Samontec SolarTechnical manual for steel structure for photovoltaics on flat roofs/ free fields

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1. Photovoltaic support systems Samontec Solar

The photovoltaic support system Samontec Solar is made from galvanized steel. The quality of the steel finish has a minimum coating of hot dip galvanization 45 microns. The purlins can be either from aluminium or galvanized steel. All of the steel accessories (bolts, nuts, etc...) are made from stainless steel A2.

The system can receive the PV panels in both portrait & landscape configuration with any angle of inclination. It also offers the ability to adjust the height of the construction in order to avoid the shadow effect and to make the necessary adjustments for creating a level construction.

Also the system can be used in free fields with a foundation of concrete or with concrete piles.

All of the constructions are tested and can be approved for static loads by the engineers of the company.

1.1 GENERAL

The support system are customized for the individual needs of each building and are capable of making the adjustments necessary for a proper installation.

The number of supports and the distance between the supports is dependant upon the requirements of each project (number of panels, inclination) and the required load combinations of the specific location.

For mounting directly to the ground use the variable angle bracket (517201) which is anchored to the cement with the appropriate anchor bolt (depending on the project Fischer has the appropriate anchor bolt).

Then the connector (517202) is attached to the angle bracket (517201) with a bolt (517158) and fastened with the washer (517206) and nut (517205).

Depending on the requirements of the project the support bracket can be either mounted directly to the ground or elevated by using a small front leg.

For mounting with an elevated front leg, choose the appropriate leg (517411/ 517412/ 517413/ 517414) which will be anchored to the cement with the appropriate anchor bolt (depending on the project Fischer has the appropriate anchor bolt).

Then the connector sleeve (517202) is fastened to the leg with a bolt (517757) to the threaded holes in the connector sleeve (517202).

Finally the variable angle bracket (517201) is fastened to the connector sleeve (517202) with a through bolt (517158) and fastened with a washer (517206) and nut (517205).

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2.1 INSTALLING THE FIRST SUPPORT

517205

517202

517206

517201

Αγκύριο517158

517205

517202

517206

517158 517411517412517413517414

517757

517201

517206

Anchor bolt

2. Assembly of support system

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2.2 INSTALLING ADDITIONAL SUPPORTS

If the dimensioning of the project allows, you can use the following pre-manufactured legs (517411/ 517412/ 517413/ 517414) which are anchored to the cement with the appropriate anchor bolt (depending on the project Fischer has the appropriate anchor bolt).

Then the connector sleeve (517202) is fastened to the leg with a bolt (517757) to the threaded holes in the connector sleeve (517202).

Finally the variable angle bracket (517201) is fastened to the connector sleeve (517202) with a through bolt (517158) and fastened with a washer (517206) and nut (517205).

If the pre-manufactured legs can not be used, then use the profile FUS41 (517426) or the FUS62 (517427), and cut it to the desired length.

First you anchor the base SFL41 (517421) to the cement with the appropriate anchor bolt (depending on the project Fischer has the appropriate anchor bolt).

Then you fasten the profile FUS41 (517426), after cutting it to the correct dimension, to the base SFL41 (517421) by using the connector FCN CLIX P (517420) and fastener bolts (517575).

Afterwards, fix the connector (517202) with the profile (517426) with the bolt (517757) using the threaded slot in the connector (517202).

Finally, the variable angle bracket (517201) is fastened to the connector sleeve (517202) with a through bolt (517158) and fastened with a washer (517206) and nut (517205).

The area that the profile (517426) is cut, must be protected from corrosion. This is done by using the special galvanic spray (509242).

Where the nut (517205) and the washer (517206) are used, they can be replaced with the flanged nut (71749).

517426517427

517420517575

517575

517206

517206

517421

Anchor bolt

517158

517201

517202

517205

517205

517202517206

517158 517411517412517413517414

517757

517201

517206

Anchor bolt

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For the girder beam use the profile FUS62 with 3m length (517427), and cut it to the appropriate dimension.

The girder beam is fastened to either the connector sleeve (517202) or the variable angle bracket (517201).

For installing the connector sleeve (517202) use two bolts (517757) with the appropriate washers (517206) and pass them through the openings in the girder beam and fasten them to the threaded slots in the connector sleeve (517202).

For installing the variable angle bracket (517201), use two bolts (517757) with the appropriate washers (517206) and pass them through the openings in the girder beam and fasten them with a washer (517206) and nut (517205).

Where the nut (517205) and the washer (517206) are used, they can be replaced with the flanged nut (71749).

The area that the profiles are cut, must be protected from corrosion. This is done by using the special galvanic spray (509242).

2.3 INSTALLING GIRDER BEAM

517202

517427517428

517757

517206

517201

517427517428

517757

517206

517206

517205

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The piles are placed in rows and are spaced according to the specifications of the project.

Diagonal bracing is also used to reinforce the construction according to the specifications of the project.

If needed the girders can be adjusted in order to insure the correct alignment.

