Assembly instructions

easySEAM

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. 0.5 mm
Aluminium, zinc min. 0.7 mm

Roof pitch:

7° — 65°

Max. module field size:

3 m long or 3 modules

Screw assembly:

M8 (A2-70) - 15Nm

M10 (A2-70) - 30Nm

Fixing screw M10x1 x12.5 - 18 Nm

Note: The tightening torque of the sheet metal folding clamps must be limited in such a way that the sheet metal fold is not damaged and the thermal expansion of the sheets is not impeded! A sufficient distance between the clamps and the push shaft must be taken into account.
38/300
Montagedetails für ALUMERO-Trapezblechdach Systeme
158/250
Montageinformationen für ALUMERO Trapezblechdach-Systeme
39/333.3
Montageinformationen für ALUMERO Trapezblechdach-Systeme
38/300
Montagedetails für ALUMERO-Trapezblechdach Systeme
158/250
Montageinformationen für ALUMERO Trapezblechdach-Systeme

Tools needed

Electric drill
Bit inserts, see below.
Jaw spanner
Bit inserts, see below.
Torque wrench
Bit inserts, see below.
Measuring tape
Bit inserts, see below.
Chalk line
Bit inserts, see below.
Spirit level
Bit inserts, see below.
Bit inserts:
SW5, SW6, SW13, SW15

Components

Standard

Double standing seam clamp 2.1 TPF
Product number:
802466
Double standing seam clamp 2.1 TBK
Product number:
802467
Angle standing seam clamp 2.1 TPF
Product number:
802462
Angled standing seam clamp 2.1 TBK
Product number:
802463
Round seam clamp 2.1 TPF
Product number:
802460
Round seam clamp 2.1 TBK
Product number:
802461
Carrier profile
Product number:
80210x
Profile connector
Product number:
80215x
End clamp "Click" with pin
Product number:
802304C P1 30-42
Middle clamp "Click" 2.1 with pin 30-45
Product number:
802301C P1 30-45
Middle clamp "Click" 2.1 30-45
Product number:
802301C 30-45
Folding clamp 2.1 RD-80 TPF
Product number:
802469
Folding clamp 2.1 K15 TPF
Product number:
802471

Optional components

Sheet metal folding clamp
Product number:
800436
Round seam clamp
Product number:
800435
Hammerhead screw
Product number:
800646
Hexagon nut
Product number:
800634
No optional components to this system.
Product number:
-/-

Accessories

Cable tie including clip
Product number:
802604
Wire clamp 8-10
Product number:
802603
Round wire
Product number:
802602
End cap 37/45
Product number:
802601

Variants

AC 2.1+ flat roof

297 mm distance 10° internal shading angle
Abmessungen für ALUMERO AC 2.1 Flachdach-Systeme

AC 2.1+ flat roof

464 mm distance 8° — 18° internal shading angle
Maße für ALUMERO AC 2.1 Flachdach-Systeme

AC 2.1 S5 flat roof

178 mm distance 30° internal shading angle
Abmessungen für ALUMERO AC 2.1 Flachdach-Systeme

AC 2.1 S5 flat roof

335 mm distance 15° internal shading angle
Abmessungen für ALUMERO AC 2.1 Flachdach-Systeme

AC 2.1 S10 flat roof

380 mm distance 25° internal shading angle
Abmessungen für ALUMERO AC 2.1 Flachdach-Systeme

AC 2.1 S10 flat roof

527 mm distance 18° internal shading angle
Abmessungen für ALUMERO AC 2.1 Flachdach-Systeme

AC 2.1 S15 flat roof

571 mm distance 25° internal shading angle
Abmessungen für ALUMERO AC 2.1 Flachdach-Systeme

AC 2.1 S15 flat roof

790 mm distance 18° internal shading angle
Abmessungen für ALUMERO AC 2.1 Flachdach-Systeme

Components

easyLIGHT East/West

Montageinformationen für ALUMERO AC 2.1 Flachdach-Systeme
1
Starting foot with building protection mat
2
Center support with building protection mat
3
Connector (long/short) with structural protection mat
4
End clamp
5
AC center terminal pre-assembled with pins

Ballasting

Komponenten für ALUMERO AC 2.1 Flachdach-Systeme
1
Gate strap screw, M8×20
2
washer
3
Allen nut, M8 SW6
4
Long ballast pan, BT1800, BT-2050, BT-2300
5
Short ballast tub, BT-880
6
Building protection mat, PES

Alpine supports

Alpinstützen für ALUMERO AC 2.1 Flachdach-Systeme
1
Alpine support at the front with structural protection mat
2
Center support with building protection mat
3
Connector (long/short) with structural protection mat

