UserManual gehrtec TOP vs-1-4-en - gehrlicher.comgehrlicher.com/fileadmin/content/pdfs/GehrTec/usermanual-GehrTec-TOP-EN.pdf · protection and roof protection walls as anti-fall protection

Document 12.05_90320051 ● R1.4 ● Errors and modifications accepted

© 2012 Gehrlicher Solar ● [email protected] ● www.gehrlicher.com

User ManualUser ManualUser ManualUser Manual

GehrTec® TopGehrTec® TopGehrTec® TopGehrTec® Top

GehrTec® TopGehrTec® TopGehrTec® TopGehrTec® Top––––TSTSTSTS

2

GehrTec® Top GehrTec® Top GehrTec® Top GehrTec® Top mountingmountingmountingmounting systemsystemsystemsystem

Dear customer,

Congratulations on your decision to select the GehrTec® Top mounting system for roof-

parallel attachment of photovoltaic elements (solar modules) on sloped roofs.

The GehrTec® Top mounting system is a modular and scalable system suitable for rooftop

mounting on many kinds of roof-top types. There are options for attaching both framed as

well as frameless solar modules - planning of the installation can be optimally adapted to

the installations parameters.

On receiving the shipment, please check the accompanying bill of delivery included to ensure

that your order has been delivered in full. Gehrlicher Solar AG does not bear any costs or

provide guarantees for any subsequent deliveries, if it is not notified until during the time of

installation that any material is missing. Please inspect the shipment for any visible damage

and contact your dealer should damage be detected.

Prior to installation, please familiarize yourself with the components of the mounting system

and their usage. Should you have any further questions, please contact us at the address

found on the last page of this user manual.

We continually strive to improve our products and welcome your feedback.

Dr. Anton Näbauer

Head of Product Development

Gehrlicher Solar AG

Email: [email protected]

Andreas Freyer

Senior Designer

Gehrlicher Solar AG

Email: [email protected]

3

Table of cTable of cTable of cTable of contentsontentsontentsontents ppppageageageage

1 1 1 1 –––– Safety instructions and general informationSafety instructions and general informationSafety instructions and general informationSafety instructions and general information .................................................................................................................................................................................................................................................................................................................................................................................................................... 4444

Duty of care on the part of the operator................................................................................................................... 4

Basic safety instructions ........................................................................................................................................................... 4

Operating personnel requirements ..................................................................................................................................... 5

Special hazard types ................................................................................................................................................................... 5

Safety and information symbols .......................................................................................................................................... 5

Safety information .......................................................................................................................................................................... 5

Rules and regulations ................................................................................................................................................................. 6

Notes about this user manual .............................................................................................................................................. 7

Further information ........................................................................................................................................................................ 7

Specific information ...................................................................................................................................................................... 8

Maintenance ....................................................................................................................................................................................... 8

Lightning and overvoltage protection .............................................................................................................................. 9

2 2 2 2 –––– InstallationInstallationInstallationInstallation ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 10101010

GehrTec® Top system overview ........................................................................................................................................ 10

Tools required ................................................................................................................................................................................ 11

Positioning on the roof ............................................................................................................................................................ 12

Maximum combined rail length........................................................................................................................................... 15

Installing roof hooks .................................................................................................................................................................. 16

Installing hanger bolts............................................................................................................................................................... 19

Installing solar fasteners ......................................................................................................................................................... 21

Installing on trapezoidal profiles ....................................................................................................................................... 23

Installing the Top-TS system ................................................................................................................................................ 25

Installing clamp holders ........................................................................................................................................................... 32

The mounting rail system ...................................................................................................................................................... 34

Mounting solar modules .......................................................................................................................................................... 36

3 3 3 3 –––– The components of GehrTec® TopThe components of GehrTec® TopThe components of GehrTec® TopThe components of GehrTec® Top .................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 38383838

Mounting rails and accessories ......................................................................................................................................... 38

Module clamps for framed modules .............................................................................................................................. 40

Module clamps for frameless solar modules ........................................................................................................... 41

Roof hooks ........................................................................................................................................................................................ 42

Hanger bolts .................................................................................................................................................................................... 43

Solar fasteners ............................................................................................................................................................................... 44

Clamp holders................................................................................................................................................................................. 45

Top-TS .................................................................................................................................................................................................. 46

Bolts and accessories ............................................................................................................................................................... 47

4 4 4 4 –––– System staticsSystem staticsSystem staticsSystem statics ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 49494949

DisclaimerDisclaimerDisclaimerDisclaimer ........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 55555555

ContactContactContactContact ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 56565656

4

1 – Safety instructions and general information

1 1 1 1 –––– Safety instructions and general informationSafety instructions and general informationSafety instructions and general informationSafety instructions and general information

The following guidelines are for your protection and the protection of installers, third parties

and the components. Other specific safety guidelines are in the supplementary sheets

provided. Adherence to these guidelines is also an absolute requirement. Installation, initial

use and maintenance may only be carried out by those who are able to guarantee that the

work is carried out properly on the basis of their professional qualifications (training and

previous activities) and experience. All instructions pertain to intended use as it is laid down

in the Product Liability Law.

Duty of care on the part of the operatorDuty of care on the part of the operatorDuty of care on the part of the operatorDuty of care on the part of the operator

The GehrTec® Top mounting system was designed and developed in respect of a risk

analysis, and following careful selection of harmonized specifications to be observed, as well

as other technical specifications. The system is state-of-the-art and guarantees the highest

levels of safety.

However, these levels of safety can only be guaranteed in the field when all necessary

procedures have been taken. Part of the duty of care on the part of the installation firm

and system operator is to plan with respect to these measures and to check they are in

place.

It is particularly important for the installers and the operator to ensure that:

o The GehrTec® Top mounting system is only installed and operated for its intended

purpose

o The GehrTec® Top mounting system is only operated while in perfect working condition

o Specific installation instructions from the module and auxiliary component manufacturers

are observed

o Installation and maintenance work is carried out by adequately qualified and trained

personnel who have carefully read, and follow, this user manual

o This user manual is kept in a legible condition at all times and is available in full where

the GehrTec® Top system is installed

o All applicable laws, directives and regulations are observed

Basic safety instructionsBasic safety instructionsBasic safety instructionsBasic safety instructions

o Barriers must be used to cordon off the area prior to installation

o All those present during installation and operation must have undergone training

o Any necessary anti-fall guards must be in place

o Any personal protective gear required must be made available (see Tab. 2)

o Adherence to the Labour Protection Law in regards to load lifting must be observed

o Modifications to the GehrTec® Top mounting system may only be carried out by

qualified personnel and only after consultation with the manufacturer.

o Caution: high voltage Protective measurements against high voltages, and resultant

electric arcs, must also be in place on the DC side because of potentially high open

circuit voltages.

5


OOOOperating personnelperating personnelperating personnelperating personnel requirementsrequirementsrequirementsrequirements

o Deploy an adequate number of authorised and qualified personnel

o Provision of general and site-specific safety instruction prior to beginning tasks

Special Special Special Special hhhhazardazardazardazard typestypestypestypes

o Third-party adaptations may only be used with prior approval from the manufacturer

o Inspection is mandatory given that hazards can arise in the event of inadequate

fastening

o Sharp-edged profile ends must also include edge protection to prevent injuries

Safety and information symbolsSafety and information symbolsSafety and information symbolsSafety and information symbols

Tab. 1: Safety and information symbols

SymbolSymbolSymbolSymbol MeaningMeaningMeaningMeaning ExplanationExplanationExplanationExplanation

DANGER “DANGER” denotes a safety guideline for which failure to

comply may result in immediate death or serious injury.

CAUTION “CAUTION” denotes a safety guideline for which failure to

comply may result in material damage.

NOTE “NOTE” denotes information that is important for optimal

operation of the product.

TIP “TIP” is information that is particularly useful and simplifies

installation.

Safety informationSafety informationSafety informationSafety information

Read this user manual carefully before starting with the installation, and observe all

applicable safety regulations and all other applicable national regulations in the country of

use.

During the installation, the installer is obliged to confirm the compliance of the user manuals

safety measures with all current rules and regulations, and to observe any new regulations

that may be applicable. Outside the European Union, adherence to applicable work safety

laws and regional national regulations for specific countries is required.

Caution!Caution!Caution!Caution! Always observe the applicable standards and regulations at the site of installation.

6


All general safety and relevant accident prevention regulations, especially these relating to

roof work, as well as all applicable environmental protection regulations, are to be observed

and followed, in addition to the work safety measures detailed in this user manual.

Follow all of the instructions given in this user manual fully, unconditionally and without

exception.

Rules and regulationsRules and regulationsRules and regulationsRules and regulations

The industrial safety act and subsequent directives, as well as the rules and regulations set

out by the professional trade association, fund for accidents at work and Central Association

of the German Roofing Trade e. V. (ZVDH), must be observed during installation and

operation.