The adjustments that can be made are the following:

The girder beam can be adjusted in length with the fastening bolt (517757).

The variable angle bracket can rotate around the bolt (517158) changing the angle of the girder beam.

The connector sleeve (517202) can be adjusted in height with the fastening bolt (517757).

3.1 ADJUSTMENTS

517201

517202

517158

517757

517757

Girder beam

Bolt Μ 12x80 (517158)

Bolt Μ 12x20 (517757)

56 Nm

56 Nm

3. Installing and aligning the support structure

Drawing Description Torque

3.3 TABLE FOR FASTENER TORQUE

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517757

Purlin

517203

The purlin is made from the profile FUS41 with a 3m length (517426) or in special cases the profile FUS62 with a length of 3m (517427).

The purlin is installed over the girder beam and fastened using the connector nut FCN CLIX P (517420), which is inserted and rotated into the channel groove of the girder beam.

Then the bolt (517757) and washer (517206) are inserted through the purlin and fastened to the connector nut FCN CLIX P (517420).

517757

Purlin517206

517420

517420

517206

4. Installing purlins

When the purlin is used continuously to span over several girders, then a special purlin connector (517203) is used to fasten the two purlins together.

The purlin connector is fastened to the under side of the purlin with four allen screws M12x30 (517757) and washers M12 (517206).

Safety nuts are not required as the connector has been threaded to directly receive the M12 bolts.

4.2.1 PURLIN CONNECTOR

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5. Installing the panelsThe panels are fixed to the purlins with special clamps. There are end clamps that are used to fix the panels at the beginning and the end of a series, and there are middle clamps that are used between two panels.

The clamps are available pre-assembled (with allen screw, spring, plastic grip, hammer-head nut) and are availble for every panel thickness.

The hammer head nut is inserted into the channel of the purlin and turned to lock into the desired position.

Then the clamp is fastened into place with the allen screw.

Hammer head nut

Clamp

Allen screw

8

F

L

L/2

1- point load

FF

L

L/3 L/3

2- point load

q

L

2 supports - Uniformly load

qL qL

L L

3 supports - Uniformly load

FUS 41

Height 41 mm

Width 41 mm

Perimeter 281,19 mm

Ix 45,33 cm

Iy 47,69 cm

Wx 32,58 cm

Wy 33,75 cm

Area 2252 mm

Weight 2060 gr/m

0

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3500

4000

4500

5000

5500

6000

6500

0,5 1 1,5 2 2,5 3 3,5 4 4,5 5 5,5 6

F (N)

L (m)

FUS 41

3-supports

2-supports

1 point load

2 point load

6. Technical data sheets

FUS 62

Height 62 mm

Width 41 mm

Perimeter 365,19 mm

Ix 417,70 cm

Iy 412,90 cm

Wx 35,62 cm

Wy 36,29 cm

Area 2405 mm

Weight 3270 gr/m

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2500

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4000

4500

5000

5500

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6500

7000

7500

8000

8500

9000

9500

10000

0,5 1 1,5 2 2,5 3 3,5 4 4,5 5 5,5 6

F (N)

L (m)

FUS 62

3-supports

2-supports

1 point load

2 point load

F

L

L/2

1- point load

FF

L

L/3 L/3

2- point load

q

L

2 supports - Uniformly load

qL qL

L L

3 supports - Uniformly load

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Drawing Code Description Drawing Code Description

517201 VB PV μhdg 517420 FCN CLIX P 12 hdg

517202 VB PV hdg 517421 SF L 41 hdg

517203FUF PV 41 connector

hdg 509242 ZINC Spray 400ml

517204 Bolt Μ 12x30 A2 hexagon head 517158 Bolt M12x80 A2

hexagon head

517205 Nut M12 A2 71749 Flange nut MU F M12 A2

517206 Washer M12 A2 517165 Hammer head nut Μ 8 6mm thick

517411 FCA 300 hdg Cantilever Arm 517757 Socket screw

Μ 12x20 A2

517412 FCA 450 hdg Cantilever Arm 517426 FUS 41/2-3m hdg

Channel

517413 FCA 600 hdg Cantilever Arm 517427 FUS 62/2,5-3m hdg

Channel.

517414 FCA 750 hdg Cantilever Arm 517428 FUS 62/2,5-6m hdg

Channel.

7. Accessories

1958, the beginning.2012, world-wide.

Founded in 1958, the fischer brand is synonymous for safe, innovative and sophisticated technical solutions which set new standards in fixing engineering. The products and applications are unique fixing systems that are invented and produced by fischer. That is the reason that there exist unlimited solutions and a large range of applications, and today is recognised as the leader in the market of fixing systems.

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www.fischer.gr

National Road Athens-Lamia (17th) & 6 Roupel str.GR - 14564 Kifissia, Athens GreeceTel.: +30 210 28 38 167, Fax: +30 210 28 38 169info@fischer.gr

The contents of this manual are subject to change without prior notice. Fischer Hellas Em

poriki EPE is not responsible for typographical errors. PLS012 05/2012