Accessories

KC-1 edge clip incl. cable tie

easyLIGHT South 5°

Komponenten für ALUMERO AC 2.1 Flachdach-Systeme
1
Starting foot S5 with structural protection mat
2
S5 connector with building protection mat
3
S5 end foot with construction protection mat
4
AC center terminal pre-assembled with pins
5
AC terminal pre-assembled with pins
6
S5 wind deflector
7
Allen screw and shim

easyLIGHT South 10°

Komponenten für ALUMERO AC 2.1 Flachdach-Systeme
1
Starting foot S10 with structural protection mat
2
S10 connector (long/short) with structural protection mat
3
S10 end foot with construction protection mat
4
AC center terminal pre-assembled with pins
5
AC terminal pre-assembled with pins
6
S10 wind deflector
7
Allen screw and shim
8
Edge clip

easyLIGHT South 15°

Komponenten für ALUMERO AC 2.1 Flachdach-Systeme
1
Starting foot S15 with structural protection mat
2
S15 connector (long/short) with structural protection mat
3
S15 end foot with construction protection mat
4
AC center terminal pre-assembled with pins
5
AC terminal pre-assembled with pins
6
S15 wind deflector
7
Allen screw and shim
8
Edge clip

Ballasting

Komponenten für ALUMERO AC 2.1 Flachdach-Systeme
1
Gate strap screw, M8×20
2
washer
3
Allen nut, M8 SW6
4
Long ballast pan, BT1800, BT-2050, BT-2300
5
Short ballast tub, BT-880
6
Building protection mat, PES

Alpine supports

Komponenten für ALUMERO AC 2.1 Flachdach-Systeme
1
Alpine support front (S5/S10/S15) with construction protection mat
2
Alpine rear support (S5/S10/S15) with construction protection mat

Accessories

KC-1 edge clip incl. cable tie

AC G+ open space

Komponenten für ALUMERO AC G+ Freiland-Systeme
1
initial foot
2
center support
3
connector
4
AC terminal pre-assembled with pins
5
AC center terminal pre-assembled with pins

ballasting

Komponenten für ALUMERO Systeme
1
Gate strap screw, M8×20
2
washer
3
Allen nut, M8 SW6
4
Long ballast pan, BT1800, BT-2050, BT-2300
5
Short ballast tub, BT-880
6
460 mm ground anchor

accessory

KC-1 edge clip incl. cable tie

components

beaver tail replacement plate

Der ALUMERO Biberschwanzersatzziegel
1
Beaver tail replacement plate AS 2.1 180 × 380 × 13 mm (W × L × H)
2
TX20 pan head screws 4 × 30mm
3
Compriband 15 × 30 × 180 mm

easySEAM TPF

Measure and mark positions

According to the ALUMERO Solar.Pro.Tool project report, measure the positions of the sheet metal clamps on the roof and mark them with a string. Position sheet metal folding clamps.

Installing the easySEAM TPF

There are 2 different types of round seam clamps, double and angled standing seam clamps. The respective assembly processes for the easySEAM TPF are described below.

Attention: It is recommended that the number and arrangement of the sheet metal clamps be selected in such a way that load transfer into the existing roof covering and roof structure is as uniform as possible.

Double standing seam clamp 2.1 TPF/angle standing seam clamp 2.1 TPF/round seam clamp 2.1 TPF

Place the clamp flush on the fold. The support profile quick assembly adapter must point towards the roof, towards the ridge. Position and align the clamps and tighten the fixing screw with a torque of 18 Nm.

Install carrier profiles and tighten them with a torque of 15 Nm.

Please note: Assembled sheet metal folding clamps must not be used as stepladders!

Note: The clamps must never be attached to the sliding pins or in the joint area of the plates.
designation
length (mm)
diameter (mm)
Component thickness (mm)
JT3-D-2H-6.5/7.0x100 E16
100
6.5
16-50
JT3-D-2H-6.5/7.0x120 E16
120
6.5
36-70
JT3-D-2H-6.5/7.0x140 E16
140
6.5
56-90
JT3-D-2H-6.5/7.0x160 E16
160
6.5
76-110
JT3-D-2H-6.5/7.0x180 E16
180
6.5
96-130
JT3-D-2H-6.5/7.0x200 E16
200
6.5
116-150
JT3-D-2H-6.5/7.0x220 E16
220
6.5
136-170
JT3-D-2H-6.5/7.0x220 E16
240
6.5
156-190
JT3-D-2H-6.5/7.0x240 E16
260
6.5
176-210
JT3-D-2H-6.5/7.0x260 E16
280
6.5
196-230
JT3-D-2H-6.5/7.0x300 E16
300
6.5
216-250

easySEAM TBK

Measure and mark positions

According to the ALUMERO Solar.Pro.Tool project report, measure the positions of the sheet metal clamps on the roof and mark them with a string. Position sheet metal folding clamps.

