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Summary of Contents for ESDEC ClickFit EVO
- Page 1 ARABIC TILES CORRUGATED STEEL ROOF BITUMEN EPDM ROOF MANUAL CLICKFIT EVO HANG- ER BOLT www.esdec.com...
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Page 2: Table Of Contents
TABLE OF CONTENTS Introduction About this document Other relevant documents Symbols used in this manual Warranty and liability Liability Warranty Product information Intended use Improper use Specifications Requirements for the work environment System and application Components Application Safety Personal protective equipment Safety warnings and regulations Installation Preparation... -
Page 3: Introduction
INTRODUCTION ABOUT THIS DOCUMENT InthismanualyouwillfindtheinstallationinstructionsfortheClickFitEVOmountingsystemforsolarpanelsonArabictiles, bitumenorEPDMroofmaterial,corrugatedironroofsandsheetmetalroofs. Thesystemissuitableformountingsolarpanelsinportraitandlandscapeorientation. Theseinstructionsareaddressedatqualifiedtechnicalpersonnel. You can download the latest version of this manual from www.esdec.com. OTHER RELEVANT DOCUMENTS WheninstallingtheClickFitEVOmountingsystem,youwillneedthefollowingdocuments: • Theprojectplan,whichyoucanmakeinthecalculatoratwww.esdec.com. • Theinstallationmanualsforthesolarpanels,invertersandanyothercomponents. Duringtheinstallationofthemountingsystem,itisimportanttoadheretotheinstallationmanualandtheaccompanying standardstopreventaccidents.Payspecialattentionto(local)standards,regulationsandlegislation(amongothers): • TheBuildingRegulations2010(latestversion) • HealthandSafetyatWorketcAct1974 • HealthandSafetyinRoofwork-HSE • Eurocodes0(EN1990-StructuralDesign) • Eurocodes1(EN1991-(Influencesonstructures) • HD-IEC60363series-Electricalinstallationsforlowvoltage • EN-IEC62305-2-Protectionlightning-RiskManagement • MIS3002–ThesolarPVstandard • MCS012-ProductCertificationSchemeRequirements:PitchedRoofInstallationKits SYMBOLS USED IN THIS MANUAL Warning! Failuretofollowthisinstructioncouldresultinseriousinjuryormajordamagetotheproduct. -
Page 4: Product Information
Maximum field size Forhorizontalandverticalrails:15mpersegment Bitumen(insulatedandnon-insulated) EPDM(insulatedandnon-insulated) ThethermaleffectofsometypesofEPDMandbitumenroofingcanhavea negativeeffectonthewaterproofing,causingitcannotbeguaranteedon everyroof.ConsulttheroofingsuppliertodeterminewhethertheClickFit EVOhangerboltscanbeusedwithouttakingadditionalsteps. Roof material Corrugatedsheets Onacorrugatedroofwithstandardcorrugationtype177/51(NENEN494), usetheClickFitEVOcorrugatedsheetbracket(articlenumber1008090).At www.esdec.comyouwillfindthecorrespondingmanual. Arabic tiles Sheet steel Purlins Roof structure Trusses Engineeredwoodboards Roof pitch 7.1-60° SubjecttoEurocodeguidelinesandnationaladditions.Usethecalculator Maximum roof height to calculate the possibilities of your project. 30cmdistancetotheridge,30cmtothesideoftheroofand30cmtothe Edge zone gutter. -
Page 5: System And Application
SYSTEM AND APPLICATION COMPONENTS COMPONENT ARTICLE NUMBER 1 a.ClickFitEVOHangerbolt-M10×200mm 1008011 b.ClickFitEVOHangerbolt-M10×250mm 1008012 c.ClickFitEVOHangerbolt-M12×250mm 1008013 d.ClickFitEVOHangerbolt-M12×300mm 1008014 e.ClickFitEVOHangerbolt-M12×350mm[DTO] 1008015 2 ClickFitEVOMountingRail 10081__ 3 ClickFitEVOModuleClampuniversal 1008020(-B) 4 ClickFitEVOMountingRailEndCap 1008060(-B) 5 a.ClickFitEVOEndClampSupport 1008065(-B) b.ClickFitEVOEndCapwithoutendclampsupport 1008066(-B) ACCESSORY ARTICLE NUMBER 6 ClickFitEVOMountingRailCoupler 1008061 7 ClickFitEVOCableClipOptimiserReady 1008062... -