Particular reference is made to the following hazards and measures for the elimination of

risk:

Tab. 2: Risks and measures

SymbolSymbolSymbolSymbol HazardHazardHazardHazard MeasuresMeasuresMeasuresMeasures

General riskGeneral riskGeneral riskGeneral riskssss

Risk assessmentRisk assessmentRisk assessmentRisk assessment

Measures to avert Measures to avert Measures to avert Measures to avert recognizedrecognizedrecognizedrecognized rrrrisksisksisksisks

Instruction/trainingInstruction/trainingInstruction/trainingInstruction/training

Labour Protection Law

BGV A1 "Basics of Prevention"

Danger of falling from roof edgeDanger of falling from roof edgeDanger of falling from roof edgeDanger of falling from roof edge

Roof safety scaffolding, roof protection wallRoof safety scaffolding, roof protection wallRoof safety scaffolding, roof protection wallRoof safety scaffolding, roof protection wall

BGV C22 "Construction work"

BGV 807 "Securing of side protection, edge

protection and roof protection walls as anti-fall

protection during construction work"

BGR 198 "Deployment of personal anti-fall protection

equipment"

Operating safety legislation

BGR 203 "Roof work"

DIN 4420-1

DIN 4426

DIN EN 13374 and DIN EN 517

Side protectionSide protectionSide protectionSide protection


BGV 807 "Securing of side protection, edge

protection and roof protection walls as anti-fall

protection during construction work"

DIN EN 13374

Operating safety legislation

7


Tab. 2: Risks and measures - continued

Danger of falling Danger of falling Danger of falling Danger of falling

through roofthrough roofthrough roofthrough roof

Safety netsSafety netsSafety netsSafety nets


BGR 179 "Deployment of safety nets"

DIN 1263 Parts 1 and 2

Danger of falling Danger of falling Danger of falling Danger of falling

through parts of the roofthrough parts of the roofthrough parts of the roofthrough parts of the roof

((((DomeDomeDomeDome lights, etc.)lights, etc.)lights, etc.)lights, etc.)

Built-in dome lights, window strips and smoke vents

with no fall protection must be secured with side

protection or covered with protective nets.

More information:


Notes Notes Notes Notes about this about this about this about this user manualuser manualuser manualuser manual

This user manual is a part of your product - please keep it in a safe place near the

product.

Note!Note!Note!Note! For installation outside the Federal Republic of Germany, the legal and insurance stipulations as well as the technical regulations of that specific country must be observed and applied.

Further informationFurther informationFurther informationFurther information

Further information is available from the download section of our website under

www.gehrlicher.com.

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Specific informationSpecific informationSpecific informationSpecific information

The roof must be capable of supporting the additional load of a photovoltaic system, i.e.

there must be guarantees in place at all times that the roof and its supporting structure can

carry the additional static loads. If in doubt, consulting a structural engineer is strongly

recommended. Load propagation within the building is not factored in here (on-site statics).

Particular guarantees must be in place tParticular guarantees must be in place tParticular guarantees must be in place tParticular guarantees must be in place to ensure that:o ensure that:o ensure that:o ensure that: The roof in question is in perfect condition The mounting system is the correct one for the solar modules used and the roof type All legal construction site regulations are observed At no time is there any risk emanating from the solar modules Measures are always in place to distribute loading when working on the roof

MaintenanceMaintenanceMaintenanceMaintenance

The materials used mean the GehrTec® TOP mounting system is broadly maintenance free.

In addition to the prescribed electro-technical system inspections of the entire photovoltaic

system, we recommend an annual maintenance inspection respective of the following

inspection of:

o the solar modules for damage and dirt

o all mechanical connections for secure fit

o the mounting system and the module frame for mechanical damage

o the roof covering for leaks

o all electrical lines for damage (caused by animals for example)

o all electrical plug-in and screw connections for reliable contact and electric shock

protection

If an increase in the number of relevant faults is observed during the electro-technical

system inspection or on other reasons, the maintenance intervals must be shortened to a

sensible period (also for maintenance inspections). Additional special inspections must be

carried out after unusually bad weather, earthquakes or other unusual events that can

negatively impact the mounting system.

If the modules need cleaning, only clear water may be used with no chemical cleaning

products (follow the instructions provided by the module manufacturer). Remove the module

cabling and undo the module clamps to replace modules. Follow the relevant safety

instructions during this process (Page 4).

If the maintenance intervals and inspections described above are adhered to and carried out

is use as intended as laid down in the Product Liability Law. Only then do the

manufacturer's product liability take effect.

The inspections can, and should, be used to ensure that minor damage can be rectified

cost-effectively and that no further damage arises over time.

9


Danger!Danger!Danger!Danger! Equipment to isolate the DC and AC voltages must be installed when carrying out maintenance work.

Lightning and overvoltage protectionLightning and overvoltage protectionLightning and overvoltage protectionLightning and overvoltage protection

You are informed that lightning and overvoltage protection of the photovoltaic system must

conform to the most recent versions of the following standards and directives.

Tab. 3: Technical rules and regulations for lightning and overvoltage protection

StandardStandardStandardStandard VersionVersionVersionVersion DescriptionDescriptionDescriptionDescription

DIN EN 62305-1

(IEC 62305-1:2006)

2006-10 Lightning protection (VDE 0185-305-1)

Part 1: General principles

DIN EN 62305-2

(IEC 62305-2:2006)


Part 2: Risk management

DIN EN 62305-3

(IEC 62305-3:2006)


Part 3: Protection of structural installations and people

DIN EN 62305-4

(IEC 62305-4:2006)


Part 4: Electrical and electronic systems in structural

installations

DIN VDE 0100-712

(IEC 60364-7-712:2002)

2006-06 Installation of low voltage systems

Part 7-712: Requirements for power supply systems (PV)

VdS 2010

2005-07 Risk-oriented lightning and overvoltage protection

Guidelines on damage prevention

Please refer to the directives and standards listed for more detailed information.

We generally recommend connecting the mounting system to the on-site potential

equalization system and using the overvoltage protection devices. Potential equalization is

always necessary when the solar modules used are not in Protection Class II and/or

transformer-less inverters are used.

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2 – Installation

2 2 2 2 –––– InstallationInstallationInstallationInstallation

The GehrTec® Top mounting system can be used under the following conditions:

o Place of use: mono pitched roof, duo pitched roof

o Slope: 5° to 50°

o Installation: Rooftop mounting

o Building height: max. 25 m

o Solar modules: Frameless (laminate) or framed (aluminium)

o Module dimensions: max. Length 2,000 mm, max. Width 1,300 mm

o Module alignment: vertically, horizontally

GehrTec® Top system overviewGehrTec® Top system overviewGehrTec® Top system overviewGehrTec® Top system overview

Fig. 1: System overview using the example of a cross-rail system for frameless solar modules

1 - Roof hooks

2 - Cross members (e.g. horizontal mounting rail)

3 - Butt connectors

4 - Main members (e.g. vertical mounting rail)

5 - Cross connectors

6 - Module end clamps (e.g. GehrTec© laminate clamp)

7 - Module centre clamps (e.g. GehrTec© laminate clamp)

11

2 – Installation

Tools requiredTools requiredTools requiredTools required

The following tools and materials are needed for simply and secure installation (dependent

on application):

Tab. 4: Tools

NameNameNameName Use, type, size, accessoriesUse, type, size, accessoriesUse, type, size, accessoriesUse, type, size, accessories

Measuring tape For levelling PV generators for example

Marking string For making long straight lines (e.g. markings on roof)

Pencil / chalk For marking

Safety angle grinder Diamond cutting wheel for roofs (clay tiles, concrete tiles)

Drill, electric For pre-drilling the substructure or roof sheeting

Battery-powered drill driver With assorted bits, e.g. hex. drive

Battery-powered blind riveter With bit for Ø 4.8mm stainless steel

Combination spanner Sizes 13, 15, 17 mm AF

Screwdriver internal hexagon Sizes 5, 6 mm AF

Spiral drill bit for wood Ø 6 mm, Ø 7 mm, Ø 9 mm

Multi-purpose drill bit Ø 13 mm, Ø 14 mm

Spiral drill bit for metal Ø 5 mm, Ø 6.5 mm, Ø 6.8 mm, Ø 7.0 mm, Ø 7.2 mm, Ø 7.4 mm

Fig. 2: Tools required

Danger!Danger!Danger!Danger! Tools and materials must be in perfect condition. The use of impact wrenches is not generally permitted.

12

2 – Installation

Positioning on the roofPositioning on the roofPositioning on the roofPositioning on the roof

Two variations for the alignment and installation of solar modules are described below.

Provided it is allowed in the manufacturer's user manual, solar modules can always be

installed vertically (Fig. 3) or horizontally (Fig. 4). The standards and guidelines that must

apply and be followed when mounting the solar modules can be found in the installation

instructions from the relevant module supplier. With our mounting system, both variations are

possible either with a single-layer rail system or with a cross-rail system, depending on the

condition of the roof substructure.