Installing the easySEAM TBK

The respective assembly processes for the easySEAM TBK are described below.

Attention: It is recommended that the number and arrangement of the sheet metal clamps be selected in such a way that load transfer into the existing roof covering and roof structure is as uniform as possible.

Double standing seam clamp 2.1 TBK/angle standing seam clamp 2.1 TBK/round seam clamp 2.1 TBK

Place the clamp flush on the fold. Align the clamp and tighten the fixing screw with a torque of 18 Nm.

When using easySEAM TBK, no carrier profiles are required. The modules are mounted directly onto the pre-assembled short rail.

Please note: Assembled sheet metal folding clamps must not be used as stepladders!
designation
length (mm)
diameter (mm)
Component thickness (mm)
JT3-D-6H-5.5/6.3x67 E16
67
5.5
30-48
JT3-D-6H-5.5/6.3x87 E16
87
5.5
41-68
JT3-D-6H-5.5/6.3x107 E16
107
5.5
51-88
JT3-D-6H-5.5/6.3x127 E16
127
5.5
71-108
JT3-D-6H-5.5/6.3x147 E16
147
5.5
91-128
JT3-D-6H-5.5/6.3x167 E16
167
5.5
111-148
JT3-D-6H-5.5/6.3x197 E16
197
5.5
141-178
JT3-D-6H-5.5/6.3x237 E16
237
5.5
171-218
JT3-D-6H-5.5/6.3x267 E16
267
5.5
201-248

easySEAM Stainless (optional)

Measure and mark positions

According to the ALUMERO Solar.Pro.Tool project report, measure the positions of the stainless steel sheet metal seam clamps on the roof and mark them with a string. Position the sheet metal folding clamps.

Installing the sheet metal seam clamp

The assembly process for the stainless steel sheet metal seam clamp is described below.

Attention: It is recommended that the number and arrangement of the sheet metal clamps be selected in such a way that load transfer into the existing roof covering and roof structure is as uniform as possible.

Please note: Assembled sheet metal folding clamps must not be used as stepladders!

Sheet metal folding clamp

Place the sheet metal seam clamp on the double standing seam, align and push up as far as possible. Tighten the side screws with 15 Nm of torque.

Install carrier profiles and tighten them with a torque of 15 Nm.

Carrier profiles

Mount the carrier profile

Install the support profile parallel to the ridge with the correct side facing upwards and tighten with a torque of 15 Nm.

Connect carrier profiles

Required if the width of the module field is greater than the length of the support profile.

Insert the profile connector up to half of the first support profile and then insert the second support profile onto the profile connector.

Please note:

  • Fix each support profile to at least two attachment points ()!
  • (🔗) Carrier profile joints with profile connectors must not be in the area of attachment points.

  • Carrier profile length: max. 3 m!
  • After max. 3 m, form an expansion joint of at least 5 cm!
  • The suspension of the support profiles over the last attachment should be the same on both sides. See sketch. Last attachment is marked with ().

  • According to the Solar.Pro.Tool project report, measure the positions of the profile connectors on the roof and optionally screw the profile connectors together.

Optional: Assembly with hammerhead screw

Insert the hammer head screw with the hammer head into the lower profile channel of the support profile and twist it transversely to the profile channel. Secure the support profile to the folding clamp with a hexagon nut.

Install end caps

Press end caps into the wearer end with your hand.

Attention: When loosening and tightening the hammer head screw several times, ensure that the hammer head is correctly oriented in the profile channel. This is indicated by a slot in the screw.

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.

Assembly of ALUMERO end clamps


Please note: The end clamps must be attached at least 20 mm from the end of the respective mounting profile.

Distance between ALUMERO end clamps and profile end
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.

Assembly of ALUMERO middle clamps

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.

The click mechanism of ALUMERO clamps

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.

Fastening the profile cables to ALUMERO profiles with cable clips

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.

Fastening the aluminum wire with a wire clamp
Fastening the aluminum wire with a wire clamp

Fastening the grounding wire with a hammerhead screw
Fastening the grounding wire with a hammerhead screw

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.

The ALUMERO “Click” end and center clamp with pin
Click end and middle clamp with pin

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.

Potential equalization at the start/end foot of the ALUMERO AC 2.1 system

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.

Contact

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