Mounting Systems Pitched ProLine Manuale utente

Pitched ProLine

Installation manual

Pitched ProLine-MA-EN-2011

Introduction

 Introduction 

. Short Description 

. About These Instructions 

. Warnings 

. Safety 

 Technical Description 

. System Overview 

. Components 

. Technical Data 

 Important Mounting Information 

. Conditions of Use 

. Mounting Preparations 

. Mounting Aids and Required Tools 

. About the Instructions 

 Planning the Module Area 

 Installation of Roof Fasteners 

. Preparation of the Roof Substructure 

. Placing the Roof Fasteners – 

Here: Standard Roof Hooks

. Placing the Roof Tiles 

 Installing the Base Rails 

. Placing and Alignment of the Base Rails 

. Connection of the Base Rails 

. Placing the End Caps 

. Telescoping End Pieces (optional) 

 Installing the Clickstones 

 Module Installation 

. Fastening the Modules on the Outer Side 

. Fastening the Modules on the Inner Side 

. Fastening Additional Module Rows 

 Options: Installing Additional Roof Fastener 

. Installation of the Heavy Load Roof Hooks 

. Installing Adjustable Roof Hooks 

. Installation of Plain Tile and Slate Roof Hooks 

. Installing Hanger bolts 

. Roof connection with hanger bolt 

. Installing Standing Seam Clamps 

 Option: Installation of the CCS-rail 

. Placing and Alignment of the CCS-rail 

. Connection of the CCS-rail 

 Option: Cross Rail Installation 

Installation manual Pitched ProLine

1. Introduction

.. Short Description

The Pitched ProLine on-roof system is a robust

mounting system for the installation of PV modules on

pitched roofs.

It consists of aluminium support rails and all necessary

small parts for the fastening of the rails to the roof, the

modules on to the rails as well as for the connection

of the components with each other. Pitched ProLine

allows for both portrait and landscape installation of

the modules.

.. About These Instructions

Content

These instructions describe the mounting of the on-

roof system Pitched ProLine and all system-speciﬁc

information for planning, components and safety

warnings.

The ﬁrst part of the Instructions (chapters –)

demonstrates the complete installation of framed

modules. Thereafter, (chapters –) the mounting

steps for certain speciﬁc roof types and material

options are explained.

Applicable Documents

In addition to this document, the document

“Installation Instructions for PV Mounting Systems:

General Part” is part of each product delivery.

This document describes the general applicable

information for Mounting Systems products on

standardisation, safety, transport, maintenance,

disassembly and disposal. Both the present Instructions

and the “Installation Instructions for PV Mounting

Systems: General Part” are an integral part of the

system Pitched ProLine and must be adhered to for

each installation.

It is crucial to carefully read these Instructions as well

as all applicable documents prior to carrying out any

installation, maintenance or disassembly work. You are

provided with the information required for the safe and

complete installation, maintenance and disassembly.

Should you have any questions, please contact

Mounting Systems GmbH.

User Group

Mounting Systems GmbH’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 visual aids will make installation easier.

Piktograms:

This symbol indicates important information

and useful tips.

This symbol indicates tips and tricks to make

processes easier.

Installation manual Pitched ProLine

1.3. Warnings

The warnings used in these Mounting Instructions

indicate safety-related information. They include:

• Warning symbols (pictograms)

• Signal words for the identiﬁcation of the hazard level

• Information about the type and source of the hazard

• Information about potential consequences in case of

the hazard being disregarded

• Measures for the prevention of hazards and the

prevention of injuries or damage to property.

The signal words of the warnings respectively indicate

one of the following hazard levels:

1.4 Safety

All generally applicable safety regulations for products

of Mounting System GmbH can be viewed in the

document “Installation Instructions for PV mounting

Systems: General Part”. Please read this document

carefully and adhere to the described points - only use

the system for its intended purpose, comply with the

obligations of the building proprietor and follow both

the general and speciﬁc safety instructions.

