PROINSO PV RACK MINI 10 PROproinsopvrack.com/wp-content/uploads/2019/07/PV... · (for top fixing clip) or 40mm (for side fixing clip) Mini 10 rail for landscape installation, with

WWW.PROINSO.NET INSTALLATION MANUAL

PROINSO PV Rack

PROINSO PV RACK

MINI 10 PRORobust aluminium structures designed and made in Europe

WWW.PROINSO.NET INSTALLATION MANUAL

1 INTRODUCTION 21.1 Short description 2 1.2 About these instructions 21.3 Warning notices 31.4 Safety 3

2 TECHNICAL DESCRIPTION 42.1 System overview 42.2 Technical data 52.3 Components 5

3 IMPORTANT INSTALLATION INFORMATION 63.1 Conditions of use 63.2 Mounting preparations 63.3 Mounting aids and required tools 63.4 On the mounting descriptions 63.5 On the assembly descriptions 6

4 PLANNING THE MODULE AREA FOR A PORTRAITLAYOUT OF THE MODULES 7

5 INSTALLING RAILS FOR PORTRAIT LAYOUT OFTHE MODULES 85.1 Placing the EPDMS 85.2 Positioning and alignment of the rails 85.3 Placing the side fixing clips 85.4 Placing the top fixing clips 95.5 Fastening the rails 95.6 Connecting rails 105.7 Securing the profile rails against excessive lateral shift 10

6. MOUNTING MODULES IN PORTRAIT ORIENTATION 116.1. Mounting clickstones 116.2. Fastening the modules on the outer side 126.2. Fastening the modules on the inner side 12

CONTENTS

WWW.PROINSO.NET INSTALLATION MANUAL | 2

1. INTRODUCTION

1.1. SHORT DESCRIPTION

The Mini 10 Pro on-roof system is a robust racking system for the mounting of PV modules on trapezoidal sheet roofs. It consists of aluminium support rails and all necessary small parts for the fastening of the modules on to the rails as well as for the connection of the components with each other. The Mini 10 Pro allows for both portrait and landscape installa-tion of the modules.

1.2. ABOUT THESE INSTRUCTIONS

CONTENT

These instructions describe the installation of the on-roof system Mini 10 Pro and all system-specific information for planning, components and safety. The drawings in the first part of the instructions show the portrait installation of framed modules. The landscape version is treated separately from chapter 7 onwards.

APPLICABLE DOCUMENTS

In addition to this document, the document “Mounting Instructions for PV PROINSO PV Rack: General Part” is part of each product delivery. This document describes the gener-al applicable information for PROINSO PV Rack’ product range on standardisation, safety, transport, maintenance, disassembly and disposal. Both the present Mounting Instructions and the “Mounting Instructions for PV PROINSO PV Rack: General Part” are an integral part of the mounting system Mini 10 Pro and must be adhered to for each installa-tion.

It is crucial to carefully read these Mounting Instructions as well as all applicable documents prior to carrying out any installation, maintenance or disassembly work. You are provided with all the information required for the safe and complete mounting, maintenance and disassembly. Should you have any questions, please contact PROINSO PV Rack.

USER GROUPS

PROINSO PV Rack's installation instructions are intended for the following persons (user group):

• skilled personnel• instructed personnel

SKILLED PERSONNEL

Skilled personnel are individuals who, on the basis of their professional training, are able to execute installation, maintenance, and disassembly work appropriately.

INSTRUCTED PERSONNEL

Instructed personnel are individuals who have been instructed and taught appropriately regarding the assigned tasks and the possible risks in the event of improper conduct. An instructed individual must have received instructions regarding the required safety policies, precautions, relevant regulations, accident prevention regulations, as well as operating conditions and must have demonstrated his/her competence. The implemented work must be approved by skilled personnel.

ORIENTATION GUIDE

The following pictograms allow for the easier orientation in this manual:

PICTOGRAMS

This symbol indicates important information and useful notes.

This symbol indicates tips and tricks for easier procedures.


