Schletter PvMax3, Mounting Instructions

Page 1: ...mbH Gewerbegebiet an der B15 Alustrasse 1 83527 Kirchdorf Haag in OB GERMANY Phone 49 8072 9191 0 E mail info schletter eu Your contact Technical advice for ground mounted solar plants Phone 49 8072 9191 203 E mail tb freiflaeche schletter de ...

Page 2: ... Schletter GmbH as of 10 2016 PvMax3 Mounting Instructions 2 35 ...

Page 3: ... 15 3 4 6 Auxiliary equipment accessories 15 3 4 7 Module clamping 16 3 4 8 Screws for Standard module clamps 17 4 Mounting information 18 4 1 Terrain 18 4 2 Foundation 19 4 2 1 Pre cast strip foundations 19 4 2 2 Dimensioning and reinforcement 19 4 2 3 Preparation of the soil and positioning of the foundations 19 4 3 Tolerances regarding inclination and distortion twist 21 4 4 Tools 22 4 4 1 Surv...

Page 4: ... entire content of these Mounting Instructions is the intellectual property of Schletter GmbH and is subject to the German copyright law Any reproduction editing propagation transfer to third parties also in excerpts and any kind of utilization beyond the limits of the copyright law must be approved in writing by Schletter GmbH Schletter GmbH reserves the right to take legal action in case of infr...

Page 5: ...ath or serious personal injury can result if proper safety precautions are not taken CAUTION indicates that minor personal injury may result if proper safety precautions are not taken DANGER due to operations with electricity Electric power can lead to serious accidents and can cause serious injuries Appropriate safety precautions are to be taken by all means Securing the working area Before the s...

Page 6: ...o avoid any danger to your eyes caused by flying liquids or parts sparks splinters Apart from that please consider the applicable rules and regulations on accident prevention and environmental protection that apply at the respective installation site as well as the work instructions and directives by the plant owner operating company or at the place of operation NOTICE warns about situations that ...

Page 7: ...ific knowledge of the relevant regulations The certified staff members must have the required knowledge of the guidelines regarding safety accident prevention and environmental protection as well as of loading and unloading regulations that apply at the respective construction site The certified professionals have the driving licenses required at the specific construction site to be able to drive ...

Page 8: ...out by trained and certified personnel only WARNING Always wear protective equipment safety shoes hard hat safety glasses protective gloves and high visibility vest when unloading the components of the PvMax3 system Besides also wear the personal protective equipment that is specified in your intra company regulations for the respective activity It is compulsory to monitor and supervise the comple...

Page 9: ...ed during incoming goods inspection or later shall be notified to Schletter GmbH in writing without undue delay A notification shall not be unduly delayed if it has been made within two weeks the timely dispatch of this notification shall be deemed sufficient to meet the deadline Regardless of the obligation to inspect and notify the customer shall notify Schletter of obvious defects including del...

Page 10: ... clamping possible with standard clamps or Rapid2 clamps Grounding clamps 3 Technical data 3 1 System description and properties 3 2 Rack tolerances PvMax3 is always configured specifically for the wind and snow loads at the respective installation site In the interest of economic efficiency usually the maximum load bearing capacity of the individual component is exploited To achieve this however ...

Page 11: ...are nut M10 Module bearing rail 3 3 Systems overview Detail A Fig 3 3 1 system visualisation PvMax3 base bracket Detail B Detail C Detail A Detail B Detail C Hexagon head screw M12x80 DIN931 and flange nut M12 Hexagon head screw M12x100 DIN931 flange nut M12 and base clamp Mounting clamp Fig 3 3 2 detail A Fig 3 3 3 detail B Fig 3 3 4 detail C Girder to strut connector front Girder to strut connec...

Page 12: ...0 Girder assembly FS2H BF1 146522 000 Girder assembly FS2H BF2 146523 000 Girder assembly FS2H BF3 Fig 3 4 1 1 147007 002 Fig 3 4 3 1 146530 000 3 4 2 Components of the strut assembly 000011 126 PvMax3 Strut 55x55 front custom cut 000011 127 PvMax3 Strut 55x55 diag custom cut 000011 128 PvMax3 Strut 55x55 rear custom cut 000011 129 PvMax3 Strut 75x55 front custom cut 000011 130 PvMax3 Strut 75x55 ...