Caution!Caution!Caution!Caution! Frameless solar modules must be mounted horizontally (see Fig. 4)

Fig. 3: Vertical alignment of solar modules on single-rail system

1 - Width of module area (generator area)

2 - Length of module area (generator area)

3 - Length of mounting rail

4 - Distance between mounting rails (note manufacturer specifications)

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2 – Installation

Fig. 4: Horizontal alignment of solar modules on cross-rail system

1 - Width of module area (generator area)

2 - Length of module area (generator area)

3 - Distance between solar module clamps

4 - Distance between mounting rails

5 - Distance between mounting rails

All of the information and specifications in this user manual assume a four-point mounting

along the long side of the solar modules (at a gap of about ½ of the module lengths

according to the static calculation). One module is therefore carried by 2 mounting rails.

This ensures uniform load distribution onto the solar module.

Caution!Caution!Caution!Caution! Always observe the module manufacturer specifications (position of clamping points, gaps, etc.).

Example:

Module length as per data sheet: 1,200 mm

Clamping point position as per manufacturer: 275 +/- 25 mm from the edge

Distance (3) = 1,200 – 2 x 275 mm = 650 mm (corresponds to about ½ of the module

length)

Distance (5) = 1,200 – 650 mm = 550 mm + 10 mm (distance between the modules) = 560

mm

14

2 – Installation

Given the different module technologies and manufacturers on the market, there is a broad

array of solar module dimensions, giving rise to many possibilities for partitioning of the roof

area. The following information and recommendations are aimed at helping you in this

important step to find the best roof arrangement for your particular circumstances. The size

of a module area is calculated from the number of individual solar module dimensions plus

appropriate additions, such as for the module clamps (Table 5).

Tab. 5: Additions for the individual clamp types

Clamp typeClamp typeClamp typeClamp type Exact spacingExact spacingExact spacingExact spacing PlanningPlanningPlanningPlanning

Module centre clamp type 1 13 mm 20 mm

Module centre clamp type 2 19 mm 20 mm

Module end clamps (35 - 50mm) 24 mm 50 mm

Laminate centre clamp Top 24 mm 30 mm

Laminate end clamp Top 24 mm 50 mm

A corresponding distance from the roof edge must also be planned in to ensure the roof is

not hindered in its function (e.g. rainwater runoff into gutter).

Tab. 6: Minimum distances from roof edge

Roof edgeRoof edgeRoof edgeRoof edge Minimum distance recommendedMinimum distance recommendedMinimum distance recommendedMinimum distance recommended

Ridge > 50 cm

Verge board > 50 cm

Roof structures (chimney, skylight, etc.) > 50 cm (bear in mind shadowing)

Eaves (roof gutter) > 50 cm

We recommend drawing up a layout plan (prior to installation) with the positioning of the

module areas on the roof. Ensure that module areas are positioned far enough away from

roof structures so that they stay out of the shade.

15

2 – Installation

Maximum combined rail lengthMaximum combined rail lengthMaximum combined rail lengthMaximum combined rail length

For the forces caused by temperature fluctuations not to negatively impact the solar

modules or roof substructure, we recommend restricting the sizes of module areas and

splitting them up into several parts. This enables expansion in the lengthwise direction to be

reduced and simplifies accessibility to the solar modules for future maintenance work by

creating maintenance areas.

Note!Note!Note!Note! If the roof area available does not allow for the planning in of maintenance areas, the mounting rails must be interrupted by an expansion gap of at least 20 mm.

For this we recommend the maximum total lengths depending on roofing type (Table 7); i.e.

the maximum length of a combined mounting rail securely attached with butt connectors to

prevent damage to the solar module and roof. The maximum lengths apply for all mounting

rails in both directions, i.e. for both the lower position for the cross-rail system and also for

the mounting rails on which the solar modules lie and are attached.

Tab. 7: Maximum overall length of mounting rails connected together

Roofing typeRoofing typeRoofing typeRoofing type Recommended overall lengthRecommended overall lengthRecommended overall lengthRecommended overall length

Clay tile roof 12.0 m

Corrugated panels (e.g. Eternit) 12.0 m

Standing seam roofs 6.0 m

Trapezoidal sheet roofs 6.0 m

16

2 – Installation

InstallingInstallingInstallingInstalling roof hooksroof hooksroof hooksroof hooks

The area of roof above a rafter must first be cleared for the attachment point planned. To

do this, remove the roof tiles until the rafter is fully exposed (Fig. 5). Then whether the

whole area of the roof hook baseplate can lay flat on the rafter must be checked.

Caution!Caution!Caution!Caution! There must be no contact with the roof tile underneath (risk of breakage). If the tile height and/or roof batten do not have the standard dimensions, a shim must be placed between the rafter and baseplate of the roof hook, such as a wooden slat (Figs. 7 and 8), to maintain the gap between roof hook and tile.

Fig. 5: Removing the roof tiles Fig. 6: Fixing roof hook to rafter

Fig. 7: Roof hook must lie flat Fig. 8: Insert wooden shim for height compensation

Caution!Caution!Caution!Caution! Clay tile roofs generally have a rafter gap of 65 to 80 cm. Rafters are normally dimensioned for the effects of dead weight, snow and wind without any considerable reserves. The substructure for the solar modules must therefore be planned such that every rafter is loaded underneath the module surface area.

WRONGWRONGWRONGWRONG RIGHTRIGHTRIGHTRIGHT

17

2 – Installation

Fig. 9: Grinding off the ridges of roof tiles

Fig. 10: Replacing the roof tiles Fig. 11: Do not use roof hooks as a climbing aid

Caution!Caution!Caution!Caution! Roof hooks in place may not be used as a climbing aid for the installation.

Attachment Attachment Attachment Attachment screwsscrewsscrewsscrews

Roof hooks may only be attached directly to supporting parts of the roof (rafters, beams) to

which the screws can be attached to secure the baseplates of roof hooks (while observing

the edge distances of screws permitted - see DIN 1052). The baseplate is long enough to

allow pulling out of the hook in the tile trough by shifting the hook sideways. Two wood

screws (d = 8mm) in the centre line of the baseplate of the rook hooks must be used. The

wood screw diameter required is governed by the minimum screw-in depth necessary into

the supporting structural member of l ≥ 60 mm.

Tab. 8: Overview of wood screws with wheel head

Part no.Part no.Part no.Part no. SizeSizeSizeSize VariantVariantVariantVariant

Z34011880 8 x 80 mm e.g. without sheathing and counter batten

Z340118100 8 x 100 mm e.g. sarking membrane, counter batten 24 mm

Z340118120 8 x 120 mm e.g. sheathing 20 mm, counter batten 30 mm

Z340118140 8 x 140 mm e.g. sheathing 30 mm, counter batten 40 mm

NoteNoteNoteNote!!!! Use on roofs with on-roof insulation must be checked on a case-by-case basis by the customer.

To attach the roof hooks, tile ridges must

be ground off with an angle grinder at the

places where passage of roof hooks

between tiles is necessary (Fig. 9). This

applies to the ridge on the top of the tile

below and for the ridge on the bottom of

the tile covering the roof hook. The tiles

are then put back into position.

18

2 – Installation

Mounting railsMounting railsMounting railsMounting rails

Tip!Tip!Tip!Tip! If only the outermost roof hooks of a rail row are attached, and the mounting rail initially only hand-tightened, the roof hooks in-between can be positioned such that alignment of the rail using the long holes of the roof hooks is simplified.

Fig. 12: Securing of mounting rail on roof hooks Fig. 13: Alignment of mounting rail

Fig. 14: Securing of mounting rail on roof hooks Fig. 15: Alignment of mounting rail

The mounting rails are attached to the roof hook with a hammerhead bolt (part no.

Z34131020 or Z34131025) and a hexagonal nut with flange M 10 (part no. Z341510).

Caution!Caution!Caution!Caution! Adherence to the safety regulations for roofing work is required (DIN 18338). DIN 1052 regulations apply.

Adjustable roof hooks with extra bracketAdjustable roof hooks with extra bracketAdjustable roof hooks with extra bracketAdjustable roof hooks with extra bracket

Adjustable roof hooks are supplied with an extra bracket that allow for certain compensation

in the roof level. The following tightening torque is stipulated for the screw connection

between roof hook and extra bracket.

NoteNoteNoteNote!!!! Guide value for the tightening torque to DIN EN ISO 3506: 30 Nm (M10 screw)

19

2 – Installation

InstallInstallInstallInstalling haning haning haning hanger boltsger boltsger boltsger bolts

Hanger bolts with adaptor plates are used for attachment to roofs with fibre cement

corrugated panels (e.g. Eternit). We strongly advise against installation on roofs containing

asbestos. Professional renovation of the roof is strong recommended before installation.

DangerDangerDangerDanger!!!! It is illegal to drill or machine asbestos cement plates! Corrugated panels made of fibre cement or synthetic materials are often not fall-through resistant. Always use planks for load distribution when carry out installation work. The relevant laws and health & safety regulations must be observed.

Tab. 9: Overview of hanger bolts

Part no.Part no.Part no.Part no. SizeSizeSizeSize

Hanger boltHanger boltHanger boltHanger bolt

Adapter plateAdapter plateAdapter plateAdapter plate

Part no.Part no.Part no.Part no.

