intm installation corrugated eternit roof

STATICS. STABILITY. SAFETY.

Corrugated eternit roofInstallation instructions

Manufacturing and distribution: Donauer Solartechnik Vertriebs GmbH. Subject to errors and technical modifications.Version: 02/2009; contact: [email protected] // www.donauer.eu

TOOLSYou require the following tools:

• 15mmand17mmring/open-endedwrenches(open-endedspanners) • Electricscrewdriver • Screwingtoolforhangerboltsorsocketwrench(7mmor8mm) • 6mmhexagonalsocketwrench(Allenkey)

Corrugated eternit roof

Pleaseread thesafety instructionscarefullybeforebeginning in-stallationwork.Corrugatedeternitroofsareusuallyimplementedasslightlyslopingpurlinroofs.Youshouldprovideapointofancho-ragetothesubstructureateverypurlin.Eachoftheseanchoringpointsisalwaysatawaveonthecorrugatedeternitpanel.Gene-rally,thespacingisapproximately1.15m.Asthecorrugationrunsat90°tothepurlins,youmustinsertahangerboltateverypointofintersectionbetweenpurlinandwave.Themodulerailsarenor-mallymountedfromtheridgetotheeaves.Themodulesarethusinstalledlandscape.Thisdoesnotapplytorafterroofs,astheraf-tersdonotalwaysrunbeneathawave.Insuchcases,youshouldaddanauxiliaryraftertothesideoftherafterinthepropermanner,soastobeabletopositionthehangerbolt.

Strongwindsuctionforcesaretobeexpectedneartheedgesandridges of gable roofs. Please take this into account when installing aPVsystem.Figures 1 and 2 show the areas where the wind suc-tionforces‘aerodynamiccoefficientsarehigh.IfyouinstallthePVsystemintheseareasaswell,themountingframemustbeabletoaccommodatethesehighloads.Alsonotethattheanti-liftingpro-tection must be sufficient for the higher wind suction forces.

If you have any additional questions, use INTERSOL‘s professi-onal and comprehensive consultation service. Our competent construction engineers and technicians are happy to help you.

InSTaLLaTIOn InSTrucTIOnS

corrugated eternit roof

roof plan

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Hanger bolts:atthefasteningpoint,drillaholeintothecorruga-ted eternit roofing and the wooden structure beneath. Make sure thatyoualwaysselectawaveastheinstallationpoint.FortheM10hangerbolt,yourequireaø7mmdrillbitforthewoodenstructure,andø11mmfortheeternitpanel.FortheM12hangerbolt,useaø8mmdrillbitforthewoodenstructure,andø13mmfortheeternitpanel.Thenscrew in the full threaded lengthof thehangerbolt.Pleaseensurethatyouadheretotheminimumanchoringdepthof8cm(M10)or10cm(M12)respectively.Whenanchoringtothesup-portstructure,youshouldprovideclearanceofatleast3cm(M10)or3.6cm(M12)fromtheedgeofthepurlin(Fig. 3).

Generally,theproductrangecomprisescompletecorrugatedeter-nit bolt connections, including accessories, such as connectingplate,EPDMsealingand3nutswithinterlocking(itemno.10301-43/1to43/6)aswellas individualcomponentssuchasM10han-gerbolt(itemno.10301-45/140,/160,/180,/200)orM12hangerbolt(itemno.10301-45/300),EPDMsealing(itemno.10301-44)andtheM10aluminium5mmconnectingplate(itemno.10301-071)orM12stainlesssteel5mmconnectingplate(itemno.10301-46).PleaseuseonlytheM10boltsandnutsprovidedondeliveryforfasteningtheframe,andtheM8boltsandnutsforfasteningthemodulestothe frame.

The following torques are to be adhered to:

• M8(A2-70/A4-70):20Nm• M10(A2-70/A4-70):45Nm

Please note: use a torque wrench to ensure adherence to these torques.Aligntheframeormodulesbeforetighteningthebolts.

