Schuco MSE210 Corrugated Roof Mount Installation Manual

Schuco MSE210 Corrugated Roof Mount Installation Manual
Solar products
Schüco Mounting System MSE 210
Mounting on trapezoidal roofing
English
| Schüco
Installation instructions: Installation instructions: MSE 210 trapezoidal roof • Art. No. 259 713 • 08.2009 - 02
Printed in Germany, copyright Schüco International KG
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259 713 - 02
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Introduction
Dear Customer,
Thank you for choosing Schüco solar products and placing your trust in our company.
Prior to your first installation, we recommend that you
attend a training course at our training centre in Bielefeld
or, if this is not possible, that you take advantage of onsite training from one of our service engineers.
Before installation, please read carefully the general
information and safety guidelines contained in these
instructions.
Schüco requires that installation only be carried out by
technically qualified and authorised personnel with a recognised qualification (verified by a state or national body)
or the appropriate expertise in the relevant technical field.
Product description:
The mounting system developed by Schüco is used to
securely fix PV modules to roofs with a roof pitch of 2° to
20°.
Frameless PV modules can only be installed on horizontal
mounting rails for the installation types shown here.
The structural calculation for the mounting system was
based on the following parameters in accordance with
DIN 1055, part 4 and 5, 2005; DIN 4113-1/A1, 2002:
Module size
A module ≤ 1.60 m²
Roof area
Areas H and I
Snow load
Characteristic snow
loads on the ground
Correct usage also includes adhering to the installation
and operating instructions and installation instructions for
additional materials.
Accepted practice as usually codified in standards, guidelines, specifications, general and technical regulations
laid down by local and national bodies, power supply
companies, trade organisations and technical committees
in the relevant sector must be followed.
The installation of solar units puts an additional load on
the building. Ensure that the permissible roof load of
your building is not exceeded. If you have any questions,
contact your architect/building contractor or a structural
engineer. Under certain circumstances, the requirement
for your roof to be watertight increases in terms of roof,
wall and sealing technology. This must ascertained
before starting work.
The product warranty and/or output guarantee will be
invalidated if the claim on the guarantee can be attributed
to incorrect transportation or handling. Details can be
found in the product warranty and/or output guarantee.
If you do not have the product warranty and/or output
guarantee to hand, Schüco will be happy to send this to
you on request.
Please call our technical support if you have any questions or suggestions:
Tel.:
0521 / 783 - 400
Fax.:
0521 / 783 - 7242
E-mail:
[email protected]
(without snow drift formation)
Sk1 ≤ 1,10 kN/m² /
Sk2 ≤ 1.30 kN/m²
Taking into account possible installation locations in
the area of the "North German lowlands" for snow load
sk1
Wind load
dynamic load q ≤ 0.80
kN/m²
Dead load
g ≤ 0.20 kN/m²
Proper use
The Schüco mounting system for framed PV modules
has been developed and constructed in line with the
latest technology and recognised safety regulations. The
mounting systems must only be used in accordance with
their stated structural capability.
An alternative use or a use beyond this remit is not in accordance with its purpose. The mounting systems are not
for mobile use. Sunlight must not be directed onto the
surface of the laminates by reflection or through a lens.
Incorrect use can result in the death or serious injury of
the user or a third party, and may damage the appliance,
the installation or other material assets. The manufacturer/supplier shall not be liable for any resulting damage.
The user alone shall bear the risk.
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259 713 - 02
Disposal of the packaging
The packaging consists of cardboard,
wood and labelled plastic. Dispose
of the packaging in accordance with
the relevant laws and with technical
regulations. Observe the environmental
requirements with regard to recycling,
re-use and disposal of operating materials and components in accordance with
the local, country-specific and international current technical regulations and
official regulations.
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List of contents
Introduction ..............................................................................3
Product description ..................................................................3
Proper use ...............................................................................3
Disposal of the packaging ........................................................3
List of Contents .......................................................................4
Hazard warnings and safety instructions..................................5
Explanation of pictograms used ...............................................6
Transport/packaging ................................................................6
Schüco MSE 210 articles-Sortiment ........................................7
Additional material required ....................................................7
Tools required ...........................................................................7
Spacing and support widths single brackets ............................8
Overview: Schüco MSE 210 trapezoidal roof
mounting system (single brackets) ...................................9
Cutting the mounting rails .......................................................9
Installing the single trapezoidal brackets ...............................10
Mounting rail for single trapezoidal roofing ............................11
Spacing and support widths double brackets ........................12
Overview: Schüco MSE 210 trapezoidal roof
mounting system (double brackets) ................................13
Cutting the mounting rails ......................................................13
Installing the double trapezoidal brackets ..............................14
Mounting rail for double trapezoidal roofing ..........................15
Connecting the mounting rails ...............................................17
Module installation .................................................................18
Electrical connection ..............................................................22
Commissioning: General instructions ....................................22
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Hazard warnings and safety instructions
Risk of death or injury,
could endanger the environment
and the product
Danger!
Risk of death or injury from electric shock.
Caution
Do not damage any cables.
There is a risk of death from electric shock if
cables are defective.
Wear protective headgear
For buildings on which lightning
protection is required, the module
array must be integrated into the
lightning conductor.
Important
Do not damage any cables.
Defective cables may result in
death from electic shock.
Wear protective gloves.
Wear a safety harness.
Section off the site and secure
against falling objects.
Do not fix safety straps to the
mounting system.
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Explanation of pictograms used
(221 038)
6
Danger Risk of death or injury, could endanger the environment and the product.
en
Flush
Important note
Align so that it is parallel
Connection - Types / - Sizes
Centre
Materials to be provided by others
Tighten to suit the material involved
Weight/total weight (kg)
Tighten firmly
Not to be walked on
See page
6-digit numbers in brackets are always
Schüco article numbers
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Overview: range of Schüco MSE 210 articles for installation on roofs with trapezoidal corrugations
BP 030 T (259 720 - 1 PU)
L = 6 180 mm
Connector kit (257 105)
including M8 x 17.5 mm
punching screws
MSE 210 trapezoidal bracket
(259 733 - 50 PU) with preapplied sealing tape (double
fixing)
Drill hole∅ = 6.8 mm
MSE 100 trapezoidal bracket
with pre-applied adhesive
sealing tape (272 140 - 10 PU
/ 259 930 - 50 PU); drill hole ∅
= 6.8 mm
Installation instructions (259
713)
272 140 as anti-slip device when double trapezoidal brackets.
Additional material required
Only use fixing material approved by the building authorities in accordance with general building approval Z-14.1-4 “Connectors for joining building components in lightweight metal construction” (e.g.
self-drilling screws or riveted joints)
Example for possible retaining clamps:
OneTurn with end retaining clamp
(For Art. No., see retaining clamps)
OneTurn with intermediate retaining clamp
(For Art. No., see retaining clamps)
Tools required
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Pencil/chalk
Folding rule/tape measure
Open-ended spanner
Screwdriver (flat blade/cross-recess)
Spirit level
Cordless screwdriver / drill
Metal saw
Rubber hammer
Socket wrench/torque wrench
Socket wrench
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Spacing and support widths for single trapezoidal bracket (272 140 / 259 930)
Design 1
with single trapezoidal brackets (272 140 / 259
930)
In general, the system specifier will configure the layout
in advance. The maximum distances can be derived from
the location (installation location).
Key:
Trapezoidal brackets (272 140 / 259 930) must
always be mounted alternately above and below
the BP 030 T
Module
Axis
Trapezoidal bracket
8
a=
Distance BP 030 T
b=
Distance from mounting rail to PV module
edge
c=
Maximum horizontal distance between
trapezoidal brackets
L=
Module length
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Overview: Schüco MSE 210 trapezoidal roof mounting system

