easyBRIDGE
Intro
Before starting assembly, please carefully read the safety instructions, which can be found at the end of these assembly instructions. Before starting installation, please make sure that you use the latest assembly instructions.
The installation system should be designed and planned using the Alumero Solar.Pro.Tool software. Please refer to the project report, which you will receive from the Solar.Pro.Tool or from your Alumero sales partner, for the required materials and the positions and arrangement of the individual components. This data is calculated statically and is of great importance for the safe and flawless functioning of the system.
Before installation, the installer of the photovoltaic system must ensure that the given roof substructure is designed for the additional loads that arise.
These assembly instructions explain the assembly processes of the eponymous system, the attachment to the roof substructure and the installation of the modules.
In the case of sheet metal roofs, the modules are usually mounted vertically so that the support profiles are parallel to the ridge. Two carrier profiles per module row are used as standard.
ALUMERO photovoltaic systems are designed exclusively to accommodate PV modules. Any other use is considered improper use.
The system is designed exclusively to accommodate PV modules. Any other use is considered improper use.
Assembly may only be carried out by trained specialists. In particular, work on the roof covering should be carried out by a roofer.
If you have any further questions, please use ALUMERO's professional and comprehensive consulting service. Our competent civil engineers and construction technicians are happy to help you.
General information
Min. sheet thickness:
Steel sheet min. 0.4 mm
Aluminum min. 0.5 mm
Roof pitch:
5–45°
High bead trapezoidal sheet:
Minimum width of the high bead 22 mm (25 mm recommended). The height of the high bead is irrelevant.
High bead distance:
Trapezoidal bridge 400:100-170/190-333 mm
Trapezoidal bridge 250:65-207mm
Connection:
Thin-sheet screws
Max. module field size:
12 m length
Screw assembly:
M8 (A2-70) - 15 Nm
M10 (A2-70) - 30 Nm
Tools needed
Components
Standard
Accessories
Optional components
Variants
AC 2.1+ flat roof
AC 2.1+ flat roof
AC 2.1 S5 flat roof
AC 2.1 S5 flat roof
AC 2.1 S10 flat roof
AC 2.1 S10 flat roof
AC 2.1 S15 flat roof
AC 2.1 S15 flat roof
Components
easyLIGHT East/West
Ballasting
Alpine supports
Accessories
easyLIGHT South 5°
easyLIGHT South 10°
easyLIGHT South 15°
Ballasting
Alpine supports
Accessories
AC G+ open space
ballasting
accessory
components
beaver tail replacement plate
Trapezoidal bridges
Modules can be arranged both vertically and horizontally.
Measure and mark positions
According to the ALUMERO Solar.Pro.Tool project report, measure the positions of trapezoidal steel bridges on the roof and mark them with a string. Measure the high-bead gap and position trapezoidal sheet-metal bridges.
Assembly of trapezoidal steel bridges
Using 4 thin plate screws, screw the trapezoidal bridge centrally onto two high beads. Note that the EPDM seal under the trapezoidal steel bridge and the sealing discs of the thin plate screws are not compressed by more than 50%.
The distance between the thin-sheet screws and the edge of the bead should be at least 8 mm.
Please note: Assembled trapezoidal steel bridges must not be used as stepladders!
Place the next trapezoidal steel bridges on the following high beads so that the distance X is maintained. The distance X depends on the module width + clamp width (20 mm) + minimum distance to the end of the respective trapezoidal sheet bridge (20 mm).
The distance Y depends on the module length and should match the selected clamping range of the module.
Please note: Please refer to the installation instructions for the modules used for the clamping areas and the resulting loads.
Note on thin-sheet screws
Screw the thin-plate screws slowly, controllably and with low torque so as not to over-tighten the screw or destroy the sheet metal. Only screw in enough to reduce the EPDM seal under the rail and the thin-sheet screws to approximately 50% of the original thickness. Continuing to turn does not increase the strength of the connection, but only the risk of failure.
Thermal separations and maintenance routes
Please note the maximum module field length of 12 m. After this length, the modules must be thermally separated. For this purpose, a high bead should be released.
Detalj: thermal separation after 12 m in a horizontal direction.
option: If the clamping area of the module and the distance between the high bead allow it, the trapezoidal sheet-metal bridge can be attached to the high bead for thermal separation. However, make sure that larger systems have enough maintenance.
Always plan horizontal and vertical maintenance for larger systems.
Assembly modules
Install end clamp
Start with the lowest row of modules. Place the first module on the carrier profiles and align them.
Click the Click end clamp slightly at an angle and push it towards the module frame.
Allen screw with a torque of 15 Nm tighten.
The presentation is exemplary and depicts the system, tending not to the profiles used.
Please note: The end clamps must be attached at least 20 mm from the end of the respective mounting profile.
Attention: When using end clamps with threaded plates, attention must be paid to the orientation. The threaded plate must be positioned transversely to the profile channel.
Install the center clamp
Place the Click center clamp on the frame of the previous module and click in at a slight angle. Push the module so that both modules are firmly in place.