3 BOLTS

ROOF FASTENING

M10≥3cm

M12≥3,6cm


Onrafterroofs,lateralreinforcementisnecessaryinsomecases,asthewavedoesnotalwaysrundirect-ly above the rafter. For inserting thehangerbolts,youcanordersuitablehexagonal½´screwingtoolsfromourproductrange,forM10(itemno.10301-47)andforM12(itemno.10301-47/1).Forsteelsupportstructures,usesolarfastenerswithø8mmthreadand anM10 x 50mm setscrew instead of hangerbolts. Please note that the substructure must be at least1.5mmthick.Pre-drillholesaccordingtothefollowing table:

Thickness of the substructure (in mm) 1,5–5,0 6,0 8,0 ≥10

Pre-drilling diameter (in mm) 6,8 7,0 7,2 7,4

Onceyouhaveputthehangerbolt/solarfastenerinplace,affixtheEPDMsealingoverthedrilledholewith anM10/M12 fixing nut (fig. 4). Subsequently,install the connecting plate between 2 additionalnuts,insuchamannerthatalevelsupportingsur-faceforthecrossgirdersiscreated,theninstallthecross girders in a tension-freemanner by placingthem on this surface (fig.5). Now fasten the con-nectingplatebyadjustingthetwonutsattheheadof the hanger bolt connection.

Note: it is strictly forbidden to install a PV system on an asbestos cement roof. Exceptions can only be granted in individual cases by the relevant indus-trial inspectorate, upon written application as per §20ofthegermanhazardoussubstanceOrdinance(gefahrenstoffverordnung,gefstoffV).

4 5


With the cross girders Standard type 2 and Lighttype2, the lowerslotserves toaccommodateM10T-head and M10 mushroom head square neckedbolts. TheupperT-shapedslot is only suitable forfasteningthemodules,becauseonlyM8squarenutscanbeinsertedhere.ThecrossgirderFutura40x40(itemno.10301-04/310,/32)canaccommodateM10boltsandnutsinbothslots.Thus,thecrossgirder’sapplication options are highly flexible. The upperT-shapedslotalsoservestoaccommodatetheM8hammerhead nut (item no. 10301-41/E) for faste-ningmoduleswithAllenbolts (itemno.10301-411to-419).All3typesofcrossgirdercanbeconnectedquicklyandeasilywiththeassemblyangle(itemno.10301-073). With the cross girders Standard type2andFutura40x40,attachtheassemblyangles insuchamannerthatthesidepiecewiththe2drilledholesservesasalateralarrester.Withthecrossgir-derStandardtype2,thearresterisnottobesituatedonthesideofthecableduct.WiththeLighttype2

crossgirder,thesidepiecewiththe3drilledholesisthelateralarrester.EachassemblyangleisfastenedwithtwoM10T-headormushroomheadsquarene-ckedboltsandM10hexagonnutswithinterlocking(itemno.10301-40/M)(fig.6to8). Make sure that theconnectingjoint isnotsituateddirectlyatafa-steningpoint.

Please note: the maximum cross girder length should not exceed 15.0m, and the cross girdersshould not protrude more than 300 mm beyond the lastcorrugatedeternitboltconnection.After15.0m,installanexpansionjointofatleast5cm.

Endcapscanbeappliedtothecrossgirdersasopti-calfinishing.Asuitableendcapisavailableforeverytypeofcrossgirder.ForcrossgirdersStandardtype2,youneedtheendcap10301-083,forcrossgirdersLight type 2 the end cap10301-082, and for crossgirders Futura 40x40, the end cap 10301-081. The

Standard type 2

cROssgiRDeRs

Light type 2

6 7M8↙

↗ M10

M8↙

↗ M10


futura40x40

M8/M10↙

↗ M10

endcapsareaffixedon theundersidewithanM10/16boltandaM10hexagonnutwithoutinterlocking(itemno.10301-41) (Fig. 9).

Installing modules portrait: for portrait module alignment, youshouldcheckwhetherthemanufacturer‘sspecificationspermitfa-steningofmodulesontheshortside.Ifso,youcaneitherproceedinthesamemannerasforlandscapeinstallation,oryoucanselectafasteningoptionwhichusesacrossrailsystem.However,ifthefasteningpointsaresituatedonlyonthelongsidesofthemodule,youmustuseacrossrailsystem.Formoredetailedinformationinthisregard,refertothespecificinstallationinstructions„Crossrailsystem“.