PV module

Connector kit (257 105)

Trapezoidal bracket (272 140 / 259 930)

Choice of end clamp brackets

BP 030 T (259 720)

Choice of intermediate retaining clamps
Cutting the mounting profile
The length of the mounting rails supplied is ~ 6180 mm
Mounting rail cutting (per array)
= ((Number of modules-1) x (Module width + 20 mm)) +
Module width
Example:
Number of modules:
6 modules
Arrangement:
portrait, adjacent in a single row
Module dimensions:
L = 1495 mm ; W = 1001 mm
Distance between the modules:
20 mm
Cutting length:
22 + (6 x (1001 + 21)) = 6154 mm
Number of mounting rails required per row:
2
Retaining clamps / module clips:
End retaining clamps: 4 per row of modules
Intermediate retaining clamps: 2 x (no. of modules -1)
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Installing the single trapezoidal brackets / BP 030 T
L
= Module length
Only use fixing material approved by the building authorities to fix the trapezoidal brackets.
Please install a single trapezoidal
bracket as an anti-slip device
Art. No. 272 140 (10 per PU).
The distance to the double trapezoidal bracket must be no more than
300 mm.
Important
Only install the trapezoidal brackets on the
raised sections of corrugated sheet, never
on the lower corrugations.
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Installing the mounting rail with single trapezoidal brackets (272 140 / 259 930)
If two BP 030 T mounting rails are installed on sheet with
trapezoidal corrugations, both mounting rails must be
aligned parallel to one another.
d1 = d2
Install a trapezoidal bracket at a maximum of every 300
mm. Always fix the trapezoidal bracket alternately – once
above the BP 030 T and once below it.
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Spacing and span widths for trapezoidal bracket 259 733
Variant 2
with double trapezoidal brackets (259 733)
In general, the system specifier will configure the layout
in advance. The maximum distances can be derived from
the location (installation location).
Key:
Module
Axis
Trapezoidal bracket
Anti-slip device (272 140)
12
a=
Distance BP 030 T
b=
Distance from mounting rail to PV module
edge
c=
Maximum horizontal distance between
trapezoidal brackets
L=
Module length
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Overview: Schüco MSE 210 trapezoidal roof mounting system