Page 13: ... BF2 146553 000 Girder assembly FS5H BF3 146560 000 Girder assembly FS6H BF0 145561 000 Girder assembly FS6H BF1 145562 000 Girder assembly FS6H BF2 146563 000 Girder assembly FS6H BF3 146110 000 Girder assembly FS1V BF0 146111 000 Girder assembly FS1V BF1 146112 000 Girder assembly FS1V BF2 146113 000 Girder assembly FS1V BF3 146120 000 Girder assembly FS2V BF0 146121 000 Girder assembly FS2V BF1...

Page 14: ...Girder assembly FS5V BF3 146160 000 Girder assembly FS6V BF0 146161 000 Girder assembly FS6V BF1 146162 000 Girder assembly FS6V BF2 146163 000 Girder assembly FS6V BF3 3 4 4 Module bearing rails 124300 001 Module bearing rail S0 custom cut 124301 001 Module bearing rail S1 ext custom cut 124302 001 Module bearing rail S1 int custom cut 124303 001 Module bearing rail S1 5 custom cut 124307 001 Mod...

Page 15: ... satin gloss 943755 925 Screw 5 5x25 self tapping JT3 6 A2 119015 000 Punched mounting tape 12x0 8 hole 5 2mm 50m 135005 000 Grounding connector kit 149100 900 Grounding pin kit variable 149100 000 Grounding pin kit 128014 000 Interior cable duct pre assembled custom cut 128014 001 Exterior cable duct left pre assembled custom cut 128014 002 Exterior cable duct right pre assembled custom cut 12901...

Page 16: ... 040 130002 001 41 mm 131001 041 131002 001 130001 041 130002 001 42 mm 131001 042 131002 001 130001 042 130002 001 43 mm 131001 043 131002 001 130001 043 130002 001 44 mm 131001 044 131002 001 130001 044 130002 001 45 mm 131004 045 131002 001 130001 045 130002 001 46 mm 131001 046 131002 001 130001 046 130002 001 47 mm 131001 047 131002 001 48 mm 131001 048 131002 001 130001 048 130002 001 49 mm ...

Page 17: ...943308 130 24 30 Hexagon socket screw M8x30 serrated DIN912 A3 943308 135 28 30 35 Hexagon socket screw M8x35 serrated DIN912 A3 943308 120 31 35 20 Hexagon socket screw M8x20 serrated DIN912 A3 943308 125 36 40 25 Hexagon socket screw M8x25 serrated DIN912 A3 943308 130 41 45 30 Hexagon socket screw M8x30 serrated DIN912 A3 943308 135 46 51 35 Hexagon socket screw M8x35 serrated DIN912 A3 ...

Page 18: ... excavations of the terrain are taken The PvMax3 system is customized for the respective installation site The following indications are already needed during the planning process Site boundaries Rights of way easements the building site must be accessible for vehicles at any time Obstacles in the subsoil pipes subterranean cables etc Weather conditions wind rain snow etc Conditions that may influ...

Page 19: ... types of foundation on request Whether or not the subsoil is suitable for a certain type of foundation generally has to be determined on site in each case As a standard strip foundations are put under the supports continuous strips parallel to the module rows are also possible The weight of the foundations has to be dimensioned in such a manner that the wind loads are compensated by the foundatio...

Page 20: ...d flush on a gravel bed The rack can only be installed properly if all foundations are correctly aligned and at the same level Maximum height tolerance within the foundations 30 mm NOTICE Also when using a cast in place foundation make sure that the foundations are cast up to the same height Fig 4 2 3 1 removing soil and grading the terrain structure Fig 4 2 3 2 aligning the concrete foundations o...

Page 21: ...Tolerances regarding inclination and distortion twist 2 Twist of the support on the con crete foundation Inclination of the concrete foundation East West 2 Fig 4 3 1 twisting of the support Fig 4 3 2 east west tilt of the concrete foundation ...

Page 22: ...ket size 19 Hammer Angle meter goniometer spirit level Measuring tape Mason s lacing cord Cordless screw driver Drill hammer with drill Air pump for blowing out the drill holes We recommend using torque wrenches for all bolted connections With fast rotary motions there is an increased danger of jamming bolt blocking NOTICE For the assembly of the PvMax3 system please exclusively use the tools reco...