Installing modules landscape: usually,thesupportingroofstruc-turewillbeapurlinroof.Therefore, lay thecrossgirdersso thattheyrunfromtheridgetotheeaves.Here,youcanusethecrossgirdersStandardtype2,Lighttype2,orFutura40x40.Fastenthecrossgirderstothehangerbolt‘sconnectingplatewithanM10T-headormushroomheadsquareneckedboltandanM10hexagonnutwithinterlocking.YoucaninserttheT-headboltanywhereinthe

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lower slot of the cross girder. Insert the mushroom headsquareneckedboltsintotheslotattheendoftherail,andslidethemtothedesiredposition(Fig. 10 and 11). If,ontheotherhand, thesubstructureisarafterroof,pleasecheckwhetherthewaverundirectlyabove thesupports. If this isnot thecase,youshouldreinforce thesupports laterally,so thatyoucan install thehangerbolt inavertical lineatthewave.

Elevated mounting: ifyouchooseafasteningoptionwith elevatedmounting, you need to use a Futura40x40asthebaserail,inordertofastenthetrian-gularsupports.Formoredetailedinformation,refertothespecificinstallationinstructions„Pitchedroofelevatedmountingframe“.

Nowpreparetheendclamps(itemno.10301-1532to-1551)/endclampsforframelessmodules(itemno.10301-98)andcentralclamps(itemno.10301-14and -141) / central clamps for framelessmodules(itemno.10301-97)forfasteningthemodulestothemodulerails.Themountingareasprescribedbythe

manufacturer of yourmodule can be found in themodule data sheet. For the cross girders Standard type2andLight type2,attachM8AllenboltswithinterlockingandM8squarenutstotheclamps.Slidetherequirednumberofclampsintotheupperslotofthemodulerails.WiththecrossgirderFutura40x40,

MODulefAsteNiNg

10 119


useanM8hammerheadnut insteadof theM8squarenut.Here,youcaninserttheclampsdirectlyintotheslotofthecrossgirderatanylocation.Nowplacethefirstmoduleonthecrossgirder,withatleast30mmclearancefromtheedge.Slidetheendclampsontothemodule‘sframe,andtightenthebolts.Tofastenthemoduleontheotherside,placeanothermodule,andfastenbothtothecentralclamps.Continueinthismanner,andlockoffthefinalmodulewithendclamps(Fig. 12 to Fig. 13).

Inordertosecurethemodulesagainsttheft,youcaninsertastar-shapedanti-theftdevice(itemno.10301-80)intotheM8Allenboltandfastenitwithacentrepunch.Thismeansthatthehexagonalsocketwrenchcannolongerbeinserted,andtheAllenboltcannotbe loosened.

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12

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PRODuctliAbility:

thetechnicaldocumentationconstitutespartoftheproduct.DonauersolartechnikVertriebsgmbhisnotliablefordamages caused by failure to observe the installation instructions, particularly the safety instructions, or caused by inappropriate use of the products.

We recommend that you read the following information carefully, as it is of great importance when handling the product. Please also inform yourself of the safety regulations which pertain to the other system components.

•oushouldadhere to these instructionsprecisely,wheneverworkingonthePVsystem.Installation,commissioning,maintenanceandre-pairsmayonlybeperformedbyappropriatelyqualifiedandauthorisedpersons.

•Pleaseobservetheapplicableregulationsandsafetyinstructions.

youmustobservethefollowingaccidentpreventionregulations:

•BGVA1–Generalregulations

•BGVA2–Electricalsystemsandequipment

•BGVC22–Constructionwork(personalfallprotectionequipment)

•Thetradeassociationhealthandsafetyatworkrules(BGR203–Wor-kingonroofs)andDINEN516„Equipmentforaccessingroofs“

•Thetradeassociationregulationsregardingworkclothingandworksafety

youmustadheretothefollowingDiNstandards:

•DIN18299–Generalrulesforallkindsofbuildingworks

•DIN18338–Roofcoveringandroofsealingworks

•DIN18360–Metalconstructionandlocksmithworks

•DIN4102–Firebehaviourofbuildingmaterialsandbuildingcompo-nents

Only authorised personnel may carry out work on Donauer Solartech-nikVertriebsgmbhsystems.theoperatorofthesystemhasthefol-lowing safety-related obligations:

• Performanceofregularannualmaintenancework,e.g.inspectionofcabling,boltconnections,andtheroofskin.