Hexagonal nutHexagonal nutHexagonal nutHexagonal nut

with flangewith flangewith flangewith flange

Part no.Part no.Part no.Part no.

PrePrePrePre----drilling diameterdrilling diameterdrilling diameterdrilling diameter

Roof tileRoof tileRoof tileRoof tile

Wooden Wooden Wooden Wooden

building building building building

structurestructurestructurestructure

340010200 M 10 x 200 Z3310003 Z341510 Ø 13 mm Ø 7 mm

340012300 M 12 x 300 Z3310004 Z3415112 Ø 14 mm Ø 9 mm

An attachment kit with an M12x300 hanger bolt is generally recommended. A M10 x 200

version is also available for special kinds of attachment for reduced horizontal spacing.

Other dimensions are available on request.

Fig. 16: Drilling through a roof tile / pre-drilling of the wooden structure

NoteNoteNoteNote!!!! Hanger bolts may not be positioned in the troughs of roof tiles (through which water passes).

20

2 – Installation

The roof tile (1) is drilled at the relevant places and then the wooden structure (2) is pre-

drilled (see Table 9 for the pre-drilling diameter). Holes may not be located in troughs

(through which water passes), only on the ridges of the panel profile. Hanger bolts must be

screwed into the supporting wooden structure over the length of the wood thread.

Hanger bolts must be screwed in at right angles to the surface to ensure perfect attachment

and protection from rain. The required screw depth into the supporting wood substructure l

must be ≥ 100 mm (Fig. 17).

TipTipTipTip!!!! An integrated power unit enables a battery-powered screwdriver or drill to be used.

Fig. 17: Screw in hanger bolt Fig. 18: Press in seal and tighten nut

For sealing, the slide-on rubber washer (part no. Z3200001) is pressed into the tile by

screwing in the hanger bolt into the hole drilled, and pressed onto the tile by hand-

tightening the hexagonal nut with flange (part no. Z341510 ) - see Fig. 18.

Caution!Caution!Caution!Caution! This is only for the purposes of sealing and is not intended to transfer any forces. Only press the rubber seal gently as there is a risk of breakage.

The mounting rails are attached to the adapter plate with a hammerhead bolt (part no.

Z34131020 or Z34131025) and a hexagonal nut with flange (part no. Z341510).

Caution!Caution!Caution!Caution! Adherence to the safety regulations for roofing work is required (DIN 18338). DIN 1052 regulations apply.

21

2 – Installation

InstallInstallInstallInstalling solar fastenersing solar fastenersing solar fastenersing solar fasteners

Our solar fasteners with adaptor plates can be used for secure and simply mounting on

roofs with a steel or wooden substructure. Easy to fit, they guarantee leak tightness, high

load bearing capacity and precise adjustment. The solar fasteners are anchored in the

substructure and transfer all resulting tensile and compressive forces into the substructure

so that, for example, the thin covers of sandwich elements are not damaged.

Solar fasteners are suitable for roofs with profile panels made of steel, aluminum, sandwich

elements or fibre cement corrugated panels.

Fig. 19: Drilling through a roof tile / pre-drilling of the substructure

The profiled tiles (1) are drilled at the relevant places, then the substructure (2) must be

pre-drilled (Fig. 19). Holes may not be located in troughs (through which water passes), only

on the ridges of profiled tiles. Select the bit length and drill hole depth in line with the

screw length. The profiled tiles and substructure must be pre-drilled in line with Table 10.

Tab. 10: Pre-drilling diameter in mm for profiled tiles and substructure

SolarSolarSolarSolar fastenerfastenerfastenerfastener

Thickness of substructure [mm], made ofThickness of substructure [mm], made ofThickness of substructure [mm], made ofThickness of substructure [mm], made of

steelsteelsteelsteel timbertimbertimbertimber

1.5 … < 5.01.5 … < 5.01.5 … < 5.01.5 … < 5.0 5.0 … < 7.55.0 … < 7.55.0 … < 7.55.0 … < 7.5 7.5 … < 107.5 … < 107.5 … < 107.5 … < 10 ≥ 10101010 ≥ 40404040

Type Z 6.8 7.0 7.2 7.4 -

Type A - - - - 6.0

TipTipTipTip!!!! For existing roofs attached to a steel substructure with Ø 5.5 mm or Ø 6.3 mm screws, the old screws can be removed and be replaced with Ø 8.0 mm solar fasteners. The pre-drill diameter must always be observed.

22

2 – Installation

NoteNoteNoteNote!!!! Fibre cement corrugated panels must be pre-drilled with an 11 mm diameter.

Fig. 20: Screwing in solar fastener

Tab. 11: Overview of type Z solar fasteners for steel substructures

Part no.Part no.Part no.Part no. DiameterDiameterDiameterDiameter LengthLengthLengthLength Screw lengthScrew lengthScrew lengthScrew length SetSetSetSetscrewscrewscrewscrew

Z34271880 Ø 8 mm 80 mm

Sandwich element

thickness / profile

height

+ 20 mm

M10 x 50 mm

Z342718100 Ø 8 mm 100 mm

Z342718125 Ø 8 mm 125 mm

Z342718150 Ø 8 mm 150 mm

Z342718200 Ø 8 mm 200 mm

Tab. 12: Overview of type A solar fasteners for timber substructures

Part no.Part no.Part no.Part no. DiameterDiameterDiameterDiameter LengthLengthLengthLength ScrewScrewScrewScrew----in depthin depthin depthin depth SetscrewSetscrewSetscrewSetscrew

Z342728100 Ø 8 mm 100 mm

In wood:

min. 34 mm

max. 96 mm

M10 x 50 mm

Z342728130 Ø 8 mm 130 mm

Z342728150 Ø 8 mm 150 mm

Z342728180 Ø 8 mm 180 mm

Z342728200 Ø 8 mm 200 mm

The M10 adapter plate (part no. Z3310003) is locked against the welded-on setscrew

between the hexagonal nuts and washers, allowing a connection to the mounting rails. This

connection to the adapter plate is established with a hammerhead bolt (part no. Z34131020

or Z34131025) and a hexagonal nut with flange (part no. Z341510).

Caution!Caution!Caution!Caution! Adherence to the safety regulations for roofing work is required (DIN 18338). The regulations lay down in DIN 1052 and DIN 18807 applies.

Solar fasteners must be secured at right

angles to the surface to guarantee perfect

supporting attachment and protection from

rain as required.

Drilling chips must be removed from the

surface.

The solar fasteners are pre-assembled and

have an integrated hexagonal recess (5

mm) so a power screwdriver can be used.

The use of impact wrenches is not

permitted.

23

2 – Installation

InstallInstallInstallInstalling oing oing oing onnnn trapezoidal profilestrapezoidal profilestrapezoidal profilestrapezoidal profiles

The T1 mounting rail enables direct installation on trapezoidal sheet roofs. It can be used

as both a simple horizontal rail system and as a cross-rail system. Applied all over the

underside is an EPDM seal that functions as a separator from the trapezoidal profile and

seals the joint.

NoteNoteNoteNote!!!! Vertical orientation of the T1 mounting rail parallel to the sheet ridges is not permitted. The T1 mounting rail must be connected with two connecting elements per ridge.

PrinciplePrinciplePrinciplePrinciple

The T1 mounting rail is placed directly on the trapezoidal profile with the underside at right

angles (!) to the sheet ridges aligned (Fig. 21) and joined. This attains as uniform a load

distribution as possible onto the trapezoidal profile.

Attachment methodAttachment methodAttachment methodAttachment method

Only fastening elements with general building authority approval are used. Different drill hole

diameters are used depending on fastening element (see Table 13). The T1 mounting rail

has a small indentation on both sides for orientation and for keeping to the edge distances

required for the drilling process. Fastening elements must be positioned at right angles to

the surface to establish a perfect supporting and rain-protected joint.

Tab. 13: Overview of fastening elements

Part no.Part no.Part no.Part no. NameNameNameName SizeSizeSizeSize PrePrePrePre----drilling diameterdrilling diameterdrilling diameterdrilling diameter Panel thickness tPanel thickness tPanel thickness tPanel thickness tIIIIIIII mmmmmmmm

Z34056325 Drilling screw 6.3 x 25 Ø 6.5 mm 0.50 ≤ tII ≤ 1.25

Z3430001 Blind rivet 4.8 x 15 Ø 5.0 mm 0.50 ≤ tII ≤ 1.25

Drilling screwsDrilling screwsDrilling screwsDrilling screws

The screws are drilling screws made of non-rusting steel with a drill bit made of case-

hardened steel. The screws are used with an EPDM sealing washer. For installing of the

screws, the T1 mounting rail (but not the trapezoidal profile) is pre-drilled with a hole with

diameter 6.5 mm. The sealing washer shows whether the screw joint has been tightened

correctly. The joint is correct when the metal back of the sealing washer is almost flat and

the remolded EPDM sealing bends up slightly out of the side. The screw is governed by

Annex 3.126 of general building regulation approval Z-14.1-4.

NoteNoteNoteNote!!!! The use of impact wrenches is not permitted. Drilling screws must be screwed in up to the end stop, guideline value: 5 Nm Screws that are not tightened adequately enough, and sealing washers compressed too much, can negatively impact the sealing function.