1.3. WARNING NOTICES

The warning notices used in this Installation Manual indicate safety-relevant information. They include:

• warning symbol (pictogram)• signal word indicating the hazard level• information on the type and source of hazard• information on possible consequences if hazards are disre-garded• measures to be taken in order to prevent• hazards and avoid injuries or damage

The signal words of the warning notices indicate the following hazard levels:

1.4. SAFETY

The complete general safety regulations for the frame systems supplied by PROINSO PV Rack are included in the further applicable document "Installation Manual - General Information". Read this document with care and always observe the notices containeduse the frame only in compli-ance with its intended purpose. Observe the duties of the principal and follow the general as well as the specific safety instructions. For any jobs you accomplish, the specific safety notes which precede the instruction steps in this productspe-cific Installation Manual must also be observed.

WARNING

CAUTION

ATTENTION

DANGER

Indicates a great, exceptional danger which, if not avoided, will result in severe personal injury or death.

Indicates a potentially dangerous situation which may result in severe or moderate personal injury and damage to property.

Points out a possibly dangerous situation which, if not avoided, may result in minor or light personal injury and damage to proper-ty.

Indicates a potential danger which may result in damage to property.


2. TECHNICAL DESCRIPTION

2.1. SYSTEM OVERVIEW

The following illustration shows all system parts.

The design of each system part may vary. It depends on:

• roof type• type of module• number of modules and configuration• local conditions

Lateral fixing clip

Module clamp

Module end clamp

EPDM

Roof


2.3. COMPONENTS

In the following all system components of the Mini 10 Pro are shown, which can be included in the scope of the delivery. The exact scope of the delivery and the number of individual components depends on your order.

Mini 10 rail

EPDM 80mm (for top fixing clip) or

40mm (for side fixing clip)

Mini 10 rail forlandscape installation,

with pre-mounted EPDM

Thin sheet-metalscrew (5.5x25mm)

Mini 10 Connector

Mini 10Connector with

grounding option

Module end clamp Position lockModule clamp

2.2 TECHNICAL DATA

Mini 10 sidefixing clip with AluFix seal

Mini 10 top fixing clip

APPLICATION Pitched roof — on-roof

ROOFING Trapezoidal sheet metal

MIN. SHEET THICKNESS Steel: 0.4mm / Aluminium: 0.8mm

MIN. BEAD HEIGHT From 20mm

ROOF SLOPE Up to 20°

BUILDING HEIGHT Up to 20m

PV-MODULES Framed, unframed

MODULE ORIENTATION Landscape

SIZE OF MODULE ARRAY Any size possible

POSSIBLE HEIGHT COMPENSATION Up to 5mm

DISTANCE BETWEEN RAIL FIXATIONS Depending on load situation (automatic verification per

design software)

STANDARDS Eurocode 1 – Action on structures

Eurocode 9 – Design of aluminium structures

SUPPORTING PROFILES Extruded aluminium profiles (EN AW 6063 T66)

RAIL FIXATIONS Side fixing clip: Aluminium (EN AW 5754)

SMALL PARTS Stainless steel (V2A)

COLOUR Aluminium: plate finish

WARRANTY 10 years


3. IMPORTANT INSTALLATION INFORMATION

3.1 CONDITIONS OF USE

The Mini 10 Pro on-roof system is designed with different rail and roof fasteners in accordance with Eurocode 1-DIN EN 1991-1-1 for various maximum loads. The suitability of the material must therefore be verified for each system, e.g. by means of the Mini 10 Pro configuration tool. Please also observe the suitability constraints, which are listed in Chapter 2.3 “Technical Data”.

3.2 MOUNTING PREPARATIONS

PROINSO PV Rack recommends that you inquire about the local conditions before ordering the Mini 10 Pro. In particular, acquaint yourself with:

• roof condition (e.g. bead distance and bead height)• the thickness and the material of the trapezoidal sheet• the quality and the condition of the trapezoidal sheet• adequate fastening of the trapezoidal sheet to the substructure

3.3 MOUNTING AIDS AND REQUIRED TOOLS

For the installation of the mounting system, you will require the following tools:

• Allen key 5 mm/ hexagon socket drill bit, 5mm,• Cordless screwdriver• Drill bit for cordless screwdriver TX30• Angle grinder with metal cutting disc• Chalk line• Spirit level• Yard stick / tape measure• Lifting gear (e.g. aerial lifts, carrying straps)• Suction lifter• If required, Spacer gauge (for landscape installation)

3.4 ON THE MOUNTING DESCRIPTIONS

In the following chapters all steps for the planning and installation of the Trapeze ProLine are listed in the correct sequence. Chapters 4, 5 and 6 describe the installation steps for a portrait layout of the modules; chapters 7, 8 and 9 describe the installation steps for a landscape installation.