• Theframemayonlybeinstalledbypersonswithsuitablequalifica-tions, technicalskills,andknowledgeof the fundamentalsofme-chanics.

• Itmustbeensuredthattheassignedpersonscanassesstheworkallocatedtothem,andcanidentifypossibledangers.

• The installation instructions are part of the product, andmust beavailableduringinstallation.

• Itmustbeguaranteedthattheinstallationinstructions,andparticu-larlythesafetyinstructions,havebeenreadandunderstoodbytheassignedpersonnelbeforeinstallation.

• Thetradeassociationregulations,thelocalworksafetyregulations,and the technical regulations must be adhered to.

• Suitablehoistingequipmentandladdersaretobeusedfortheins-tallationwork.Noleaningladdersmaybeused.

• Itisnecessarytoarrangeforaqualifiedconstructionengineertoas-sessthebuilding‘sexistingstaticloadingcharacteristicswithregardtotheadditionalloadsofaPVsystem.

• Anygeneral loadreductionmeasuresspecifiedbyDonauerSolar-technikVertriebsGmbH(e.g.theneedtoclearsnow,soastolimitthesnowload)aretobeobserved.

PrODucT LIaBILITY / cOMMErcIaL GuaranTEE (LIaBILITY EXcLuSIOn IF aPPLIcaBLE)

• Thedimensioninginformationincludedintheseinstructionsmerelyrepresentsinformationgatheredinpractice.Bindingstaticloadingcharacteristicsformountingframescanbecompileduponrequest.

• Astheinstallationcompany,youareresponsibleforcorrectexecuti-on of installation work.

• DonauerSolartechnikVertriebsGmbHisnotliableforthedimensi-oninginformationincludedincommercialsystemproposals.

• Astheinstallationcompany,youareresponsibleforthemechanicalstabilityoftheinstalledinterfaceconnectionsatthebuildingenvelo-pe,andinparticularfortheirleak-tightness.ThecomponentsfromDonauerSolartechnikVertriebsGmbHaredesignedforthispurpo-se,accordingtotheexpectedloadsandthecurrentstateoftechno-logy.Tothisend,withinthescopeofthequery/order,youmustpro-videDonauerSolartechnikVertriebsGmbHwithwrittennotificationof all general technical framework conditions on the project datacollectionsheet (detailsof thesupport structure, snow loadzone,buildingheights,windloadsetc.).

• Donauer Solartechnik Vertriebs GmbH is not liable for incorrecthandlingoftheinstalledparts.

• Useinthevicinityoftheseaisprohibited,duetoriskofcorrosion.

• DonauerSolartechnikVertriebsGmbHgrantsa2-yearproductgu-arantee on the service life and stability of themounting systems,subject to correct handling, dimensioning in accordance with thestaticloadingconditions,normalenvironmentalconditions,andnor-malambientconditions.Thisapplieswithinthegenerallyprevalentweatherconditionsandenvironmentalconditions.

• Material andworkmanship guarantee: Donauer Solartechnik Ver-triebsGmbHgrantsa12-yearmaterialandworkmanshipguaranteeonthematerialsused.Consultthespecificguaranteeconditionsformore detailed information.

stANDARDsANDguiDeliNes

Allstandardsandguidelineslistedareissuedforgermany,andaretobeappliedforgermany,intherespectivevalidversion.Outsidegermany,youmustalsoobservetherelevantnationalstandardsandguidelines.

nOTES On ELEcTrIcaL InSTaLLaTIOn WOrK

Only if you are a qualified electrician, may you perform any electrical work. The applicable DIN standards, VDE regulations, VDEW guideli-nes, VDN guidelines, accident prevention regulations and the regulati-ons of the local utility company are authoritative in this regard.