24

2 – Installation

Blind rivetsBlind rivetsBlind rivetsBlind rivets

A rivet is a blind rivet with an aluminum sleeve and a rustproof steel mandrel. Blind rivets

are used with "under-head seals". To fit blind rivets, the T1 mounting rail and the

trapezoidal profile are pre-drilled with a hole of diameter 5.0 mm. Blind rivets are governed

by Annex 2.15 of general building regulation approval Z-14.1-4.

NoteNoteNoteNote!!!! To prevent corrosion and leaks, we recommend removal ALL drill shavings from the roofing and adjacent areas, such as the guttering. We recommend using a suitable vacuum cleaner or compressed air to remove the drill shavings so that the roofing is not damaged in any way.

Using conventional cleaning equipment (such as a broom) presents a risk of damaging the

protective paint of the roof.

Fig. 21: Placing and positioning of mounting rail Fig. 22: Pre-drilling of the T1 mounting rail

Fig. 23: Screwing in of hanger bolt Fig. 24: Inserting a blind rivet

TipTipTipTip!!!! When using the drilling screw, we recommend pre-drilling the T1 mounting rail near the bottom bead to prevent pre-drilling the trapezoidal profile.

25

2 – Installation

InstallInstallInstallInstalling the Toping the Toping the Toping the Top----TS systemTS systemTS systemTS system

The GehrTec® Top-TS system allows the mounting of framed solar modules directly on

trapezoidal profile plates and is based on the attachment of the T1 mounting rail. The solar

modules can be attached to very slightly sloped roof areas using the additional setting

angle, and on roof areas pointing in an unfavorable direction with perfect alignment towards

the sun. The setting angle attained in relation to the roof surface is 15°. The slope of the

roof can be between 5° and 20°. The GehrTec® Top-TS system can be used under the

following conditions:

o Place of use: mono pitched roof, duo pitched roof (trapezoidal sheet)

o Roof slope: 5° to 20°

o Building height: max. 25 m

o Solar modules: Framed (aluminium), frame height 35 to 50 mm

o Module dimensions: Max. 1700 mm x 1100 mm

o Module alignment: horizontal

Alignment of the solar modulesAlignment of the solar modulesAlignment of the solar modulesAlignment of the solar modules

The solar modules themselves must be positioned horizontally (as seen in the direction of

sun rays) on the attachment system, and must form a row of solar modules next to each

other. These solar module rows can be aligned to two different roof boundaries. There is

alignment of the solar module rows parallel to the two gable boards of a roof surface (see

Fig. 25) - recommended for roof surfaces pointing mainly in the east/west direction. This

variant is referred to as installation variant A below.

Fig. 25: Example of Top-TS installation, alignment of the solar module rows parallel to the gable board

26

2 – Installation

There is also an option of positioning the solar module rows parallel to the roof ridge or

eaves on roof surfaces that point in exactly the right direction as regards the sun but only

have a gentle slope (see Fig. 26). This variant is referred to as installation variant B below.

Fig. 26: Example of Top-TS installation, alignment of the solar module rows parallel to the roof ridge/eaves

Orientation of the T1 mounting rail stays the same in both cases, i.e. parallel to the roof

ridge/eaves and running at right angles to the top bead of the trapezoidal profile (see Fig.

27).

Fig. 27: Alignment of the T1 mounting rail

NoteNoteNoteNote!!!! The specifications and guidelines for attaching the T1 mounting rail are described in Section "Installing of trapezoidal profiles" and must be observed.

27

2 – Installation

PositioningPositioningPositioningPositioning on the roofon the roofon the roofon the roof

The arrangement and positioning of T1 mounting rails essentially depend on the dimensions

of the solar modules used and the orientation of the solar module rows. For installation

variant A, the gaps are given by the position of the clamping points on the solar modules

(see Fig. 28). For installation variant B, the gaps between mounting rails are determined by

the distance between base supports (see Figs. 29 and 30). Distance x between the solar

module rows must be taken into consideration to prevent shadowing.

Caution!Caution!Caution!Caution! Always observe the module manufacturer specifications (position of clamping points, gaps, etc.).

Example of clamping point positioning

Module length as per data sheet: 1,650 mm

Clamping point position as per manufacturer: 330 +/- 25 mm measured from the edge (A3)

Distance (A1) = 1,650 mm – 2 x 330 mm = 990 mm

Distance (A2) = 2 x A3 + 20 mm (distance between modules) = 2 x 330 mm + 20 mm =

680 mm

Fig. 28: Distance between clamping points

28

2 – Installation

The base supportsThe base supportsThe base supportsThe base supports

The actual Top-TS system comprises the base supports and the module clamps. There is

short base support 1 for holding the solar module directly above the T1 mounting rail, and

two-part base support 2 that lifts the solar module to the required angle of 15°. The length

of base support 2 can be adjusted so that solar modules having different dimensions can be

installed (see Figs. 29 and 30).

Fig. 29: Example module width 800mm Fig. 30: Example module width 1,100mm

Fig. 31: Mounting together base support 2

An M10x25 hammerhead bolt (part no. Z34131025) and a hexagonal nut with flange (part no.

Z341510) are used for securing onto the T1 mounting rail.

Fig. 32: Mounting base support 1 Fig. 33: Mounting base support 2

NoteNoteNoteNote!!!! Guide value for the tightening torque to DIN EN ISO 3506: 30 Nm (M10 screw)

The following parts are required for

mounting base support 2.

1 x base support 2-1

(part no. Z3340014)

1 x base support 2-2

(part no. Z3340015)

2 x hexagonal bolt with M10x30 flange

(part no. Z34291030)

2 x hexagonal nut with M10 flange

(part no. Z341510)

29

2 – Installation

Tab. 14: Overview of distances in relation to module width

Module widthModule widthModule widthModule width Length aLength aLength aLength a Centre to centre Centre to centre Centre to centre Centre to centre

distance ddistance ddistance ddistance d Height hHeight hHeight hHeight h

800 mm 241 mm 803 mm 207 mm

810 mm 244 mm 814 mm 210 mm

820 mm 247 mm 824 mm 212 mm

830 mm 249 mm 835 mm 215 mm

840 mm 252 mm 845 mm 217 mm

850 mm 255 mm 855 mm 220 mm

860 mm 257 mm 866 mm 223 mm

870 mm 260 mm 876 mm 225 mm

880 mm 263 mm 886 mm 228 mm

890 mm 265 mm 897 mm 230 mm

900 mm 268 mm 907 mm 233 mm

910 mm 271 mm 917 mm 236 mm

920 mm 273 mm 928 mm 238 mm

930 mm 276 mm 938 mm 241 mm

940 mm 279 mm 948 mm 243 mm

950 mm 281 mm 959 mm 246 mm

960 mm 284 mm 969 mm 248 mm

970 mm 287 mm 980 mm 251 mm

980 mm 289 mm 990 mm 254 mm

990 mm 292 mm 1,000 mm 256 mm

1,000 mm 295 mm 1,011 mm 259 mm

1,010 mm 297 mm 1,021 mm 261 mm

1,020 mm 300 mm 1,031 mm 264 mm

1,030 mm 303 mm 1,042 mm 267 mm

1,040 mm 305 mm 1,052 mm 269 mm

1,050 mm 308 mm 1,062 mm 272 mm

1,060 mm 311 mm 1,073 mm 274 mm

1,070 mm 314 mm 1,083 mm 277 mm

1,080 mm 316 mm 1,093 mm 280 mm

1,090 mm 319 mm 1,104 mm 282 mm

1,100 mm 322 mm 1,114 mm 285 mm

NoteNoteNoteNote!!!! Centre to centre distance d is for the bolts (see Figs 34 and 35)

30

2 – Installation

Distance between solar module rowsDistance between solar module rowsDistance between solar module rowsDistance between solar module rows

Because of the additional angle of 15°, roof planning must take into consideration an

appropriate distance between solar module rows for shadowing. This distance is dependent

on the module width used and the orientation and slope of the roof surface. For a roof

pointing southwards, there should be no shadowing at midday on midwinters day (21

December), i.e. when the sun is at its lowest point. In Germany, the elevation angle of the

sun is about 15°, from which the necessary clearances can be calculated.

Fig. 34: Clearances for installation variant A

The height of the structure at right angles to the roof surface is an important part of the

calculation and dependent on the module width.

Fig. 35: Distance x between module rows for installation variant B

NoteNoteNoteNote!!!! Calculation of the distances (x) should only be performed by experienced system planners

hhhh

dddd

dddd xxxx

dddd

dddd

31

2 – Installation

InstallInstallInstallInstalling of solar modulesing of solar modulesing of solar modulesing of solar modules

After the base supports have been mounted, the solar modules can be inserted (Fig. 36) and

then secured into place with Top-TS module clamps (part no. Z3340016) and appropriate

hexagonal bolts with cheese head (see Table 15) - Fig. 37.

