System FS Gen6 - Schletter · PDF file6 / 10 System FS Gen6 Mounting Instruction Schletter mb ewerbegebiet an der B15 Alustrae 1 352 irchdorf/aag i. OB ermany Tel.: +49 02 9191-200

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System FS Gen6 Mounting Instruction

© Schletter GmbH • Gewerbegebiet an der B15 • Alustraße 1 • 83527 Kirchdorf/Haag i. OB • Germany • Tel.: +49 8072 9191-200Fax: +49 8072 9191-9200 • E-mail: [email protected] • www.schletter.eu • Updated 11/2013 • Subject to change without noticeYour contact in the UK: Schletter UK Limited, Tel.: +44 1296 461 800, Fax: +44 1296 461 801, E-mail: [email protected]

System FS Gen6 Mounting Instructions

CONTENTS Page

1 General 2

2 Pile driving 3

3 Mounting the individual assembly groups 4

4 Components list 6

5 Torque specifications 9

6 Module mounting 9

7 Cable mounting 10

8 Tolerances 10

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1.2 Planning

A general layout drawing and a screw layout plan are drawn up for each system prior to delivery. Defined measurements and the position of individual components and connecting materials must all be discern-ible on these drawings. The recommended torque specifications are outlined in this mounting instruction under Point 5.

1 General 1.1 Information The FS open area system is customized to each individual location. A corresponding detailed structural analysis must be carried out to determine the cross section, as well as a geotechnical report to identify the depth required for pile driving.

In the general layout drawing, the components of one cross section must be displayed with their corresponding dimensions. A parts list is supplied along with the drawing. Items, quantities and article numbers can there-fore be referenced both on the delivery note and on the detail drawing.

Example parts list

Example general layout drawing

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2 Pile driving

2.1 Positioning Pile driving work must be undertaken by specialist companies. In order to ensure a smooth workflow, pile-driving plans must be generated by the client based on our rack drawings. These plans must be available at least one week prior to the beginning of the pile-driving operations. These plans must include the positions of the piles and their corre-sponding dimensions. The position of the first and last pile of each row must be marked on the terrain with a wooden stake. With rows of length in excess of 50 meters, additional stakes must be placed along the row.

2.2 Pile-driving on difficult subsoil

• Irregular pile-driven profiles must be clearly identified and documented in a pile driving plan.• Inconsistencies in the terrain which could hinder pile driving efforts must be documented, (e.g. slant po-

sition, deceleration and subsequent sudden acceleration of the penetration speed, swift penetration of the pile while pile-driving etc.).

• All pile-driving procedures derogating from the specifications must be approved by Schletter GmbH.• If pile-driving operations are impeded by unexpected obstacles (blocks, solid rock on the site), the

following procedure must be implemented:

1. Pre-drill to the target pile-driving depth.2. Clear the borehole. Alternatively, the remaining cuttings should be compacted.3. The borehole must be filled in layers with compressed concrete of strength C16/20 then compacted. 4. The pile should then be driven without delay.

+ 20 mm + 3° + 3°

Height Inclination (East-West)

Inclination (North-South)

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3 Mounting the individual assembly groups

1. Drive the piles and coat with a zinc dust primer

2. Mount and adjust the head

3. Mount the girders

A zinc dust primer should be used to coat the top 3cm of the profile, inside and out

Adjusting the head assembly

Hook in the pre-assembled girder as-sembly to the spacer tube

Unfold the girder and bolt to the pile-driven foundation

Zinc dust primer is the only coat-ing approved, according to the standards, to provide the required protection. Basic zinc spray coatings do not provide long-term protection.

Verify the torque of all screws! Readjust the inclination of the girder if required!

Components must be accurately adjusted to avoid cumulative ten-sion in the module. The founda-tion heads are aligned with the help of a string line.Once the head assembly group has been aligned, please verify the torque of the bolts!

Tolerance of N-S and O-W

inclination +-3°

Tolerance of the pile height in accordance

with terrain topography

+-100mm

Test for stability of the piles prior to mounting the racks!

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4. Hammer in the safety wedge

5. Mount purlins

7. Modulmontage

Loosen the upper mounting claw and slide the purlin into the lower claw

Tighten module clamps

Tighten the mounting claw

We recommend the use of a plastic hammer when adding the safety wedge! The wedge must be hammered to sit flush in the designated groove!

Please observe the manufacturer stipulations regarding clamping points when mounting modules!