Page 23: ...chor dowel acc to structural analysis Washer Pay regard to manufacturer specifications Hexagon head screw M12x120 DIN931 A2 Flange nut M12 serrated DIN6923 A4 56 Nm Hexagon head screw M10x80 DIN933 A2 GMC Flange nut M10 serrated DIN6923 A4 56 Nm Hexagon head screw M10x30 DIN933 A2 GMC Flange nut M10 serrated DIN6923 A4 Washer 10 5 DIN7349 A2 33 Nm Hexagon head screw M10x25 DIN933 A2 GMC Square nut...

Page 24: ... GMC 42 5 55 mm 14 Nm H V and Kombi Always fasten the bolted connection by turning the bolt head When checking the pre stress of the bolts it has to be considered that constraints and frictional forces can lead to a loss of clamping force This was taken into consideration when the tightening torques were determined When a bolted connection is checked it must not loosen when 50 of the specified tig...

Page 25: ...ionally fastened to guarantee a safe transport Only move the lifting vehicle on sufficiently compacted terrain and in adequate distance from overhead power lines or other obstacles NOTICE The selected fasteners e g screw anchors dowels must be appropriate for the fastening forces that are specified in the structural analysis For this purpose a corresponding data sheet has to be added to the docume...

Page 26: ...he base brackets and pre drill as indicated there 1 Insert the fasteners into the pre drilled holes as specified in the manufacturer information Fig 5 1 2 inserting the fasteners 2 2 Position the strut assembly onto the fasteners and fasten using nuts 3 3 Fig 5 1 3 positioning and fastening the strut assembly Fig 5 1 4 PvMax3 front base bracket Fig 5 1 5 PvMax3 rear base bracket ...

Page 27: ...components and square nuts 1 1 CAUTION Wear adequate protective equipment especially a hard hat when mounting the girder assembly Secure all parts that need to be fastened against slipping Use appropriate auxiliary devices to handle heavy loads and ask your co workers for help Keep the work area clean to avoid falls Never walk under suspended loads and secure objects and tools against falling down...

Page 28: ...at a 90 angle to the girder The distances between purlins must be observed as specified in the drawing The pre assembled distances between the mounting clamps on the girder assembly are not always as required according to the general layout drawing It is essential that you check these distances before mounting the module bearing rails in order to avoid problems when it comes to mounting the module...

Page 29: ...ounting clamps onto the edge of the module bearing rail and fasten according to the torque specifications 3 5 4 Mounting the purlin connectors optional Shift one half of the purlin connector into the module bearing rail and fasten with a self drilling screw Then slide the second module bearing rail onto the connector and again fasten with a self drilling screw Fig 5 4 1 mounting the purlin connect...

Page 30: ...s points out that the safety notices and mounting instructions of the module manufacturer are to be observed And please also note the notices given in these Mounting Instructions when mounting the photovoltaic modules The following points must be taken into consideration at any event Photovoltaic modules are electrical devices They must be treated carefully Impacts kicks shocks or vibrations must ...

Page 31: ...ails using standard clamps or Rapid2 clamps Push the module to the clamp observing the clearance Fasten hexagon socket screw with a torque of 14 Nm 14 Nm Fig 6 1 1 clicking in the module clamp Fig 6 1 2 pushing sliding the module to the clamp Fig 6 1 3 fastening the hex socket screw 1 2 3 1 Insert the module clamp into the click channel duct of the module bearing rail 2 3 ...

Page 32: ... 1 1 2 Clamping at the long side of the module to the upper and lower module bearing rail Clamping at the short side of the module to the inner module bearing rail Fig 6 2 1 combined module clamping Fig 6 2 2 upper and lower module clamping Fig 6 2 3 module clamping at the inner side 1 2 Fig 6 2 4 clamping of the upper module Fig 6 2 5 clamping of the inner module Fig 6 2 6 clamping of the lower m...

Page 33: ...lectric scrap aluminium stainless steel copper brass etc Dispose of the components in accordance with the local regulations Fig 7 1 general recycling symbol WARNING Always wear protective equipment safety shoes hard hat safety glasses protective gloves and high visibility vest when disassembling the PvMax3 components And make sure that no unauthorized persons can enter the danger area Do not step ...

Page 34: ...d or testing and inspection intervals The customer exclusively shall bear the costs for damage or consequential damage that is due to one or several of the causes mentioned above The Mounting Instructions as well as the maintenance instructions in combination with a warranty extension refer exclusively to the mechanical metal structure supplied by Schletter GmbH Components of the solar plant like ...

Page 35: ... Schletter GmbH as of 10 2016 35 35 Notes Schletter GmbH 2016 I400085GB V4 ...