AEROCOMPACT CompactPITCH XW, Assembly Instructions Manual

Page 1: ...CompactPITCH XW Hanger bolt Assembly Instructions Version 01 Language English Original language German Original installation instructions Important Read carefully before installation ...

Page 2: ...instructions in another lan guage are a translation of the assembly instructions in German The assembly instructions are protected by copyright Without written permission from AEROCOMPACT the assembly instructions may not be copied reproduced microfilmed translated or converted for storage and processing in computer systems either in part or in full Copyright by AEROCOMPACT Manufacturer AEROCOMPAC...

Page 3: ...g objects 8 Personal protective equipment PPE 8 System Overview 9 Basic components XW hanger bolts 9 Hanger bolt options 10 Installing Rails and Cross Connectors 11 Module Accessories 11 Bonding and Grounding Accessories 11 Assembly 13 Measure the area 13 Mount hanger bolts 13 Mount and align angle adapter 15 Rail X40 X50 15 XW Hanger bolt with T Bolt 15 XW hanger bolt with quick mount adapter 16 ...

Page 4: ...tructions symbols terms and abbreviations are used The following symbols indicate notes which are not relevant to safety but which make working with the assembly instructions easier Requirements for an action are depicted with this symbol Make sure that all requirements are met before you carry out the following actions Action steps are depicted with this symbol Carry out the steps in the specifie...

Page 5: ...e module manufacturer AEROCOMPACT accepts no liability for loss of performance or damage of any kind to the PV modules Any other use of the CompactPITCH XW system is considered improper Liability Warranty Guarantee These assembly instructions and the project report supplied with the product are integral parts of the product The information data and instructions given in the assembly instructions w...

Page 6: ...rocompact system must be designed and planned with the AEROTOOL software Aerocompact is not responsible for the project related structural integrity of the roof structure for obtaining and documenting the roof manufacturer s approval for the installation of the corresponding fasteners on the respective roof in terms of warranties nor for the professional execution Errors and damage as well as limi...

Page 7: ...e surface Define walking routes and secure them with load distribution measures On roofing or roof structures that do not have sufficient load bearing capacity e g thin sheets corrugated fibre cement always work with load distribution aids Climbing aids Only use suitable intact and tested ladders Set up and secure ladders according to instructions Separate rules apply to mechanical climbing aids l...

Page 8: ...any falling objects Where this does not succeed affected areas must be closed to the public Persons involved in the construction project must wear safety helmets Personal protective equipment PPE Personal protective equipment is required to prevent injuries during assembly work Wear protective goggles when drilling Wear safety boots Wear cut resistant work gloves during assembly Helmets are requir...

Page 9: ...Hanger bolt System Overview www aerocompact com 9 SYSTEM OVERVIEW Basic components XW hanger bolts 1 Mid Clamp CLM10 2 Hanger bolt XWSxxx XWSxxxCL 3 Rail X40 X50 5500 mm X40 5500 X50 5500 4 End Clamp CLE10 ...

Page 10: ... screw M10x180 mm M10x200 mm M10x250 mm M10x300 mm M12x200 mm M12x250 mm M12x300 mm XW10180 XW10200 XW10250 XW10300 XW12200 XW12250 XW12300 2 XW Hanger bolt with Click fast connector M10x200 mm M10x250 mm M10x300 mm M12x200 mm M12x250 mm M12x300 mm XW10200CL XW10250CL XW10300CL XW12200CL XW12250CL XW12300CL ...

Page 11: ...500 mm X40 3300 X40 4400 X40 5500 2 Rail X50 3300 mm 4400 mm 5500 mm X50 3300 X50 4400 X50 5500 3 Cross Connector X40 X50 XDL Module Accessories 1 Microinverter T Bolt Assembly for Top Rail Channel MA RA 2 Microinverter Clamp for Module Frame MA MO 3 Cable Tie Clip for Module Frame CLP M Bonding and Grounding Accessories ...