Please note that the purlin must be mounted at a 90°-angle to the girder! The distances between purlins must be observed as specified in the drawing!

6. Mounting the connector (optional)

Slide one half of the connector into the purlin and fasten with an EJOT screw

Mount the next purlin and fasten with an EJOT screw

Verify stability of all mounted module clamps!

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4 Components list

Pile-driven foundation

Module-bearing profile (custom cut)

Module-bearing profile - connector (optional)

143007-000143008-000

Pile driven foundation (FG7 ) cust. sizePile driven foundation (FG8 ) cust. size

Strut

142002-001 Strut 55x55 custom size

124300-001 Module-bearing profile S0

124302-001 Module-bearing profile S1 interior 124303-001 Module-bearing profile S1.5 124307-001 Module-bearing profile S1.8 124304-001 Module-bearing profile S2 124400-001 Module-bearing profile KP0 exterior

124402-001 Module-bearing profile KP1 exterior

124404-001 Module-bearing profile KP1.5 exterior

124406-001 Module-bearing profile KP2 exterior

124700-001 Module-bearing profile Optibond OS0 124701-001 Module-bearing profile Optibond OS1

124301-001 Module-bearing profile S1 exterior

124401-001 Module-bearing profile KP0 interior


124405-001 Module-bearing profile KP1.5 interior


129300-000 Connector for module-bearing profile S0 kit

129303-000 Connector for module-bearing profile S1.5 kit129304-000 Connector for module bearing profile S2 kit129305-000 Connector for module-bearing profile S3 kit129306-000 Connector for module-bearing profile S1.5 kit129307-000 Connector for module-bearing profile S4 kit129400-000 Connector for module-bearing profile KP0 kit129401-000 Connector for module-bearing profile KP0 kit internal

129403-000 Connector for module-bearing profile KP1 kit interior

129405-000 Connector for module-bearing profile KP1.5 kit interior

129407-000 Connector for module-bearing profile KP2 kit exterior

129301-000 Connector for module-bearing profile S1 kit

129402-000 Connector for module-bearing profile KP1 kit exterior

129404-000 Connector for module-bearing profile KP1.5 kit exterior

129406-000 Connector for module-bearing profile KP2 kit interior

129600-000 Connector for module-bearing profile Optibond S0 kit129601-000 Connector for module-bearing profile Optibond S1 kit

143006-004 Pile driven foundation (FG6 ) cust. size

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Head assembly (pre-assembled)

Safety wedge

Girder assemblies (pre-assembled)

142500-006 Head assembly Gen6

142500-003 1x spacer tube142500-005 1x foundation head

943610-030 2x bolts M10x30 hex DIN931

943000-050 1x bolt M12x120 hex DIN931

943912-010 2x flange nuts M10 serrated DIN6923943912-012 1x flange nut M12 serrated DIN6923

943000-001 2x washer 10.5 DIN7349

142500-001 1x foundation collar

147005-000 2 x base claw

each consisting of:��

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142009-001 Safety wedge Generation 6

141113-001 Girder assembly FS1V-T3 Gen6

141115-000 Girder assembly FS1V-T5 Gen6141123-001 Girder assembly FS2V-T3 Gen6141124-001 Girder assembly FS2V-T4 Gen6141125-000 Girder assembly FS2V-T5 Gen6141133-001 Girder assembly FS3V-T3 Gen6141134-001 Girder assembly group FS3V-T5 Gen6

141114-001 Girder assembly FS1V-T4 Gen6

140001-001 1x girder shoe foundation Gen6943610-080 2x bolt M10x80 hex DIN933943912-010 2x flange nuts M10 serrated DIN6923 129010-001 *x KlickIn click component for nut M10

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147001-001 1x strut Gen5 55x55 custom cut141003-000 1x strut shoe

141002-001 1x girder shoe for strut Gen6

141003-001 1x girder T3each consisting of:

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1x girder T41x girder T5

141006-000 *x mounting claw 40 mm141006-004 Mounting claw new 40mm terminal141006-002 *x Mounting claw new 40 mm open

943914-010 *Nut M10 square DIN557 943610-025 *x bolt M10x25 hex DIN933943922-010 2x washer size M10 DIN9021

* variable depending on girder assembly

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Accessories

964000-176 Coating: Zinc Dust Silver-Grey Silky Luster

149114-001 Edge fastener connector kit KP1 717 mm149113-001 Edge holder connector kit KP1.5 726 mm149112-001 Edge fastener connector kit KP2 751 mm