Fig. 36: Inserting a solar module Fig. 37: Mounting TOP TS module clamps

Tab. 15: Overview of the bolts for the Top-TS module clamp (part no. Z3340016)

Cylinder head M 8xCylinder head M 8xCylinder head M 8xCylinder head M 8x [mm][mm][mm][mm] [mm][mm][mm][mm] [mm][mm][mm][mm] [mm][mm][mm][mm] [mm][mm][mm][mm] [mm][mm][mm][mm]

Frame height 35 40 42 45 46 50

Part no. Z34118xx 35 40 45 45 50 50

(Example: part no. Z3411850 for Allen screw M8x50)

Component part listComponent part listComponent part listComponent part list

Tab. 16: Components required to attach a solar module

Part no.Part no.Part no.Part no. NameNameNameName SizeSizeSizeSize QtyQtyQtyQty.... / solar module/ solar module/ solar module/ solar module

Z3340013 Base support 1 60 mm 2

Z3340014 Base support 2-1 60 mm 2

Z3340015 Base support 2-2 60 mm 2

Z3340016 Top-TS module clamp 60 mm 4

Z34291030 Hexagon bolt with flange M10x30 4

Z34131025 Hammerhead bolt M10X25 4

Z341510 Hexagon nut with flange M10 8

Z34118xx Allen screw M8xL 4

32

2 – Installation

InstallInstallInstallInstalling clamp holdersing clamp holdersing clamp holdersing clamp holders

We use special clamp holders for mounting solar power systems on metal roofs. For

standing seam roofs in particular, and pre-manufactured profile sheets such as Kalzip, Bemo

and RibRoof, the roofing is not damaged by using the clamp system because clamp holders

are attached to the sheet seam.

NoteNoteNoteNote!!!! Adherence to the relevant building regulation approvals of the manufacturer is an absolute requirement for installing profile sheet systems (Kalzip, BEMO, etc.).

The specification of the number of clamp holders is dependent on the design, weight and

size of the solar modules.

Tab. 17: Overview of the different clamp holders

Part no.Part no.Part no.Part no. Sheet profileSheet profileSheet profileSheet profile LengthLengthLengthLength MaterialMaterialMaterialMaterial Profile typesProfile typesProfile typesProfile types

Z3330001 Standing seam 110 mm Aluminium Standing seam and similar

Z3330002 Round head profiles 110 mm Aluminium Bemo, Kalzip and similar

Z3330003 Round head profiles 110 mm Aluminium RibRoof 465/480, Domico

Z3330004 Round head profiles 110 mm Aluminium RibRoof 500

Z3330005 Round head profiles 55 mm Aluminium Bemo, Kalzip and similar

Z3330006 Round head profiles 55 mm Aluminium RibRoof 465/480, Domico

Caution!Caution!Caution!Caution! The individual wind-drag loads and snow loads possible must be established to determine the load transfer to the wooden substructure. A check must be carried out by the customer on whether attachment with clamp holders is sufficient or whether the system needs to be secured with additional measures.

The number of attachment points must be determined by a structural engineer based on the

conditions on site. An extraction force of about 400 N (40 kg) must be applied for nails

used for securing on metal roofs. This can result in the sheet metal clips coming off the

wooden substructure before the clamp holder comes off the sheet seams.

Specific informationSpecific informationSpecific informationSpecific information

The following special guidelines must be followed for mounting on sheet profile systems

(Kalzip, BEMO, etc.). Most sheet profile systems are attached with clips (spacers) to the roof

substructure (e.g. steel girders). The loads caused by tensile and compressive forces that can

be taken up by the sheet profile system flange depend on the centre spacing of these clips

and the sheet thickness.

For the securing of the sheet profiles in the event of thermal agitation and for the transfer

of shear and normal forces arising in the roof due to the solar power system, fixed points

are provided where, in compliance with the building authority approval from the

manufacturer, the mounting system for the solar power system must be mounted and

connected.

33

2 – Installation

A clamp holder that attaches the profiles of the substructure to the roof can generally

transfer greater loads than the flange of the sheet profile system.

Elevations must generally be rated critically for sheet profile systems. Elevations are not

permitted at all for standing seam roofs.

NoteNoteNoteNote!!!! Adherence to the regulations of the metal roofer trade is required (DIN 18339).

Fig. 38: Mounting a clamp holder Fig. 39: Securing a mounting rail

Fig. 40: Aligning the mounting rail Fig. 41: Cross-rail system

34

2 – Installation

The The The The mountingmountingmountingmounting rail systemrail systemrail systemrail system

The GehrTec® Top mounting system from Gehrlicher Solar AG boasts an innovative mounting

rail system - every groove allows quick and simple insertion of nuts and bolts at any

position, simplifying considerably installation.

NoteNoteNoteNote!!!! All connections on mounting rails must be tightened by hand. Guide values for tightening torques to DIN EN ISO 3506: 15 Nm (M8) / 30 Nm (M10)

Fig. 42: Inserting a bolt Fig. 43: Turning in the bolt

Fig. 44: Turning a hammerhead bolt Fig. 45: Side view of hammerhead bolt

Fig. 46: Turning a hammerhead nut Fig. 47: Side view of hammerhead nut

Tab. 18: Overview of hammerhead nuts and bolts

Part no.Part no.Part no.Part no. NameNameNameName SizeSizeSizeSize MaterialMaterialMaterialMaterial

Z34131020 Hammerhead bolt M 10x20 Stainless steel A2

Z34131025 Hammerhead bolt M 10x25 Stainless steel A2

Z34149 Hammerhead nut M 8 Stainless steel A2

35

2 – Installation

The GehrTec® Top mounting system from Gehrlicher Solar AG is a general purpose system

that always works to the same principle. Mounting rails are attached to the roof, on which

solar modules are secured at four clamping points. The mounting rails run either horizontally

(see Fig. 2) or vertically (see Fig. 3) depending on orientation and positioning of the solar

modules. The mounting rails are secured to the roof substructure with attachment points

(dependent on roofing) - e.g. roof hooks.

If the roof substructure does not offer any suitable attachment points for the mounting rails,

a cross-rail system is recommended. Using a second rail level, offset by 90°, means the

system can be used flexibly in both directions.

NoteNoteNoteNote!!!! We generally recommend a cross-rail system for frameless solar modules. A cross-rail system does not reduce the number of attachment points required.

Rail cross connectorsRail cross connectorsRail cross connectorsRail cross connectors

Crossing points are established with our rail cross connector (Fig. 48). The following parts

are required:

1 x rail cross connector (part no. Z3110002)

2 x Allen key bolt M8x16 (part no. Z34111816)

2 x M8 hammerhead nut (part no. Z34149)

Fig. 48: Rail cross connector Fig. 49: Butt connector

Butt connectorButt connectorButt connectorButt connector

Two butt connectors are used to connect the mounting rails. The cross-section is designed

such that they can be inserted into the profile channel (Fig. 49). The following parts are

required for every butt connection:

2 x butt connectors (part no. Z3110001)


4 x M8 thrust washer (part no. Z34188)

NoteNoteNoteNote!!!! All butt connections must be made with two butt connectors and must be positioned within two support points. No cantilever arm may be extended. Use in the top profile channel may lead to overlaps with module clamps or solar modules >> note the position of butt connectors!

36

2 – Installation

MountMountMountMounting solar modulesing solar modulesing solar modulesing solar modules

Framed solar modulesFramed solar modulesFramed solar modulesFramed solar modules

Framed solar modules are clamped to the mounting rails with our module centre clamps and

an appropriately long Allen key bolt plus hammerhead nut M8 (part no. Z34149). Used on

both ends of a module row are our module clamps for the relevant module frame height

and M8x16 Allen key bolts (part no. Z34111816) plus hammerhead nuts M8 (part no.

Z34149).

Tab. 19: Overview of the bolts for module centre clamp 1 (part no. Z3120001)

Countersunk head M 8xCountersunk head M 8xCountersunk head M 8xCountersunk head M 8x [mm][mm][mm][mm] [mm][mm][mm][mm] [mm][mm][mm][mm] [mm][mm][mm][mm] [mm][mm][mm][mm] [mm][mm][mm][mm]

Frame height 35 40 42 45 46 50

Part no. Z34128xx 50 55 55 60 60 65

(Example: part no. Z3412860 for Allen countersunk screw M8x60)

Tab. 20: Overview of the bolts for module centre clamp 2 (part no. Z3120010)

Cylinder head M 8xCylinder head M 8xCylinder head M 8xCylinder head M 8x [mm][mm][mm][mm] [mm][mm][mm][mm] [mm][mm][mm][mm] [mm][mm][mm][mm] [mm][mm][mm][mm] [mm][mm][mm][mm]

Frame height 35 40 42 45 46 50

Part no. Z341118xx 16 20 20 25 25 30

(Example: part no. Z34111820 for Allen key bolt M8x50)

Fig. 50: Mounting a module centre clamp Fig. 51: Mounting a module end clamp

37

2 – Installation

Frameless solar modulesFrameless solar modulesFrameless solar modulesFrameless solar modules

Frameless solar modules (laminates) are attached with our Gehrtec® Laminate Clamp. These

laminate clamps are two-part, i.e. comprise a top and a bottom part. The bottom clamp part

can be pressed into the groove of the mounting rail and positioned (Fig. 53) using the

special Top clip (part no. Z3120018) already with an M8 hammerhead nut (part no. Z34149)

and that is clicked into the bottom clamp part (Fig. 52). This enables precise alignment of

the clamping points and insertion of the frameless solar modules into the bottom clamp

parts positioned (Fig. 54). The last step is inserting and screwing in the top clamp parts with

Allen countersunk screws (part no. Z3412835) - Fig. 55.

