easyLIGHT South
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
Range of use:
Foil-bitumen roofs as well as gravel and green roofs
Module dimensions:
950 — 1150 mm × 1500 — 2250 mm (width x length)
Module tilt angle:
5 — 15° (south orientation)
Distance from roof surface:
Approx. 60 mm
Roof pitch:
Up to 5°, depending on roof conditions, possible without roof anchors, above 5° only with roof anchors
Wind load:
Suction load up to 2.4 kN/m²
Snow load:
Standard up to 2.4 kN/m², alpine version up to 4.4 kN/m²
Proof of stability:
Software-based on wind tunnel tests
Roof condition:
The static load capacity of the roof structure and the building structure as well as an adequate pressure load capacity of the thermal insulation must be ensured on site.
Underconstruction material:
EN AW 6060 aluminum; steel sheets with alu-zinc coating; small parts made of A2-70 stainless steel; polyester fleece building protection mat.
Tools needed
Components
Standard
Optional components
Accessories
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
Underconstruction
Information about installation on gravel roofs
The planning documents define whether the system is set up directly on the seal or protective fleece (coefficient of friction 1.5) or is set up freely on the gravel (coefficient of friction 0.3).
Place the system on sealing or protective fleece
Gravel height: 30 — 60 mm
Since excessive point loads can cause damage to the roof sealing, do not install the system on the gravel if there is a layer of gravel of up to 60 mm.
- In the area of the module field, carefully remove the gravel.
- Install the system directly on the seal or on the protective fleece.
According to the Alumero.pro.tool report, use the gravel for ballasting.
Set up the system on the gravel
Gravel fill 60 — 100 mm and protective fleece (min. 300 g/m2) is available or gravel fill is 100 mm or higher.
- Set up the system on the gravel.
Pre-install clamps
Install the end or center clips on the start feet, connectors, and end feet as required.
End clamps
Middle clamps
Measure the area, place components
- Copy the dimensions of the module field from the planning documents.
- Measure the length of the module field and mark the line.
- Measure the width of the module field and mark the line.
- Place the start feet connectors and end feet in the module field.
Margins: Place start feet, center supports, and connectors with end clamps.
Middle rows: Place start feet, center supports, and connectors with center clips.
Modules
Mount modules
Tip: During installation, wire the modules at the same time.
The cables can be attached to the module with the cable tie clip.
The distance between the terminals is determined by the feets/connectors or by the module size.
Install the first row of modules
- Place the feets/connectors so that the terminals rest flush with the module.
- Tighten the clamps carefully. Make sure that the feet/connector is straight.
- Weigh down the initial feet with ballast stones.
- Place the module on the feet or connector.
When installing the modules, make sure that the feets/connectors are straight at the edge of the module field.
Install variant S5 30° modules
- Align each module with the notches on the start foot.
- Install the rear module with 150 mm overhang.
- Tighten the screws at the end terminals with 15 Nm.
- In the last row of modules, install the modules on each of the notches on the end feet.
Install the S5 18°, S10 and S15 variant modules
- Align the module with the notches on the feet/ connectors.
- Tighten the screws at the end terminals with 15 Nm.
- Place the next module.
- Tighten the screws at the center terminals of the previous module with 15 Nm.
- Place clamps at marked points and tighten the screws with 15 Nm.
Optional: alpine supports
Install alpine supports
When a certain snow load is reached, additional support legs (alpine supports) are mounted centrally on the module. The planning documents show whether alpine supports are required.
Before installing the alpine supports, ensure that the modules are suitable for increased snow load and clamping at the intended clamping area.
Install an end clamp on each of the front and rear alpine support.
The alpine supports are installed in parallel with the modules.
- Place a front and a rear alpine support in the middle of each module.
- Make sure that the end clamps rest flush with the module.
- Tighten screws to 15 Nm.
Wind deflector
Never leave the construction site until the wind deflectors have been installed. There is a risk of personal injury and property damage!
Complete all wiring work before installing the wind deflectors.
Version S5
With the easyLIGHT South S5, the long ballast pans can replace the wind deflectors. Wherever long ballast pans are installed, do not install wind deflectors.
- Place wind deflectors on the back of the connectors or end feet so that they overlap.
- When installing alpine supports: screw the wind deflectors on the lower hole to the alpine supports.
- Screw the wind deflectors on the oblong holes to the connectors or end feet.
- Tighten screws to 15 Nm.
Version S10
To keep installation costs as low as possible, the wind deflectors are installed together with the ballast tanks.