Page 6: Application
APPLICATION Usethecalculatortodeterminethecorrectrailorientationforyourproject.Thecalculatortakesintoaccount,for example,thetypeofroofcoveringandthestructuresupportingtheroof. 1 Checktherooftypeandtheroofstructuretype.Isitaroofwithpurlinsortrusses,orwithsolidengineeringwoodboards? 2 Lookupthetypeofroofcoveringofyourprojectinthetable. 3 Checkthetablefortherecommendedorientationofthesolarpanelsandrails. ROOF MATERIAL TRUSSES PURLINS ENGINEERED WOOD BOARDS Portraitpanelsand Portraitpanelsand Landscape panels and horizontalrails BITUMEN INSULATED horizontalrails vertical rails Landscape panels and vertical rails Portraitpanelsand horizontalrails BITUMEN UNINSULATED Landscape panels and vertical rails Portraitpanelsand EPDM (INSULATED AND... -
Page 7: Safety
SAFETY PERSONAL PROTECTIVE EQUIPMENT Hearing Safety helmet Safetyglasses Facemasks Safetygloves Safetyclothing Safety shoes protection SAFETY WARNINGS AND REGULATIONS Warning! Installation work should always be carried out by at least two skilled people. Donotusecomponentsfromothermountingsystems. Donotleaveoutparts. Alwaysworkaccordingtothecurrentregulationsforworkingonroofs. Donotperformtheinstallationinstrongwinds,orwhentheroofisslipperyorwet. Alwaysworkontheroofwithfallprotectionand,ifnecessary,withsafetynetsandedgeprotection. Neverstandonorinthegutter. Alwaysusealiftingaidorhoistingdevicewhenmovingheavyequipment. Alwaysplaceladdersonastrong,stablesurface. Caution! Walkaslittleaspossibleontheroof.Useanaerialplatform,ladderorothersolution. -
Page 8: Installation
INSTALLATION PREPARATION 1 INSPECT THE ROOF Theroofisingoodcondition. Theroofconstructionhassufficientbearingcapacitytosupporttheinstallation,takingintoaccountwindandsnow loads. ThethermaleffectofsometypesofEPDMandbitumenroofingcanhaveanegativeeffectonthewaterproofing, causingitcannotbeguaranteedoneveryroof.ConsulttheroofingsuppliertodeterminewhethertheClickFit EVOhangerboltscanbeusedwithouttakingadditionalsteps. 2 CHECK THE PROJECT PLAN AND COMPONENTS Checktheprojectplan.Istherenoprojectplan?Thencreateoneintheonlinecalculatorbeforestartinginstallation. Checkthatallcomponentsarepresent(page5). Determinethepositionofthehangerbolts.Usethepurlinsortrussesifpresent. 3 MAKE SURE ALL THE REQUIRED TOOLS ARE AT HAND Markerorchalk Brush Tape measure Hacksaw Adjustable pliers General Ratchet with Cordless Open-end wrench... - Page 9 4 CLEAN AND TIDY THE ROOF 5 DETERMINE THE POSITION OF THE SOLAR PANELS ON THE ROOF ≥ 30 cm ≥ 30 cm ≥ 30 cm Takeintoaccountsunlightandshadeoverthewholeyear.Ifnecessary,useapoweroptimizerormicroinvertertogetthe most out of your installation. Thedistancefromtheedgeofsolarpanelstoboththeridgeandtheguttermustbeatleast30cm. Thedistancefromthesolarpanelstothesideoftheroofmustbeatleast30cm.
- Page 10 6 DRAW THE LINES AND END POINTS FOR THE MOUNTING RAILS Consulttheprojectplantodeterminethepositionofthemountingrailsforyourpanel. 7 MARK THE POSITION OF THE HANGER BOLTS. Preferablyuseexistingscrewholesfortheinstallationofthehangerbolts,especiallyoncorrugatedroofs.Ifyouusetoo manyscrewsinacorrugatedsheetroof,itmeansthattheroofmaterialmayhavetoolittlespacetocompensatefor thermalexpansion/contraction. Whenmeasuringandmarkingthefield,takeintoaccountthepositionofthepurlinsortrusses. Consulttheprojectplantodeterminethepositionofthehangerboltsforyourproject.