The module clamps have special EPDM rubber profiles, meaning the frameless solar module

is only clamped and not subjected to mechanical loading. Please refer to the user manual

from the relevant manufacturer for the positions of the clamping points on the solar module.

Our laminate clamps are suitable for frameless solar modules having a thickness of 6.8 – 7.0

mm.

Fig. 52: Click the TOP clip into the bottom part Fig. 53: Press in and align the bottom part

Fig. 54: Insert a solar module Fig. 55: Insert the top clamp part and the screws

NoteNoteNoteNote!!!! Follow the installation instructions for the GehrTec® laminate clamps (see package insert). Follow the installation instructions from the module manufacturer (minimum distances, clamping points, etc.). Frameless solar modules must be mounted horizontally.

38

3 – Components of GehrTec® Top

3 3 3 3 –––– The components of GehrTec® TopThe components of GehrTec® TopThe components of GehrTec® TopThe components of GehrTec® Top

Mounting rails and accessoriesMounting rails and accessoriesMounting rails and accessoriesMounting rails and accessories

Mounting rail 1Mounting rail 1Mounting rail 1Mounting rail 1 Part no.:Part no.:Part no.:Part no.: Z3100001Z3100001Z3100001Z3100001

Usable as cross beam (cross-rail system) or as main beam.

EN AW6063 T66

Standard length: 6,000 mm

Cross-section: 30 x 50 mm


Usable as cross beam (cross-rail system).

EN AW6063 T66





EN AW6063 T66





EN AW6063 T66



39




EN AW6063 T66



Mounting rail T1Mounting rail T1Mounting rail T1Mounting rail T1 Part no.:Part no.:Part no.:Part no.: Z3100006Z3100006Z3100006Z3100006

For mounting on trapezoidal sheet roofs with special EPDM

sealing on the underside.

EN AW6063 T66


Cross-section: 30 x 30 (80) mm

Butt connectorButt connectorButt connectorButt connector Part no.:Part no.:Part no.:Part no.: Z3110001Z3110001Z3110001Z3110001

Fastening element for mounting rails.

EN AW6063 T66

Length: 100 mm

Accessories required:


2 x M8 thrust washer (part no. Z34188)

Rail crossRail crossRail crossRail cross----connectorconnectorconnectorconnector Part no.:Part no.:Part no.:Part no.: Z3110002Z3110002Z3110002Z3110002

Fastening element for the cross-rail system.

EN AW6063 T66

Two mounting holes for M8




40


Module clamps for framed modulesModule clamps for framed modulesModule clamps for framed modulesModule clamps for framed modules

Module centre clamp type 1Module centre clamp type 1Module centre clamp type 1Module centre clamp type 1 Part no.:Part no.:Part no.:Part no.: Z3120001Z3120001Z3120001Z3120001

For attaching solar modules with aluminium frame.

EN AW6063 T66, length 80mm

General purpose


1 x M8 countersunk screw (part no. Z34128xx)


Module centre clamp type 2Module centre clamp type 2Module centre clamp type 2Module centre clamp type 2 Part no.:Part no.:Part no.:Part no.: Z3120010Z3120010Z3120010Z3120010



General purpose


1 x M8 Allen key bolt (part no. Z3411xx)


Module end clamp 35Module end clamp 35Module end clamp 35Module end clamp 35 Part no.:Part no.:Part no.:Part no.: Z3120007Z3120007Z3120007Z3120007

Module end clamp 40Module end clamp 40Module end clamp 40Module end clamp 40 Part no.:Part no.:Part no.:Part no.: ZZZZ3120008312000831200083120008










41


Module clamps for frameless solar modulesModule clamps for frameless solar modulesModule clamps for frameless solar modulesModule clamps for frameless solar modules

GehrTec© laminate centre clampGehrTec© laminate centre clampGehrTec© laminate centre clampGehrTec© laminate centre clamp Part no.:Part no.:Part no.:Part no.: Z3120016Z3120016Z3120016Z3120016

For attaching frameless solar modules.

EN AW6063 T66

Special EPDM rubber profiles

Approved by First Solar PD-5-321-34 EU


1 x countersunk screw M8x35 (part no. Z3412835)

1 x TOP clip (part no. Z3120018)

IMPORTANT: Follow the installation instructions (see package

insert)

GehrTGehrTGehrTGehrTec© laminate end clampec© laminate end clampec© laminate end clampec© laminate end clamp Part no.:Part no.:Part no.:Part no.: Z3120017Z3120017Z3120017Z3120017

For attaching frameless solar modules.

EN AW6063 T66

Special EPDM rubber profiles

Approved by First Solar PD-5-321-34 EU


1 x countersunk screw M8x35 (part no. Z3412835)

1 x TOP clip (part no. Z3120018)

IMPORTANT: Follow the installation instructions (see package

insert)

Top clipTop clipTop clipTop clip Part no.:Part no.:Part no.:Part no.: Z3120018Z3120018Z3120018Z3120018

For quick and easy mounting of GehrTec© laminate clamps.

Synthetic ASA

Colour: light grey

Already with M8 hammerhead nut (part no. Z34149)

42


Roof hooksRoof hooksRoof hooksRoof hooks

Slate rooSlate rooSlate rooSlate rooffff hookhookhookhook Part no.:Part no.:Part no.:Part no.: Z3301017Z3301017Z3301017Z3301017

For attachment on slate roofs.

Stainless steel 1.4301

Bracket cross-section: 35x6 mm

Mounting holes d=9mm

Beaver tail roof hookBeaver tail roof hookBeaver tail roof hookBeaver tail roof hook Part no.:Part no.:Part no.:Part no.: Z3301018Z3301018Z3301018Z3301018

For attachment on plain tile roofs.



Mounting holes d=9 mm

Frankfurter Pan roof hookFrankfurter Pan roof hookFrankfurter Pan roof hookFrankfurter Pan roof hook Part no.:Part no.:Part no.:Part no.: Z3301002Z3301002Z3301002Z3301002

For attachment on pan roofs for normal static requirements.



Baseplate mounting holes d=9 mm


For attachment on pan roofs for increased static requirements.




43



For attachment on pan roofs for normal static requirements.




Adjustable version with extra bracket


For attachment on pan roofs for increased static requirements.




Adjustable version with extra bracket

Hanger boltsHanger boltsHanger boltsHanger bolts

Hanger bolt M10x200Hanger bolt M10x200Hanger bolt M10x200Hanger bolt M10x200 Part no.:Part no.:Part no.:Part no.: Z340010200Z340010200Z340010200Z340010200

For attachment on the supporting wooden substructure.

Stainless steel 1.4301, size M10x200


3 x hexagonal nut with M10 flange (part no. Z341510)

1 x M10 adapter plate (part no. Z3310003)

1 x rubber seal (part no. Z3200001)

Also available OPTIONALLY as a pre-assembled set:

1 x hanger bolt set M10x200 (part no. Z340010200S)

Hanger bolt M12x300Hanger bolt M12x300Hanger bolt M12x300Hanger bolt M12x300 Part no.:Part no.:Part no.:Part no.: Z340012300Z340012300Z340012300Z340012300






1 x rubber seal (part no. Z3200001)

Also available OPTIONALLY as a pre-assembled set:

1 x hanger bolt set M12x300 (part no. Z340012300S)

44


Solar fastenersSolar fastenersSolar fastenersSolar fasteners

Solar faSolar faSolar faSolar fastener / steelstener / steelstener / steelstener / steel Part no.:Part no.:Part no.:Part no.: On requestOn requestOn requestOn request

For attachment to the supporting steel substructure.

Stainless steel 1.4301, Ø 8.0 x L mm

Setscrew: M10 x 50 mm

Already with nuts and EPDM seal

With general building regulation approval



Solar fastener / woodSolar fastener / woodSolar fastener / woodSolar fastener / wood Part no.:Part no.:Part no.:Part no.: On requestOn requestOn requestOn request


Stainless steel 1.4301, Ø 8.0 x L mm

Setscrew: M10 x 50 mm

Already with nuts and EPDM seal

With general building regulation approval



M10 adapter plateM10 adapter plateM10 adapter plateM10 adapter plate Part no.:Part no.:Part no.:Part no.: Z3310003Z3310003Z3310003Z3310003

For attachment of mounting rails on hanger bolt / solar fastener.

Stainless steel 1.4301, size 30 x 80 mm

Round hole: Ø 11 mm

Long hole: 11 x 40 mm

M12 adapter plateM12 adapter plateM12 adapter plateM12 adapter plate Part no.:Part no.:Part no.:Part no.: Z3310004Z3310004Z3310004Z3310004

For attachment of mounting rails on hanger bolt / solar fastener.