Allen screw with a torque of 15 Nm tighten.
The last module in a series of modules with terminators, as before
described, assemble. Assembly of the remaining module rows analogously.
The presentation is exemplary and depicts the system, tending not to the profiles used.
Please note:
- Distance from the clamp to the ends of the support profile: min. 20 mm!
- Middle clamps must not be mounted directly on the support joint!
- Clamp the modules only at prescribed mounting areas! These can be found in the module manufacturer's data sheet.
- Distance (horizontal and vertical) between modules: approx. 20 mm!
module cable | potential equalization | grounding
Fasten module cable
Module cables should not hang down or rest on the roof covering. Push the clip attached to the cable tie into a profile channel of the support profile. Use the cable tie to tie the cable together.
Remove the clip by sliding it laterally out of the profile channel.
Potential equalization
Potential balancing between the individual plant components must be carried out in accordance with the respective country-specific regulations. One way of grounding the ALUMERO sheet metal folding roof system is shown below. Cable averages and overall grounding concept are not included in these instructions and must be calculated or prepared by the contractor in accordance with the applicable standards and guidelines. Professional grounding methods other than those listed here are also possible.
Grounding of carrier profile rows
In each row of carrier profiles, insert a wire clamp into the lower profile channel of the carrier profile. Insert the aluminum wire into the wire clamp and secure by tightening the screw. In this way, connect all rows of modules to each other conductively.
Earthing the modules
Whether the modules need to be grounded is specified by the module manufacturer in the respective module data sheet. If so, the potential equalization of the modules can be created in the following way, recommended by ALUMERO:
To integrate the modules into potential equalization, you can use ALUMERO end and middle terminals with pins. The pins sit in the terminals, pierce the anodized layer of the module frames and thus conductively connect all module rows together.
All product images included in these assembly instructions are for illustrative purposes and are not true to scale. Subject to changes and errors!
Optional: potential equalization | grounding
Install grounding/potential equalization
The grounding/potential equalization is attached to the edge of a module field on a foot with a screw (max. M8). The components are not included.
- Securely connect the ground wire (on site) to the cable lug.
- Install the shim and cable lug with the screw in the order shown.
Safety and warning notices
Please note the following information!
We recommend that you read the following notes carefully as they are very important when using the product. Please also check the safety regulations for the other system components.
Safety and warning notices
ALUMERO mounting systems are designed exclusively to accommodate PV modules. Any other use is considered improper use. Proper use also includes compliance with the instructions in these assembly instructions. ALUMERO is not liable for damage resulting from failure to comply with the assembly instructions, in particular the safety instructions, or from misuse of the product.
- ALUMERO assumes no liability for loss of performance or damage to the module of any kind.
You should follow these instructions carefully when working on the PV system. Installation, commissioning, maintenance and repair may only be carried out by persons who are suitably qualified and authorized.
Please comply with the applicable regulations and safety instructions.
You must take these accident prevention regulations into account:
- BGV A 1 — General regulations
- BGV A 3 — Electrical systems and equipment
- BGV C 22 — Construction work (personal protective equipment against falls)
- BGV D 36 — ladders and steps
- Professional association rules for safety and health at work BGR 203 (roof work) and DIN EN 516 facilities for entering the roof
- Work clothes and occupational safety regulations in accordance with the regulations of the professional association
Please comply with the applicable regulations and safety instructions.
You must comply with the following DIN standards:
- DIN 18299 — General regulations for all types of construction
- DIN 18338 — Roofing and roof sealing work
- DIN 18360 — metal construction, locksmith work
- DIN 4102 — Fire behavior of building materials and components
Work on Alumero Systematic Solutions GmbH's systems may only be carried out by authorized personnel. The operator of the plant has the following safety-related obligations:
- We require that the installed ALUMERO components and roof covering be inspected and serviced at least once a year.
- At a minimum, the following points should be checked:
- all mechanical connections are in correct fit and strength
- the position of the system on the roof and the system itself with regard to deformations
- keeping the cabling intact
- the PV modules for damage
The frame may only be assembled by persons with appropriate qualifications, manual skills and basic mechanical knowledge.
It must be ensured that the commissioned persons are able to assess the work assigned to them and identify potential hazards. The assembly instructions are part of the product and must be available during installation.
The assembly instructions are part of the product and must be available during assembly.
It must be ensured that the installation instructions and in particular the safety instructions are read and understood by authorized personnel before installation.
The regulations of the professional association, local occupational safety regulations and technical rules must be complied with.
Suitable hoists and ladders must be used for installation. Staff ladders must not be used.
It is necessary to have the existing building statics checked by an expert civil engineer with regard to the additional loads from a PV system.
Any general load limits imposed by Alumero Systematic Solutions GmbH (e.g. the need to remove snow to limit the snow load) must be taken into account.
Warranty/product liability (exclusion)
The sizing instructions contained in these instructions are only practical tips. Binding assembly frame statistics can be created with the Alumero Solar.Pro.Tool program.
As an installer, you are responsible for the correct installation. Alumero Systematic Solutions GmbH is not liable for the sizing instructions contained in commercial plant offers.