• DINVDE0100(Installationofhighvoltagesystemswithnominalvol-tagesupto1000V)

• VDEWguidelineforparalleloperationofdomesticpower-generationsystemswiththelowvoltagegridoftheutilitycompany

• VDI6012sheet2,guidelinefordecentralisedenergysystemsinbuil-dings:Photovoltaics

• LeafletforVDEWguideline„Domesticpower-generationsystemsonthelowvoltagegrid“

• VDNguideline„Domesticpower-generationsystemsonthelowvol-tagegrid“

• DIN/VDEregulations,DIN/VDE0100„Installinghighvoltagesystemswithgridvoltagesupto1000V“, inparticularVDE0100,Part410,„Protectionagainstdirectandindirectcontact(Directcurrent>120V,<1000Vdirectcurrent)“andthe„Accidentpreventionregulationsofthecommercialtradeassociations“VBG4„Electricalsystemsandequipment“

• DINVDE0100-540Selectionandinstallation–Earthing,protectiveconductorsandequipotentialbondingconductors

• DIN57185VDE0185InstallationofalightningprotectionsystemandVDS2010

IMPOrTanT WarnInGS

Solar modules generate electricity as soon as they are exposed to light. There is always a voltage present. The fully insulated plug con-tacts provide a level of contact protection but when dealing with solar modules, the following points must be observed:

• Donotinsertelectricallyconductivepartsintotheplugsorsockets.

• Donotinstallsolarmodulesandwiringusingwetplugsorsockets.

• Exerciseutmostcautionduringallworkonthewiring.

• Donotcarryoutanyelectricalinstallationworkindampconditions.

• Alsowith low lighting, connectingsolarmodules in series causesveryhighDCvoltagestooccur,whichcanbelife-threateninguponcontact.Inparticular,notethepossibilityofsecondarydamageintheeventofelectricshocks.

The inverter can produce high touch voltages, even when not connec-ted:

• Exerciseutmostcautionwhenworkingonthewiringandinverter.

• After switching off the inverter, it is essential towait for the timeintervalspecifiedbythemanufacturerbeforebeginninganyfurtherwork.Thisallowsthehighvoltagecomponentstimetodischarge.

• Pleasealsoobservetheinvertermanufacturer‘sinstallationregula-tions.

When breaking a connected string of modules (e.g. when disconnec-tingtheDclinefromtheinverterunderload),alethallystrongelectricarc can occur:

• Neverdisconnectthesolargeneratorfromtheinverterwhilethein-verterisconnectedtothemainsgrid.

nOTES On THE InSTaLLaTIOn OF MOunTInG FraMES

For installation in roof areas, you must observe the currently appli-cable construction engineering regulations, especially the require-ments formulated in the DIN standards and in the „Regulations of the germanRoofing industry“ („RegelwerkdesDeutschenDachdecker-handwerks“).

• Checkwhetherallboltconnectionsaretight.

• Adheretothespecifiedtorques.

• Regardlessofverifiablestatic loadingconditions,youmustensurethat theproductcomplieswith thestatic loadingrequirementsonsite,asperDIN1055,beforeeveryinstallation.

• DINstandard1055„Actionsonstructures“

Part 1:Densitiesandweightsofbuildingmaterials,structuralele-ments and stored materials

Part 4:Windloads

Part 5: Snow load and ice load

Part 100:Basisofstructuraldesign–Safetyconceptanddesignrules

• Themounting frame isdimensionedasperDIN4113 „Aluminiumconstructions under predominantly static loading“ and DIN 18800„Structuralsteelwork;dimensioningandconstruction“ortherele-vantEurocodeEC1,EC3,EC9.

• Makesurethatthesubstructureisappropriatewithregardtoloadcapacity(dimensioning,stateofmaintenance,appropriatematerialspecifications),supportingstructure,andanyotherlayerswhich itaffects(e.g.insulationlayer).

• Makesurethattherainwaterrunoffisnotimpeded.

• Payattentiontothephysicalconstructionaspects(e.g.possiblecon-densationproblemscausedbypenetrationofinsulatinglayers).

SafetY inStruCtionS and WarningS


Stan

d02

/09

STATICS. STABILITY. SAFETY.

STILL HaVE QuESTIOnS?We will be happy to provide you with more information.

Distributed by

Donauer Solartechnik Vertriebs GmbH Zeppelinstr.10 82205Gilching Germany Telephone +49(0)8105/7725-0 Fax +49(0)8105/7725-100

[email protected] // www.donauer.eu

youcanalsovisitusonlineat:

www.intersol.eu

Ifyoustillhaveunansweredquestionsorsuggestions,youarewelcometo call us. You can reachour competent consultants,whowill answerall your questions regarding products, planning and installation, at +49(0)8105/7725-0.Here,youcanalsoobtaininformationonthein-stallationsystemsforallotherrooftypes.

Just get in contact with us!

intm installation corrugated eternit roof

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