In addition, please observe the speciﬁc safety

instructions which precede the process steps in the

present product-speciﬁc Mounting Instructions.

Indicates a great and extraordinary

danger, which may result in death

or serious injury if ignored.

Indicates a potentially dangerous

situation, which may result in

serious or medium injury or

damage to the property.

Indicates a potentially dangerous

situation, which may result in

minor injuries or damage to the

property if ignored.

Indicates potential danger,

which can result in damage

to the property.

WARNING

CAUTION

ATTENTION

DANGER

Installation manual Pitched ProLine

2. Technical Description

2.1 System Overview

In the following, the most important system parts are

described.

The design of the individual system components can vary,

or additional components may be required, depending on:

• Type of roof (substructure and roof cladding)

• Type of module

• Number of modules and configuration

• Local conditions

Image 2.1-1 Portrait Installation

Pitched ProLine Components:

a Roof hook

b Base rail

c Connector

d Telescoping end piece (optional)

e Module clamp

f Module end clamp

c d

Installation manual Pitched ProLine

2.2 Components

In the following all mounting system parts of the Pitched ProLine 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.

2.2-1 Base rail (BR), options:

• BR 4/35 in various lengths

• BR 6/40 in various lengths

• BR 10/48 in various lengths

• 0.6 m pieces in black

(respectively for BR 4/35 and BR 6/40)

• BR 4/35 CCS

2.2-2 Connector, options:

• Internal connectors (respectively for BR)

• External connectors (respectively for BR)

• Connector CCS

2.2-3 Telescoping end-piece (optional), options:

• For BR 4/35 and BR 6/40

• Either with mill ﬁnished or black end piece

2.2-4 Module end clamp, options:

• For dierent module frame heights

• Mill ﬁnished or black

2.2-5 Module clamp, options:

• For dierent spans of module frame heights

• Mill ﬁnished or black

2.2-6 Roof fastener, options:

• Roof hooks in various designs

(example shown here: standard roof hook)

• Hanger bolts in various designs

(example shown here: hanger bolt with rubber seal)

• Sheet-metal clamps in various designs

(example shown here: Kalzip clamp)

2.2-7 Fastening materials for roof hooks in various

designs depending on type of roof hook

2.2-8

Small parts for connecting the roof fastener to the

base rail, options:

• L-bracket + small parts (required for some roof

hooks, hanger bolts and sheet-metal clamps)

• T-head bolt and serrated lock nut (supplied loose)

2.2-9 Cross rail connector

2.2-10 End caps (optional), options:

• For BR 4/35, BR 6/40 and BR 10/48

• Grey or black

2.2-1

2.2-2

2.2-3

2.2-9 2.2-10

2.2-4 2.2-5

2.2-6

2.2-7

2.2-8

Installation manual Pitched ProLine

2.3 Technical Data

Application Pitched roof – on-roof

Roof cladding Suitable for most types of roof cladding

Roof slope Up to 60° 1

Building height Up to 20 m 1

PV modules Framed, unframed

Module orientation Portrait, Landscape

Size of module array Any size possible 2

Position of the module array No special requirements

Distance between roof

fixing points

Up to 2m 1

Standards Eurocode 1 – Actions on structures

Eurocode 9 – Design of aluminium structures

Supporting profiles Extruded Aluminium (EN AW 6063 T66)

Hooks, small parts Stainless steel (V2A)

Colour Aluminium: plate finish; on request:

Visible components available in black

Warranty 10 Years 3

Dierent maximum values may apply, depending on site, building, choice of roof ﬁxations and module type.

Using the Pitched ProLine calculation tool, you can have the exact values for your speciﬁc project calculated quickly and easily.