As an installer, you are responsible for the mechanical durability of the assembled interface connections on the building envelope, in particular for their tightness. The components of Alumero Systematic Solutions GmbH are designed for this purpose in accordance with the expected loads and the current state of the art. To do so, as part of the request/order to Alumero Systematic Solutions GmbH, you must provide all general technical conditions in the project data sheet (information on the supporting structure, snow load zone, building heights, wind loads, etc.) in writing.
Alumero Systematic Solutions GmbH is not liable for improper handling of the installed parts.
To prevent corrosion, the aluminum structure must only come into contact with media (solid, liquid, gaseous) that have a pH of 4.5 to 8.5.
With proper handling, dimensioning in accordance with static conditions and normal environmental and environmental conditions, Alumero Systematic Solutions GmbH provides a 2-year product warranty on the lifetime and durability of the frame systems. This applies within the framework of generally prevailing weather and environmental conditions.
Material and workmanship guarantee: Alumero Systematic Solutions GmbH provides a material and workmanship guarantee of 10 years on the materials used. For more information, please see the separate warranty conditions.
Electrical installation notes
You may only carry out all electrical work if you are a qualified electrician. The applicable DIN standards, VDE regulations, VDEW guidelines, VDN guidelines, accident prevention regulations and the regulations of local electricity supply companies (EVU) are decisive.
- DIN VDE 0100 (installation of heavy-current systems with nominal voltages up to 1000 V)
- VDEW guideline for the parallel operation of self-generating plants with the low voltage power supply network
- VDI 6012 Guideline for Decentralized Energy Systems in Buildings: Photovoltaics
- Information sheet on the VDEW guideline “Self-generation systems on the low-voltage grid”
- VDN guideline “Self-generating systems on the low-voltage grid”
- DIN/VDE regulations, DIN/VDE 0100 “Installation of high-voltage systems with line voltages up to 1000 V”, in particular VDE 0100 part 410 “Protection against direct and indirect contact” (DC voltages > 120 V, < 1000 V DC voltage) and the “Accident prevention regulation of commercial professional associations” VBG4 “Electrical systems and equipment”
- DIN VDE 0100-540 Selection and Installation — Grounding, Protective Conductor and Potential Equalization Conductor
- VDE 0185 Construction of a lightning protection system and VDS 2010
Important warnings
Solar modules generate electricity as soon as they are exposed to light and are therefore always under voltage. Although the fully insulated plug contacts provide protection against contact, you must pay attention to the following when handling the solar modules:
- Do not insert any electrically conductive parts into the plugs and sockets.
- Do not install solar panels and cables with wet plugs and sockets.
- Perform all work on the pipes with extreme caution.
- Do not perform an electrical installation when it is damp.
- Even with low lighting, the series connection of solar modules produces very high DC voltages, which are life-threatening when touched. In particular, consider the possibility of secondary damage in the event of electric shock.
High contact voltages can occur in the inverter even when switched off:
- Be particularly careful when working on the inverter and cables
- After switching off the inverter and carrying out further work, be sure to follow the time intervals specified by the manufacturer so that the high-voltage components can discharge.
- Please also note the inverter manufacturer's installation instructions.
- Opening a closed string (e.g. when disconnecting the DC line from the inverter under load) can result in a deadly arc:
- Never disconnect the solar generator from the inverter while it is connected to the grid.
Standards and guidelines
All standards and guidelines listed have been published and applied for Germany. They must be considered in their current version. Outside of Germany, please also comply with the relevant national standards and guidelines.
Frame installation instructions
For installation in the roof area, you must comply with the currently valid rules of construction technology, in particular the requirements set out in the DIN standards and in the “German Roofing Trade Rules”.
- Check that all screw connections are tight.
- Maintain the specified torques.
- Regardless of verifiable statics, you must ensure in advance of each installation that the product meets the static requirements on site in accordance with DIN EN 1991.
- DIN standard EN 1991 “Effects on structures” — and all related national application documents
Part 1-1: Weights, dead weight and payloads in building construction
Part 1-3: Snow Loads
Part 1-4: Wind Loads - DIN standard EN 1990: “Principles of structural engineering” — and all related national application documents
- The assembly frame is measured in accordance with DIN EN 1993 “Design and construction of steel structures” and DIN EN 1999 “Design and construction of aluminum structures”
- Make sure that the substructure is suitable in terms of load capacity (dimensions, state of preservation, suitable material characteristics), supporting structure and other layers affected by it (e.g. insulation layer).
- Make sure that the runoff of rainwater is not impeded.
- Take into account aspects of building physics (e.g. possible condensation when penetrating insulation layers).
- For installation in the roof area, you must comply with the currently valid rules of construction technology, in particular the requirements set out in the DIN standards and in the “German Roofing Trade Rules”.
Product liability
The technical documentation is part of the product. Alumero Systematic Solutions GmbH is not liable for damage resulting from failure to comply with the assembly instructions, in particular the safety instructions, or from misuse of the products.