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Page 11: Cutting Mounting Rails To Required Size
CUTTING MOUNTING RAILS TO REQUIRED SIZE 1 DETERMINE THE LENGTH OF THE MOUNTING RAILS BASED ON THE SOLAR PANELS 20-35 mm 20-35 mm 12 mm Measurethesolarpanelsandallowanadditional12mmbetweeneachsolarpanelfortheuniversalmoduleclamp.Allow anadditional30mmoneachsideformountingtheendclampandendcap. Calculatetheminimumlengthofthemountingrails:(panelsize+12mm)xnumberofpanels-12mm+(2x30mm) Iftheoverhangissmallerthan250mm,keepaminimumof20mmtoamaximumof35mmraillengthoverhangfor mountingtheendcap(art.no.1008060(-B)). 2 OPTIONAL: USE COUPLERS TO CONNECT THE MOUNTING RAILS... -
Page 12: Install The Hanger Bolts
3 EXTEND THE MOUNTING RAIL TO THE NEXT BEAM, TRUSS OR PURLIN. >250 mm Doestheouterpaneledgeprojectmorethan250mmbeyondthelasthangerbolt?Thenextendthemountingrailsoit goes50mmbeyondthenexthangerboltandattachthemountingrailhere.Thisextra50mmprovidessufficientlength tofitanendcap(articleno.1008066(-B))tothemountingrails.Fortheendclampyoumustthenusetheendclamp support(articleno.1008065(-B)). INSTALL THE HANGER BOLTS Areyouinstallinghangerboltsinawoodenroofstructure?Thencontinuetostep3.1. Areyouinstallinghangerboltsinaconcreteroofstructure?Thencontinuetostep3.3. 1 PREDRILL THE HOLES IN THE ROOF (WOODEN SUBSTRUCTURE: PURLINS/TRUSSES) >50 mm Thesubstructuremustbeatleast50mmthick. Clearthedrillholeandsurroundingareaofdrillcuttings. Forcorrugatedroof:usetheexistingscrewholesasmuchaspossible.Makesurethatyoudonotplacetoomanyscrews inacorrugatedroof,becausethentheroofmaterialwillnothaveenoughspacetoworkthermally. Diameter of hanger bolt Drill through roofing material Predrill holes in roof structure... - Page 13 2 TIGHTEN THE HANGER BOLT >50 mm >50 mm Bitumen roofing insulated Corrugated roofs >50 mm >50 mm Bitumen uninsulated / EPDM (insulated and Sheet steel non-insulated) Makesureyouthatthehangerboltgoesintothestructurestraight(attherightangle). Usethehangerboltwasher(articleno.1003070)onabitumenorEPDMroof. Continuetostep3.6.
- Page 14 3 PREDRILL THE HOLES IN THE ROOF (CONCRETE SUBSTRUCTURE) > 100 mm Arabic tiles > 80 mm Concreteslab Pre-drillArabictilesatthehighestpointontherooftile.Thisensuresgooddrainage.Thedrillingdepthisatleast100mm. Foraconcreteslab,thedrillingdepthisatleast80mm. Clearthedrillholeandsurroundingareaofdrillcuttings. Diameter of hanger bolt Predrill holes in roof structure Ø14mm Ø16mm 4 YOU USE A CHEMICAL ANCHOR TO FIX THE HANGER BOLT. CONSULT THE INSTRUCTIONS FROM THE SUPPLIER OF THE CHEMICAL ANCHOR BEFORE STARTING.
- Page 15 5 INSERT THE HANGER BOLT AND ALLOW CHEMICAL ANCHOR TO HARDEN. Alignthehangerboltswitheachother. 6 TIGHTEN THE NUT SO THAT THE RUBBER SEAL DEFORMS AND THE SCREW HOLE IS SEALED 7 SEAL THE HOLE Bitumen roof material: EPDM roof material: Arabic tiles: • Tixophaltekit(articleno. • EPDMkit(articleno. • Waterproofingkit(not...
- Page 16 8 ROTATE THE CLICK CONNECTION INTO THE CORRECT ORIENTATION Forhorizontalrailorientation,makesurethatthecabletrayoftheclickconnectionsisalwayspointingdownwards. Forverticalrailorientation,ensurethattheadaptersareallplacedonthesamesideofthehangerboltwiththeclick connectionspointinginthesamedirection.
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Page 17: Attaching The Mounting Rails
9 TIGHTEN THE NUT ON THE TOP OF THE HANGER BOLT UsethecrosshairsontheadapterforagoodbasicpositionoftheEVOclickconnectionandtocompensateforanyroof irregularities. Diameter of hanger bolt Tightening torque Minimumof25Nm Minimumof40Nm ATTACHING THE MOUNTING RAILS 1 USE THE NUTS TO ALIGN THE CLICK CONNECTIONS AND ADAPTERS IN THE DIFFERENT AXES. Arethehangerboltsnotproperlyalignedinrelationtoeachother?Usethemountingrailtoadjustthehangerbolts. Loosenoneorbothnutshalfaturnandclickthemountingrailintotheclickconnections.Therigidityoftherailensures thattheadaptersandclickconnectionssetthemselvesintothecorrectposition.Thenretightenthenuts. - Page 18 2 PLACE THE MOUNTING RAIL IN THE CLICK CONNECTION. 3 CLICK IN THE MOUNTING RAILS 4 FOR VERTICAL MOUNTING: SECURE THE MOUNTING RAILS TO THE CLICK CONNECTIONS SW-10 Securethebottomclickconnectionwithaself-drillingscrew.Skiptwoclickconnectionsandthenscrewdownthefourth click connection. Repeat until the top click connection.