Please adhere to the mounting steps listed here and be sure to follow the safety instructions.

3.5 ON THE ASSEMBLY DESCRIPTION

The following chapters describe all steps necessary for the planning and assembly of Triangle S Pro in their correct order. Chapter 5 describes the assembly steps for the corner clamping of the modules at the short side, chapter 6 includes the additional assembly steps necessary for the rail clamping of the modules at every quarter of the long side. Follow these

RISK OF FATAL INJURY FROM DAMAGE TO ROOF

Excessive loads can severely damage the roof.

• Before mounting and installation, please make sure that the building and especially the roof cladding meets the increased structural requirements for the PV system and the mounting operation.

RISK OF FATAL INJURY FROM FALLING OBJECTS

Parts falling from the roof can resultin serious injuries or death.

• Before commencing with the installation, please ensure that the material used meets thestructural requirements of the site.

DANGER

DANGER


4. PLANNING THE MODULE AREAFOR A PORTRAIT LAYOUT OF THE MODULES

For portrait installation, the profile rails are fastened to the beads of the trapezoidal sheet by means of fixing clips. The clips must be mounted with a defined distance, which depends on the material and thickness of the trapezoidal sheet, the distance to the high beads, the position on the roof and the on-site conditions.* The layout is defined by the design in the configuration tool or by project-related struc-tural analyses. Taking the above mentioned points into account, the fixing clips must be placed in such a way that they are as close as possible to the module clamps.

When positioning the fixing clips take into account that:

• The specified dimensions are approximate values• The dimensions of the trapezoidal sheet and the high beads define the true horizontal distance.

* Layout required according to local conditions in accordance with Euroc-ode 1-DIN EN 1991-1-1/Eurocode 9-DIN EN 1999-1-1.

RISK OF FATAL INJURY FROMDAMAGE TO ROOF

Excessive loads can severely damage the roof.

• Before mounting and installation, please make sure that the building and especially the roof construction meets the increased struc-tural requirements resulting from the PV system and the assembly operation.

RISK OF FATAL INJURY FROMFALLING OBJECTS

Parts falling from the roof can result in serious injuries or death.

• Before any mounting or installation, please make sure that the material used is suitable for the building structure and meets the structural requirements applicable on-site.

DANGER

DANGER

b

4.1

1

52

3

4

3

1 Height of the module field: Number of modules vertically x module length (+ desired clearances)

2 Width of the module field: Number of modules horizontally x (module width + 19 mm) + 41 mm

3 Vertical distance of the rail (in accordance with the clamp-ing points defined by the module manufacturer): Approx. quarter points of the modules = 1/2 x module length

4 Horizontal distance of the fixing clips: According to the plan, depending on the trapezoidal sheet and the structural calculations*

5 Distance between the modules = 17-19 mm

* Layout required according to local conditions in accordance with Euroc-ode 1-DIN EN 1991-1-1/Eurocode 9-DIN EN 1999-1-1.


5. INSTALLING RAILS FOR PORTRAIT LAYOUT OF THE MODULES

5.1 PLACING THE EPDMS

MOUNTING STEPS:

• Determine the position of the rails on the trapezoidal sheet taking into account the permissible clamping points of the PV modules used.• Mark the position of the EPDMs on each high bead with the aid of a chalk line.• Stick an EPDM strip onto each high bead on which the rails rest.• For the fixation of the rails with side fixing clips, EPDM 40x20x1mm is used; for the top fixing clips, use EPDM 80x20x1mm. Make sure that the rail is not positioned on callottes. The rail position might have to be adapted accord-ingly, taking the clamping area of the modules into account.

5.2 POSITIONING AND ALIGNMENT OF THE RAILS

MOUNTING STEPS:

• Position the total rail length and perform any necessary rail cuts.• Place the rails on the applied EPDMs.• Align the rails by using a chalk line or spirit level.

5.3 PLACING THE SIDE FIXING CLIPS

MOUNTING STEPS:

• Insert the side fixing clip in the side channel.• Press the clip onto the side of the high bead and make sure that it makes even contact and that it is hooked in correctly in the side channel of the rail.• The side fixing clips are fastened to opposite sides of the high bead.