- Place wind deflectors on the back of the connectors or end feet so that they overlap.
- When installing alpine supports: screw the wind deflectors on the lower hole to the alpine supports.
- Screw the wind deflectors on the oblong holes to the connectors or end feet.
- Tighten screws to 15 Nm.
- Install a clip at the point of overlap.
Version S15
To keep installation costs as low as possible, the wind deflectors are installed together with the ballast tanks.
- Place wind deflectors on the back of the connectors or end feet so that they overlap.
- When installing alpine supports: screw wind deflectors to the alpine supports with 2 screws each.
- Screw the wind deflectors to the oblong holes with the connectors or end feet with 2 screws each.
- Tighten screws to 15 Nm.
- Install a clip at the point of overlap.
Ballasting
Depending on the circumstances, the system is ballasted differently.
Ballasting on gravel roofs
Place the system on sealing or protective fleece
- Install ballast pans according to plan.
- According to the ALUMERO Solar.Pro.Tool report, use existing gravel to ballast.
- Spread remaining gravel evenly over the roof.
- Make sure that there is enough gravel on the entire roof. If necessary, add gravel.
Option 1: Ballasting directly on the start or end feet
In this ballast variant, the ballast stones are placed directly on the initial feet, connectors or central supports.
The exact number and position of the ballast stones can be found in the ALUMERO Solar.Pro.Tool planning documents.
Recommendation: Glue the building protection mats and ballast stones with weather-resistant construction adhesive.
- To adjust the height, position building protection mats on the right and left of the start or end foot.
- Put on ballast stone.
Version 2: short ballast pan
The short ballast tray can be placed in the following positions:
1 at the initial foot
2 on the connector
3 at the end foot
The exact number and position of the short ballast tanks can be found in the ALUMERO Solar.Pro.Tool planning documents.
Installing a short ballast tray
- Place structural protection mats right and left on the edge of the ballast pan.
- Place the ballast pan centrally on the base or connector.
- The ballast pan is screwed to the starting base with a hinge screw, shim and Allen nut.
- On the connector and end base, screw the ballast pan with the existing Allen screw to the wind deflector.
- Tighten screws with 15 Nm.
Version 3: long ballast pan
The long ballast tray can be placed in the following positions:
1 at the initial foot
2 on the connector
3 at the end foot
The exact number and position of the long ballast pans can be found in the ALUMERO Solar.Pro.Tool planning documents.
Place building protection mats
Depending on the length of the ballast pan, a different number of structural protection mats are required per ballast pan:
Length 1800 mm: 3 structural protection mats per ballast tray
Length 2050 mm: 4 building protection mats per ballast tray
Length 2300 mm: 5 building protection mats per ballast tray
When positioning the building protection mats, make sure that the drain holes are not covered.
Spread building protection mats evenly under the ballast pans.
Version 3: long ballast tray S5, S10, S15
In the S5 system, the long ballast pans can replace the wind deflectors. Wherever long ballast pans are installed, no wind deflectors are installed.
In the S10 and S15 systems, the ballast tank is installed together with the wind deflectors.
- If several ballast pans follow one after the other: design ballast pans so that they overlap at the connectors or end feet.
- Secure the ballast pan to the supports with a gate screw or Allen screw.
- Tighten screws with 15 Nm.
S5 long ballast pan
Long ballast pan S10, S15
Roof anchor connection
Roof anchor dimension
The roof anchors must be installed on site and are not included in the package. To install the roof anchor connection, the roof anchors must be equipped on site with a threaded rod with a maximum size of M10.
The number and positions of roof anchors can be found in the ALUMERO Solar.Pro.Tool planning documents.
ALUMERO Solar.Pro.Tool only marks the component on which the roof anchor is mounted.
Connect system to mounting bracket
- Position the angle connector and bracket flush together.
- Connect the angle connection and bracket to the existing Allen screws at each of the elongated holes.
- Connect both angle connectors with hinge screw, shim and Allen nut.
- Screw the angle connector to the roof anchor prepared on site.
- Tighten the screws with 15 Nm each time.
Grounding/potential equalization
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.
- Grounding wire (on-site) Tight with the cable lug connect.
- bezel and cable lug in the order shown with the screw attach.
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 additional documents!
In addition to the installation instructions and for the correct installation of the system, the following documents are absolutely necessary:
- Project report from ALUMERO.PRO.TOOL
- Planning documents and drawings
- The generally valid document ”Assembly instructions”
Please also check the safety regulations for the other system components.
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.
