Position

the adapter in the inner part of the module field so that its

centre point is located in the 19 mm clearance space

between the modules. A minimum distance of 25 mm must

separate the adapter edge of the adapters on the right and

left edge and the module field edge.

5 Important installation information

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5 Important installation information

5.1 Preparation work

Mounting Systems recommends that you inform yourself

about the local conditions prior to ordering Theta.

In particular, be familiar with:

| The roof construction

| The roof batten thickness

| The roof batten quality

| The roof batten spacing

5.2 Installation aids and required tools

The following tools will be needed for the installation of

Theta:

| Roof ladder

|Foldingrule

| Chalk line to align the adapters

| Aluminium level (to check the flatness of the battens

and the module field)

| Cut-off grinder with a stone disc (to fit the tiles)

| Metal cutters (for cutting the metal sheets, sealing

strip, etc.)

| Roofing tinsmith tools, i.e. crimping or clinching

pliers (for possible work on the flashings)

| Rubber hammer

| 6 mm Allen key

| Cordless drill with an 8 mm hex headbit (for adapter

screws) and torx bit (for calottes and roofing screws)

5.3 Additionally required material

Depending on the system plan, the following additional

materials may be necessary:

| Double-sided adhesive tape

| Roof battens

| Appropriate wood screws for fixing roof battens

| Appropriate material for sealing and additional fixing

of the surrounding tiles, as needed.

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