NOTE!

Connected rail tracks should not exceed a length of 12m. The total rail length required depends on the width of the module field (see Chapter 4). The permissible cantilever (over-hanging of the loose rail ends over the last positioning on a high bead) is limited to a maxi-mum of 17.5cm. Do not exceed this limit. If necessary, cut rails accordingly or use connec-tors.

5.1-1

5.2-1

5.1-2


5.4 PLACING THE TOP FIXING CLIPS

MOUNTING STEPS:

• Place the fixing clip from above on to the EPDM and the lateral fixing channel of the rail.• Place the opposite clip. Remember to use the longer EPDM pieces of 80x20x1mm.

5.5 FASTENING THE RAILS

MOUNTING STEPS:

• Fasten the fixing clips on the side or on the top with the supplied thin sheet-metal screws 5.5x25mm with sealing washer. Make sure not to over tighten the screws. The appro-priate tightening torque depends on the strength and the material of the trapezoidal sheet.

MATERIAL DAMAGE DUETO INCORRECT MOUNTING

Incorrectly mounted fixing clips can pull out.

• When inserting the fixing clips, always ensure the correct fit of the clip in the channel.

5.3-1 5.3-2

5.4-1 5.4-2

5.5-1 5.5 -2

5.5-3 5.5 -4

CAUTION


Incorrectly mounted fixing clips can pull out.

• When inserting the fixing clips, always ensure the correct fit of the clamp in the rail channel.

CAUTION

DAMAGE TO BUILDING FROM LEAKING

Incorrectly mounted fixing clips and thin sheet-metal screws can lead to leaks.

• Check that the fixing clips sit evenly on the high bead.• Make sure that the AluFix seal between the high bead and the clip has a clean fit.• When mounting the top fixing clips, make sure the EPDMs are set correctly.

CAUTION

DAMAGE TO THE BUILDING AND THE PV SYSTEM DUE TO INCORRECT MOUNTING

Incorrect distance between the fixing clips can cause damage to the building and the PV system.

• When fastening the fixing clips to the rails, make sure to adhere to the distances defined in the calculation tool or the project- specific analysis.• Distinguish between and adhere to the possi-bly differing distances in the centre and at the edges of the roof.

CAUTION

MATERIAL DAMAGE DUE TO INCORRECT MOUNTING

Incorrectly mounted thin sheet-metal screws can pull out.

• Fasten the thin sheet-metal screws tightly but do not overtighten.

CAUTION

NOTE!

Do not fasten all rails at once, but alternate between installation steps 5.5 and 5.6. Mount the individual rails, which have been connect-ed with a connector.


5.6 CONNECTING RAILS

MOUNTING STEPS:

• Insert the connector into the first rail.• Slide the next rail onto the placed connector.• When using the rail connector with bonding option, tighten the two pre-mounted screws.

5.7 SECURING THE PROFILE RAILS AGAINST EXCESSIVE LATERAL SHIFT

The rails must be secured in their position. The clips used allow the rail to expand lengthwise, which would e.g. occur during fluctuation in temperature. In order to secure the position of the rails and still allow for expansion, a position lock is inserted at the side of the rail ends. Rows of rails which are connected with connectors only need to be secured once with two position locks. Individual rails must be provided with two position locks each.

MOUNTING STEPS:

• Place one lock at each end of a row of rails.• Keep a distance of approx. 2cm to the last fixing clip.

5.6-1 5.6-2

5.6-3 5.6-4

5.6-5 5.6-6

5.7-1

5.7-3

5.7-2

NOTE!

Rail connectors are provided for linking individual rails. There are two different types of connectors, with and without screws for a bonded connection between the rails.

NOTE!

The connected rail tracks should not exceed a length of 12m. Thereafter, an expansion joint (approx. 5cm) must be considered. Do not install modules over the expansion joint.


6.1. MOUNTING CLICKSTONES

Clickstones are used for the installation of the modules. The Clickstone is a special clip with which the module clamps are fastened to the rail. You only need an Allen key (5mm) for the mounting. You can insert the Clickstone from above into the channel of the rail.

