Assembly instructions

easySPEED East/West

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 green and gravel roofs

Module dimensions:

990 — 1200 mm × 1650 — 2300 mm (width x length)

Module tilt angle:

10°

Distance from roof surface:

approx. 70 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:

Alpine version up to 5.4 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.

Substructure material:

EN AW 6060 aluminum; steel sheets with alu-zinc coating; small parts made of A2-70 stainless steel; polyester fleece building protection mat.

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.
Allen wrench
Bit inserts, see below.
Torque wrench
Bit inserts, see below.
Bit inserts:
SW 6

Components

Standard

Large plate 140
Product number:
24219
Small plate 140
Product number:
24218
Tall lift
Product number:
24217
Small lift
Product number:
24216
Centre clamp
Product number:
2423X
End clamp
Product number:
2423X
Wind deflector 1945
Product number:
24220
Wind deflector 2145
Product number:
24226
Wind deflector 2395
Product number:
24227

Optional components

Large plate 220
Product number:
24768
Small plate 220
Product number:
24767
Base plate
Product number:
24770
Ballast brace
Product number:
24303
Large cable cover
Product number:
24769
Small cable cover
Product number:
24668
Ballast tray 2025
Product number:
24221
Ballast tray 2225
Product number:
24228
Ballast tray 2475
Product number:
24229
Ballast tray gravel 2025
Product number:
24664
Ballast tray gravel 2225
Product number:
24665
Ballast tray gravel 2475
Product number:
24666

Accessories

Wind deflector clip
Product number:
20915
Cable tie including clip
Product number:
15820
Washer
Product number:
19073
Allen screw
Product number:
17256

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

Assembly

Front support

Position the lift small on the middle holes of the plate.
Tighten the Allen screws with 15Nm.

Lower center support

Position the lifts small, each on the outer holes of the plate.
Tighten the Allen screws with 15Nm.

Make sure that the slope of the two lifts descends onto the inside of the plate.

High center support

Position the lifts large, each on the outer holes of the plate small.
Tighten the Allen screws with 15Nm.

Make sure that the slope of the two lifts descends towards the outer side of the plate.

Pre-install clamps

As required, screw the end and center clamps onto the already assembled lifts of the front and middle supports with approx. 2 turns.

End & center clamps

Front support

High center support

Lower center support

Tip: Check the orientation of the small and large lifts again.
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

Installation

Positioning the supports

Position the module fields on the selected roof area in accordance with the ALUMERO project report.
To do this, measure the length and width of the module field and place the front supports, center supports up and center supports down.
The exact distance between the supports depends on the module length and the module width.

When placing the supports, make sure that the stop on the lift is small and the curve on the lift is large, as in the detailed images below.

Using the alpine version:
Be careful! With the alpine version, pay attention to the placement of the front and middle supports! Here, the modules are positioned on the respective characteristics of all supports.

Mount modules

First series of modules:
Place the first module horizontally on the front supports and center supports so that it is small flush with the stop at the front of the lift and the characteristic curve at the back of the lift is large. See detailed images below.
Tighten the terminals with 15 Nm.

Push the next module up to the middle terminals of the previous module and tighten the center terminals with 15 Nm. Mount further modules analogously.

If ballast pans are required, install them before the second row of modules is placed.

Second series of modules:
Place the first module horizontally on the center supports down and middle supports up so that it is small flush with the stop at the front of the lift and the characteristic curve at the back of the lift is large. See detailed images below.
Tighten the terminals with 15 Nm.

Push the next module up to the middle terminals of the previous module and tighten the center terminals with 15 Nm. Mount further modules analogously.

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

Optional: alpine version

Positioning the supports

Position the module fields as described in the previous chapter.

Installation of additional supports

Install additional front supports, center supports up, and center supports down in the middle of the module.

Make sure that the modules of all supports are positioned flush with the low lift curve and large with the lift curve. See detailed images below.

Be careful: Don't use the lift stop small!

Install additional end clamps

Screw the additional end clamps into the already placed lifts of the alpine supports. Tighten it with 15Nm.

Ballast tray assembly

Use of additional shims

Depending on the system, the ballast pans are mounted on the small and large plates.

Place additional shims under the ballast pans and fix them to the holes of the respective plates using washers and Allen screws.

Depending on the system, the ballast pans are mounted on various supports, such as front supports, back supports, center supports, etc.

Installing the ballast tray (shown on easySPEED South)

Standard version

If you have > 8 bricks or > 64 kg, use two plates per ballast pan.

Depicted on easySPEED South

If you have < 8 bricks or < 64 kg, use only one base per ballast pan.

Depicted on easySPEED South

Alpine version

Do not use a base plate for < 8 stones or < 64 kg, as the alpine support is already in the middle.

If you have > 8 bricks or > 64 kg, use two plates per ballast pan.

Depending on the system, the ballast pans are mounted on various supports, such as front supports, back supports, center supports, etc.

Ballasting

The ballast calculation is always carried out on a project-specific basis and is calculated exclusively using the ALUMERO Solar.Pro.Tool.

Based on the dimensions and weight of the stone, it is calculated how many stones are required at which point to secure the position of the system.

Use ballast pans or ballast braces to secure the position of the stones.

Ballasting using a ballast tray

The stones are placed directly in the ballast pans.

Depicted on easySPEED South
The number and position of the stones are described in detail in the project report.

Ballasting with ballast braces

The stones can be placed directly on the plates using ballast clips. Position the ballast clip at the edge of the stone so that it rests on 3 points.

Cable management assembly

Push the module cables into the cable cover.


Position the cable cover at the edge of each plate so that it is flush with the plate and fix it to the holes in the plate using an Allen screw.


Tighten the Allen screw with 15Nm.

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

Please fill out the form completely and we will get back to you shortly.
Thanks for your message!
Oops! Something went wrong while submitting the form.