PV module

Choice of end clamp brackets

Trapezoidal bracket (259 733)

Choice of intermediate retaining clamps

BP 030 T (259 720)

Single trapezoidal bracket as anti-slip device (272
140)

Connector kit (257 105)
Cutting the mounting profile
The length of the mounting rails supplied is ~ 6180 mm
Mounting rail cutting (per array)
= ((Number of modules-1) x (Module width + 20 mm)) +
Module width
Example:
Number of modules:
6 modules
Arrangement:
portrait, adjacent in a single row
Module dimensions:
L = 1495 mm ; W = 1001 mm
Distance between the modules:
20 mm
Cutting length:
22 + (6 x (1001 + 21)) = 6154 mm
Number of mounting rails required per row:
2
Retaining clamps / module clips:
End retaining clamps: 4 per row of modules
Intermediate retaining clamps: 2 x (no. of modules -1)
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Installing the double trapezoidal brackets / BP 030 T
L
= Module length
Mount a single trapezoidal bracket (272 140)
on a free top corrugation.
This prevents the mounting rail from slipping
sideways.
Only use fixing material approved by the building authorities to fix the trapezoidal brackets.
Important
Only install the trapezoidal brackets on the
raised sections of corrugated sheet, never
on the lower corrugations.
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Installing the mounting rail with a double trapezoidal bracket (259 733)
Slide the required number of trapezoidal brackets onto
the mounting rail. This can be done prior to moving it
onto the roof.
If required, use insulating tape to secure the outermost
trapezoidal brackets against slipping down.
Slide the trapezoidal brackets to the correct position on
the raised sections of the corrugated sheet.
Adhere to the maximum spacing of 600 mm.
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If two BP 030 T mounting rails are installed on sheet with
trapezoidal corrugations, both mounting rails must be
aligned parallel to one another.
d1 = d2
After aligning the mounting rails, screw in all the trapezoidal brackets tightly. Make sure that the mounting
rails do not slip.
Note:
In this type of installation, prevent the
mounting rail from slipping sideways using
one single trapezoidal bracket (259 930) per
mounting rail.
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Connecting the mounting rails (connector kit 257 105)
Important
The connector kit does not fulfil any
structural function.
1.
Slide the connector kit half into the BP 030 T
screw channel.
2.
Slide the second BP 030 T onto the connecting kit.
3.
Ensure that the connector kit is evenly distributed on both BP 030 T
Ensure that the BP 030T mounting rails are
not butt-joined. There must always be a gap of
approx. 20 mm between the BP 030T mounting
rails.
This will prevent any damage to the profiles in
the event of temperature-induced expansion.
4.
Tighten the punching screws of the connecting kit.
~ 20 mm
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Module installation
Mounting system overview:
Install the modules as soon as you have installed all the
required mounting rails and checked that the trapezoidal
brackets are securely positioned.
18
A module must not be installed over a mounting rail connector. The connector kit does not
fulfil any structural function.
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Installing the first module
Using the OneTurn retaining clamp as an example
OneTurn with
intermediate retaining
clamp
OneTurn with end retaining
clamp
Schüco has developed the OneTurn fixing system to
mount modules quickly and securely.
To make installation work even easier, you need the
Schüco Allen key. This enables you to install all the
retaining clamps with one hand.
Always ensure that the module cables are guided
securely to prevent the cable from becoming damaged.
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Position the end retaining clamp flush with the module
frame. Lock the OneTurn in place by turning it 90°
clockwise.
Now tighten the threaded sleeve.
Install the second module
Only lock the intermediate retaining clamps
in place.
Do not tighten yet
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Before the second module can
be pushed under the intermediate retaining clamps, the cable
plug connections must be connected together correctly.
Slide the second module flush
below the OneTurn.
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Electrical connection
Lightning protection
As a rule, no additional lightning conductor is required for
photovoltaic installations, as the danger to the building is
not increased.
If there is already a lightning conductor present, you
must connect this into the photovoltaic installation.
Commissioning: General instructions
Handover to the operator
You must instruct the operator in how to operate and use
the photovoltaic system.
•
•
•
•
•
22
Give the operator all relevant instructions and documents for safekeeping.
Make the operator aware that the instructions must
be kept in a safe place so that they are always readily
available.
Go through the operating instructions with the operator and answer any questions.
Point out to the operator the safety instructions, to
which he or she must pay particular attention.
Make the operator aware that regular inspection/
maintenance of the system is required and recommend an inspection and maintenance agreement.
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Schüco International KG • Whitehall Avenue • Kingston, Milton Keynes • MK10 0AL • United Kingdom
Phone +44 19 08 28 21 11 • Fax +44 1908 28 21 24 • www.schueco.co.uk
Schüco International KG • Karolinenstraße 1-15 • 33609 Bielefeld • Deutschland
Telefon +49 5 21-7 83-0 • Telefax +49 5 21-7 83-4 51 • www.schueco.com
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