MOUNTING STEPS:

• Insert the Clickstone at a slight angle into the rail channel.• Push the Clickstone down. Make sure you hear the Click-stone clicking into the rail• Tighten the hexagon socket bolt with a torque of 8 Nm.

6.1-1 6.1-2

NOTE!

The shape of the Clickstone corresponds exactly to the profile of the rail channel. It has been consciously constructed not to run easily in order to prevent unintentional slipping for vertical rail tracks. To move the Clickstone, press lightly on the bolt, from above, and move the stone sideways by applying a little pressure.

NOTE!

The lugs on the inside of the Clickstone are designed in such a way that once the bolt has been tightened, they prevent a “click out” mechanically. Accordingly, the bolt must first be unscrewed to above the lugs before the Clickstone can be removed from the rail by pressing the sides of the stone together and lifting.

MATERIAL DAMAGE DUETO INCORRECT INSTALLATION

Incorrectly mounted Clickstones can become loose; as a result, PV modules can fall and be damaged.

• Mount all Clickstone connections in accord-ance with the instructions.

MATERIAL DAMAGE CAUSED BYDEFORMED CLICKSTONES

If clearly deformed Clickstones are used, the safety of the module fastening is not guaran-teed. PV modules can fall and be damaged.

• Only use Clickstones where the lugs are parallel to each other and you can clearly hear them clicking into the rail channel.• Replace deformed Clickstones prior to installation.

6. MOUNTING MODULES INPORTRAIT ORIENTATION

The modules are mounted to the rails one by one. PROINSO PV Rack recommends mounting the modules starting from one side. Module clamps and module end clamps are used for the fastening of the modules. The module end clamps can hold one module each. The module clamps are positioned between two modules.

CAUTION

CAUTION


6.2. FASTENING THE MODULES ON THE OUTER SIDE

The margin modules of the PV system (for portrait mounting, the left and right module column) are fastened on the outer side with two module end clamps each.

MOUNTING STEPS:

• Place and align an outer module. The rail must protrude the module by 30mm.• Insert the Clickstone of the module end clamp into the channel of the rail.• Push the module end clamp right to the module frame.• Tighten the bolt (torque 8 Nm) and thus clamp the module.

6.3. FASTENING THE MODULES ON THE INNER SIDE

Two module clamps are fastened between two modules.

MOUNTING STEPS:

• Insert the Clickstone of the module clamp into the rail chan-nel of the rail.• Push the module clamp all the way to the frame of the already mounted module.• Push the second module to the module clamp and align.• Tighten the bolt (torque 8 Nm) and thus clamp the modules.

6.2-1

6.2-3

6.3-1

6.3-3 6.3-4 6.3-5

6.3-2

6.2-2


Incorrectly fastened modules can fall and become damaged.

• Make sure the Clickstones click in correctly.• Push the module end clamp all the way to the module.• Adhere to the stipulated torque when tight-ening the bolt.• Check the module fits tightly after mounting.

CAUTION


Incorrectly fastened modules can fall and become damaged.

• Make sure the Clickstones click in correctly.• Push the module clamp all the way to the module.• Adhere to the stipulated torque when tight-ening the bolt.• Check the modules fits tightly after mount-ing.

CAUTION

WWW.PROINSO.NET

PROINSO PV Rack

PROINSO HQ

943 Yeovil RoadSL1 4NH Slough

UNITED [email protected]

+44 (0)1753 538 448

PROINSO SOUTH AFRICA

7th Floor, Mandela Rhodes Place,Cnr of Wale and Burg Street,

Cape Town, 8000, South [email protected]

+27 (0)21 410 8908

PROINSO AMERICAS

1030 Riverside PKWYSuite 130 West Sacramento

CA 95605, United [email protected]

+1 (0)916 374 8722

PROINSO EAST ASIA

15th Floor,100 Queen’s RoadCenter Central, Hong Kong

[email protected]+852 (0)39 606 363

PROINSO SOUTH ASIA

2-22 Evergreen IndustrialEstate Shakti Mill Lane

Mahalaxmi400011 Mumbai, India

[email protected]+91 (0)22 4004 2286

Documents

PROINSO PV RACK MINI 10 PROproinsopvrack.com/wp-content/uploads/2019/07/PV... · (for top fixing clip) or 40mm (for side fixing clip) Mini 10 rail for landscape installation, with