Page 12: ...XW Hanger bolt System Overview www aerocompact com 12 1 Grounding Clamp 8 10 mm WCL8 10 2 Aluminium Wire 8 mm for Grounding AWR8 please use properly sized copper wire in the USA ...

Page 13: ...nd attached as straight as possible The hanger bolts are each screwed into the purlins and or rafters see AEROTOOL planning documents Refer to the dimensions of the module field from the AEROTOOL planning documents Determine module size Determine the distances between the rafters Determine and mark the positions of the hanger bolts Mount hanger bolts ...

Page 14: ...r bolt Pre drill wood rafters Ø 7 mm roofing material Ø 13 mm M12 hanger bolt Pre drill wood rafter Ø 8 4 mm roofing material Ø 15 mm Screw in the hanger bolts slowly and straight Observe the minimum screw in depth of the thread A in the load bearing timber M10 hanger bolt at least 40 mm M12 hanger bolt at least 48 mm Tighten the lower nut until the rubber seal bulges slightly outward tightening t...

Page 15: ...r Loosen and tighten nuts and until the desired position is reached Align all angle adapters at the same height Small height differences can be compensated with the nut at the hammerhead screw or at the quick mount adapter Rail X40 X50 XW Hanger bolt with T Bolt Make sure that the angular adapters in a module row are each aligned outwards ...

Page 16: ...ers in a module row are each aligned outwards Attach the rail to each quick mount adapter Tighten the screws with a torque of 15 Nm or 11 ft lb Installing modules Never step on the modules when mounting them Spans and cantilevers need to be in accordance with the structural design as issued in the AEROTOOL report Refer to the AEROTOOL report for the exact positions of the module clamps ...

Page 17: ...d clamps into the rails Mount the module Hand tighten the screws of the end clamps After each module click the mid clamps into the rail Place the next module flush against the mid clamps Press the clamp onto the modules Hand tighten the screws of the mid clamps ...

Page 18: ... row Tighten the screws of all clamps with 15 Nm or 11 ft lb each Reposition replace clamps Demount clamp Unscrew the screw at the clamp completely Depending on the mounting situation squeeze the clamp laterally and pull it out or pull it laterally out of the rail Mounting the microinverter with a T Bolt Assembly MA RA The microinverter can be installed on the rail below the module ...

Page 19: ...ted on the support rails Depending on the installation the module rows are connected to each other by the module clamps Exemplary representation Bonding modules through module clamps Bonding the individual module rows Grounding the array by terminating to on site ground Attach the T Bolt Assembly to the rail Place the grounding wire onto the rails Attach the clamp and tighten with the nut Tighten ...

Page 20: ...XW Hanger bolt Assembly www aerocompact com 20 Connect the wire to the on site ground ...

Page 21: ...aintenance items once a year A test of the system is necessary after severe weather events e g wind storm snow hail etc as well as after extreme events such as a hurricane or earthquake Complete System Check all components of the system for damage Replace damaged components as soon as possible Fittings Check all screw connections Tighten loose screw connections Confirm the tightening torque accord...

Page 22: ...act com 22 DISMANTLING Disassemble components Disassembling the system Carry out the assembly steps in reverse order Dismantle clamps Completely unscrew the screw on the clamp If clamps are re installed Make sure that the O ring is not lost ...

Page 23: ...n of Conformity XW and XWS 21 Manufacturer AEROCOMPACT For the declaration of per formance Designation Hanger bolt system CompactPITCH XW and XWS for for trapezoidal sheet and corrugated roof Identification code XW XWS Applied standard EN 1090 Certification body 2397 ...

Page 24: ...USA AEROCOMPACT Inc 901A Matthews Mint Hill Road Matthews NC 28105 USA phone 1 800 578 0474 e mail office us aerocompact com India AEROCOMPACT India Private Ltd Hub and Oak C 360 Defence Colony New Delhi 110024 phone 91 88826329 e mail office in aerocompact com www aerocOMPACT com CompactPITCH XW EN Art No 942313 Find this manual online ...