2 Due to thermal expansion of the material, we recommend an interruption of the array after 12 m.

3 Please ﬁnd the exact terms in the Mounting Systems GmbH warranty document.

Installation manual Pitched ProLine

3. Important Installation Information

. Conditions of Use

The Pitched ProLine on-roof system is designed

with dierent rail and on-roof fastener variations in

accordance with Eurocode -DIN EN -- for various

maximum loads. The suitability of the material must

therefore be veriﬁed for each system, e.g. by means of the

Pitched ProLine conﬁguration tool. Please also observe

the constraints, listed in chapter . “Technical Data”.

. Mounting Preparations

Mounting Systems GmbH recommends you inquire about

the local conditions before ordering the Pitched ProLine.

In particular, acquaint yourself with:

• The roof structure,

• Dimensions, material, quality and distance of the

rafter purlins

• the rafter purlins distance with any irregularities

• Type, quality and fastening method of the roof tiles/

rooﬁng

. Mounting Aids and Required Tools

For the installation of the mounting system, you will

require the following tools:

• Allen key/hexagon socket drill bit,  mm and  mm

• Socket key/socket key attachment size  and size 

• Cordless screwdriver/electric drill with attachment for

fastening the wood screws; varying depending on the

roof hooks selected:

• Cross recess (for chipboard screws)

AW  (for x wood screws)

• Socket key attachment size 

(for x wood screws)

• Socket key attachment size 

(for Mx hanger bolts)

• Socket key attachment size 

(for Mx hanger bolts)

• Angle grinder with

- Metal cutting disc

- Stone disc

• Chalk Line

• Spirit level

• Yard stick/tape measure

. About the Installation Instructions

In the following chapters all steps for the planning

and mounting of the Pitched ProLine are listed in the

correct sequence. Chapters , ,  and  describe the

mounting steps of the modules, chapters – describe

the mounting steps for other material and installation

variations.

Please adhere to the mounting steps listed and be

ensure to follow the safety instructions.

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 result

in serious injuries or death.

• Before commencing with the

installation, please ensure that

the material used meets the

structural requirements of the site.

DANGER

Installation manual Pitched ProLine

4. Planning the Module Area

For installation, the base rails are fastened to the

rafters or purlins (for metal roofs) of the building with

roof fasteners (e.g. roof hooks). The roof fasteners must

be mounted at deﬁned distances, depending on the

distance of the rafters/purlins, the position on the roof

and on the on-site conditions*. The layout is deﬁned

using a conﬁguration tool or project-related structural

analyses.

* Layout required according to local conditions in

accordance with Eurocode -DIN EN --/

Eurocode -DIN EN --.

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

construction meets the increased

structural requirements resulting

from the PV system and the

assembly operation.

Risk of fatal injury from

falling 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

Image  –  Modul Area

aHeight of the module ﬁeld: Number of modules

vertically x module length (+ any clearances)

bWidth of the module ﬁeld: Number of modules

horizontally x (module width +  mm) +  mm

cDistance of the base rails vertically (taking into

account the tile pattern as well as the number and

positioning of module clamping points approved

by the manufacturer): Approx. quarter points of the

modules = / x module length.

dDistance of the roof hooks horizontally: According to

the project layout, depending on the rafter distance

and the structural calculations*

eDistance between the modules = – mm

* Layout required according to local conditions in

accordance with Eurocode -DIN EN --/

Eurocode -DIN EN --.

 Installation manual Pitched ProLine

Risk of fatal injury due to falling

Falling from the roof can result in

serious injuries or death.

• Please wear the statutory

protective equipment.

• Secure yourself against falling.

• Do not perform any work in strong

winds.

Risk of fatal injury from

falling objects

Parts falling from the roof can result

in serious injuries or death.

• Block off the hazard area on the

ground prior to the mounting work

to prevent falling objects injuring

persons.

• Ensure that no parts can fall off

the roof.

• Please wear the statutory

protective equipment.

• Do not stay in the hazard area.

• Do not perform any work in strong

winds.

• After completion of the

installation, check the racking

system and the modules for a

tight fit.

DANGER

Indice

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