119008-050 - 119008-853 Mod. anchor Optibond 80 mm rubber assembly

943000-329 Barbed clout nails for fastening the end caps

943610-090 Bolt M10x90 hex for mounting the head as-sembly to the pile-driven foundation

943921-010 Washer 10 DIN125

119015-000 Punched mount.tape 12x0.8 hole 5.2 mm-50 m

149100-900 Earthing pin kit variable

149115-001 Edge fastener connector kit KP0 689 mm

943912-010 Flange nut M10 serrated

135005-000 Earthing connector kit

149100-000 Earthing pin kit

128014-000 Interior cable duct, pre-assembled

128014-002 Exterior right cable duct, pre-assembled 129012-010 Proklip2000-B cable clip round duct M10

128014-001 Exterior left cable duct, pre-assembled

943755-925 Screw 5.5x25 self-tapping

129012-002 Proklip2000-P cable clip round design S129042-001 Proklip-F

141135-000 Girder assembly group FS3V-T5 Gen6

141524-001 Girder assembly FS2H-T4 Gen6


141535-000 Girder assembly FS3H-T5 Gen6141544-001 Girder assembly FS4H-T4 Gen6141545-000 Girder assembly FS4H-T5 Gen6









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149114-001

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5 Torque specifications

Image Name Tightening torque (MA-Nm)Hexagon head bolt DIN933 M10x25Square nut DIN557 M10KlickIn click component M10

30 Nm

Hexagon head bolt DIN931 M10x30Washer DIN9021 Flange nut DIN6923 M10

30 Nm

Hexagon head bolt DIN931 M10x90Washer DIN125 10Flange nut DIN6923 M10

30 Nm

Hexagon head bolt DIN931 M10x80Flange nut DIN6923 M10

30 Nm

Hexagon head bolt DIN931 M12x120Flange nut DIN6923 M12

50 Nm

6 Module mounting

Modules are mounted according to the drawing, using the supplied module clamps.

23 mm

5 mm

The distance between modules can deviate from the standard value. Tolerated variance is 23 mm on the clamped side and 5 mm on the unclamped side.

The variance is outlined with a detail drawing in the overview plan. (c.f. example gen. layout drawing, Page 2)

Modules are fastened to the module-bearing profile using end- and middle clamps. Ar-range the KlickIn click compo-nents M8 and the square nuts along the module-bearing pro-file, position the module clamps at the clamping points and fasten with M8 Inbus screws.

The M8 bolts for the module clamps must be tightened to a torque of 14Nm unless otherwise specified by the manufac-turer!

When mounting modules, please observe the clamp-ing points specified by the module manufacturer!

When checking preload of the bolts, care must be taken that constraints and frictional forces cannot lead to a loss of tension. This is taken into account when compiling the tightening torque specification. When tested, the nut must retain its scheduled torque to 50% if the connection is twisted.

Please ensure a joint clearance of 1.5mm!

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7 Cable mounting

In the majority of installations, cables are fastened with simple cable ties. These become brittle very quickly, however, particularly in hotter climates, with the result that cables often hang down from the pro-files after only two years. This can lead to water damage in the plugs and loosened connections due to wind impact on the cables.

8 Tolerances

Schletter mounting racks for open area plants are always explicitly dimensioned for the wind and snow loads at the target location. In the interest of economic efficiency, the maximum capacity potential of individual components is generally exploited. To achieve this, however, the racks must be mounted with the utmost precision. Significant deviation from the mounting plans can lead to mechanical tension in the cells. Adherence to the specified tolerances is therefore essential to the structural safety.

Span between fields ± 150 mmLinear projection of purlins ± 100 mmLower girder connection ± 100 mmUpper girder connection ± 100 mm

In the event of deviation, this must be communicated to Schletter immediately!

Span width of the fields

Lateral cantilever

Upper girder connection

Lower girder connection

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Proklip-Q The running of ca-bles along the module-bearing profile by clipping in to the bottom flange of the profile

Proklip2000-B: Routing of cables along the girder by running through and clipping into the Klick duct

Proklip-F For the mounting of ductwork for running cables along the piles

Cable duct: Screwed to the module-bearing profile, the duct provides optimal cable routing with edge protection.

Cable mounting accessories (ref. Page 8):

Documents

System FS Gen6 - Schletter · PDF file6 / 10 System FS Gen6 Mounting Instruction Schletter mb ewerbegebiet an der B15 Alustrae 1 352 irchdorf/aag i. OB ermany Tel.: +49 02 9191-200