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Page 19: Optional: Attaching The Cable Clips
OPTIONAL: ATTACHING THE CABLE CLIPS 1 CLICK THE CABLE CLIP ONTO THE RAIL Useonecableclippersolarpanel. 2 GUIDE THE CABLE THROUGH THE CLICK CONNECTION AND THE CABLE CLIP 3 OPTIONAL: CLICK THE OPTIMISER ON THE CABLE CLIP Withverticalrailorientationyouhavetofixthecableclipbybendingtheedgeofthemountingrailwithadjustablepliers. -
Page 20: Mounting The First Panel
MOUNTING THE FIRST PANEL 1 OPTIONAL: CLICK THE AUXILIARY SETON THE PANEL 2× 2 OPTIONAL: CLICK THE CABLES OF THE PANEL FIRMLY INTO THE CABLE CLAMP 3 CLICK THE UNIVERSAL MODULE CLAMP ON THE RAILS 2×... - Page 21 4 SLIDE THE END CAPS ONTO THE RAILS 2× 5 ROTATE THE UPPER PART OF THE MODULE CLAMP OVER THE END CAP 6 OPTIONAL: CLICK THE CABLES OF THE PANEL IN THE CABLE CLIP...
- Page 22 7 PLACE THE PANEL ON THE RAILS 8 SLIDE THE PANEL AGAINST THE CLAMPS 9 SCREW THE CLAMPS ONTO THE PANEL 4,5Nm TR-30...
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Page 23: Mounting The Following Panels
MOUNTING THE FOLLOWING PANELS Optional:Repearsteps6.1.ClicktheAuxiliarysetonthepaneland6.2.Clickthecablesofthepanelfirmlyintothe cable clamp. 1 CLICK THE UNIVERSAL MODULE CLAMP ON THE RAILS 2× Installthemoduleclampwiththedrainagechannelofthemoduleclamppointingdownwards. Repeatstep6.7.Placethepanelontherails 2 SLIDE THE PANEL AGAINST THE CLAMPS... -
Page 24: Mounting The Last Panel
3 SCREW THE CLAMPS ONTO THE PANEL TR-30 4,5Nm MOUNTING THE LAST PANEL Optional:Repearsteps6.1.ClicktheAuxiliarysetonthepaneland6.2.Clickthecablesofthepanelfirmlyintothe cable clamp. Repeatstep6.7.Placethepanelontherails Repeatstep7.2.Slidethepanelagainsttheclamps 1 OPTIONAL: SAW THE MOUNTING RAILS TO SIZE 20-35 mm <250 mm >250 mm Iftheoverhangissmallerthan250mm,keepaminimumof20mmtoamaximumof35mmraillengthoverhangfor mountingtheendcap(art.no.1008060(-B)). Doestheouterpaneledgeprojectmorethan250mmbeyondthelasthangerbolt?Thenextendthemountingrailsoit goes50mmbeyondthenexthangerboltandattachthemountingrailhere.Thisextra50mmprovidessufficientlength tofitanendcap(articleno.1008066(-B))tothemountingrails.Fortheendclampyoumustthenusetheendclamp support(articleno.1008065(-B)). - Page 25 2 CLICK THE UNIVERSAL MODULE CLAMP ON THE RAILS 2× 3 SLIDE THE END CAPS ONTO THE RAILS 2× 4 ROTATE THE UPPER PART OF THE MODULE CLAMP OVER THE END CAP...
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Page 26: Mounting Multiple Rows
5 SCREW THE CLAMPS ONTO THE PANEL TR-30 4,5Nm MOUNTING MULTIPLE ROWS 1 MOUNT EACH NEXT ROW AGAINST THE PREVIOUS ROW 10 mm Alwayskeepaminimumof10mmbetweeneachrowofpanelsinthecaseofhorizontallyorientedrails,oreachpanel column in the case of vertically oriented rails. Always follow the project plan from the calculator. REMOVAL AND RECYCLING GENERAL Alwaysfollowlocallawsandregulationswhendismantlingthemountingsystemanddisposingofit. - Page 27 Esdec Londenstraat16 7418EEDeventer TheNetherlands +31850702000 info@esdec.com www.esdec.com...
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