Stainless steel 1.4301, size 30 x 80 mm

Round hole: Ø 13 mm

Long hole: 11 x 40 mm

45


Clamp holdersClamp holdersClamp holdersClamp holders

Standing seam clampStanding seam clampStanding seam clampStanding seam clamp ParParParPart no.:t no.:t no.:t no.: Z3330001Z3330001Z3330001Z3330001

For attachment on standing seam roofs.

Aluminium, length 110 mm

Fixed with 2 round-head screws M 8x35 mm

Two long holes: 9x25 mm and 11x25 mm

Rounded seam clampRounded seam clampRounded seam clampRounded seam clamp Part no.:Part no.:Part no.:Part no.: Z3330002Z3330002Z3330002Z3330002

For attachment on round-head profile roofs (Kalzip, BEMO, etc.).




Seam clamp 465/480Seam clamp 465/480Seam clamp 465/480Seam clamp 465/480 Part no.:Part no.:Part no.:Part no.: Z3330003Z3330003Z3330003Z3330003

For attachment on clamped seam profile roofs (RibRoof 465/480,

Domico).




Seam clamp 500Seam clamp 500Seam clamp 500Seam clamp 500 Part no.:Part no.:Part no.:Part no.: Z3330004Z3330004Z3330004Z3330004

For attachment on clamped seam profile roofs (RibRoof 500).




Girder claw Kalzip©Girder claw Kalzip©Girder claw Kalzip©Girder claw Kalzip© Part no.:Part no.:Part no.:Part no.: Z3330008Z3330008Z3330008Z3330008

For attachment on Kalzip profile roofs.


Attachment screw M 6

One round hole: d = 11 mm

46


TopTopTopTop----TSTSTSTS

Base support 1Base support 1Base support 1Base support 1 Part no.:Part no.:Part no.:Part no.: Z3340013Z3340013Z3340013Z3340013

For elevated mounting of framed solar modules.

Aluminium EN AW6063

Fixed with hammer-headed bolt and flanged hexagonal nut

Also available as pre-assembled set:

1 x pre-assembled base support 1 (type no. Z3340020)

Base support 2Base support 2Base support 2Base support 2----1111 Part no.:Part no.:Part no.:Part no.: Z3340014Z3340014Z3340014Z3340014


Aluminium EN AW6063

Fixed with hammer-headed bolt and flanged hexagonal nut



Base support 2Base support 2Base support 2Base support 2----2222 Part no.:Part no.:Part no.:Part no.: Z3340015Z3340015Z3340015Z3340015


Aluminium EN AW6063

Screwed joint with base support 2-1 (see part no. Z3340014)



TopTopTopTop----TS module clampTS module clampTS module clampTS module clamp Part no.:Part no.:Part no.:Part no.: Z3340016Z3340016Z3340016Z3340016

For attaching framed solar modules.

Aluminium EN AW6063

Frame height from 35 - 50 mm


1 x M8 Allen key bolt (part no. Z34118xx)

47


Bolts and accessoriesBolts and accessoriesBolts and accessoriesBolts and accessories

Hammerhead bolt M10x20Hammerhead bolt M10x20Hammerhead bolt M10x20Hammerhead bolt M10x20 Part no.:Part no.:Part no.:Part no.: Z34131020Z34131020Z34131020Z34131020

Hammerhead bolt M10x25Hammerhead bolt M10x25Hammerhead bolt M10x25Hammerhead bolt M10x25 ParParParPart no.:t no.:t no.:t no.: Z34131025Z34131025Z34131025Z34131025




Hammerhead nut M8Hammerhead nut M8Hammerhead nut M8Hammerhead nut M8 Part no.:Part no.:Part no.:Part no.: Z34149Z34149Z34149Z34149

Stainless steel 1.4301, size M8

With Clemm-Loc thread lock

Hexagon nut with M10 flangeHexagon nut with M10 flangeHexagon nut with M10 flangeHexagon nut with M10 flange Part no.:Part no.:Part no.:Part no.: Z341510Z341510Z341510Z341510


To DIN EN 1661 (DIN 6923)

Hexagon nut with M12 flangeHexagon nut with M12 flangeHexagon nut with M12 flangeHexagon nut with M12 flange Part no.:Part no.:Part no.:Part no.: Z3415112Z3415112Z3415112Z3415112


To DIN EN 1661 (DIN 6923)

Thrust washerThrust washerThrust washerThrust washer Part no.:Part no.:Part no.:Part no.: Z34188Z34188Z34188Z34188

Stainless steel A4, size Ø 8.2 mm

For high-strength joints with normal contact surface

48


Wheel head wood screwWheel head wood screwWheel head wood screwWheel head wood screw Part no.:Part no.:Part no.:Part no.: See Page 16See Page 16See Page 16See Page 16

Stainless steel 1.4301, size Ø 8 mm

With wheel head d=19mm

Drive AW40 / TX40

With building regulation approval

Drilling screw 6.3Drilling screw 6.3Drilling screw 6.3Drilling screw 6.3x25x25x25x25 Part no.:Part no.:Part no.:Part no.: Z34056325Z34056325Z34056325Z34056325

Stainless steel 1.4301, with sealing washer Ø 16 mm


Blind rivet 4.8x15Blind rivet 4.8x15Blind rivet 4.8x15Blind rivet 4.8x15 Part no.:Part no.:Part no.:Part no.: Z3430001Z3430001Z3430001Z3430001

Sleeve: Aluminium, pin tap: Stainless steel

With under-head seal


Allen screwAllen screwAllen screwAllen screw Part no.:Part no.:Part no.:Part no.: See Page 36See Page 36See Page 36See Page 36

Stainless steel 1.4301, size M8, 5 AF

With cylinder head to DIN 7984

Allen screwAllen screwAllen screwAllen screw Part no.:Part no.:Part no.:Part no.: See Page 36See Page 36See Page 36See Page 36

Stainless steel 1.4301, size M8, 5 AF

With countersunk head to DIN EN ISO 10642 (DIN 7991)

Hexagon bolt with flangeHexagon bolt with flangeHexagon bolt with flangeHexagon bolt with flange Part no.:Part no.:Part no.:Part no.: Z34291030Z34291030Z34291030Z34291030


With flange to DIN EN ISO 1665 (DIN 6921)

49

4 – System statics

4 4 4 4 –––– System staticsSystem staticsSystem staticsSystem statics

The basis for planning and sizing the mounting system is a static type calculation with

tabular summaries of the sizing parameters, from which the constructive installation for the

specific case is carried out.

For the complex task of planning and static sizing of the mounting system, a high degree of

expert knowledge is necessary, for which a structural engineer must be brought in on a

case-by-case basis. Since an individual static calculation would, for small systems, put the

cost-effectiveness of the project into question, we have designed a type calculation in

cooperation with expert planners from the building industry and had it tested by the LGA®

Public Law Corporation Bavaria (Bavarian State Trade Agency). This allows sizing of the

supporting profiles (mounting rails) and connections on the substructure and meets the

demands of the specific structural conditions on site.

For many building projects, especially in the public sector, static calculations for mounting

solar modules are required in individual cases. With the static type calculation from LGA®

Public Law Corporation Bavaria, the building authority is released from its obligation to

examine the calculation once again. This way there is no complex, project-related static

calculation, thereby saving valuable time and financial resources. It does not, however,

release one from the structural-related examination of structural analyses and drawings for

adjacent structural members.

NoteNoteNoteNote!!!! The static type test does not release the constructor from the obligation to obtain a construction permit for each project, as long as the respective building regulations or other legal directives do not basically free him of this obligation.

Static calculations for special applications outside of the type calculation can be performed

on request.

Technical regulations and standardsTechnical regulations and standardsTechnical regulations and standardsTechnical regulations and standards

Our products and the type calculation are based upon valid standards and technical

regulations and therefore comply with recognized rules of technology. This applies to the

selection of materials and for the static type calculation and construction design.

Tab. 21: Technical regulations for materials


DIN EN 485-2 2007-07 Aluminium and aluminium alloys – strips, sheets and plates

Part 2: Mechanical properties

DIN EN 573-3 2007-11 Aluminium and aluminium alloys – chemical composition and

form of semi-finished products

Part 3: Chemical composition and product forms

DIN EN 15088 2006-03 Aluminium and aluminium alloys – products for structural

applications

Technical shipping conditions

DIN EN 10088-1 2005-09 Non-rusting steels

Part 1: Register of non-rusting steels

50


Tab. 21: Technical regulations for materials - continued



Part 2: Technical shipping conditions


Part 3: Technical shipping conditions

Tab. 22: Technical rules and regulations for nuts and bolts


DIN EN ISO 4762 2004-06 Allen head screws with cylindrical head

DIN EN ISO 10642 2004-06 Allen head countersunk screws

DIN EN 1661 1998-02 Hexagon nut with flange

DIN EN 1665 1998-02 Hexagon bolts with flange

DIN 571 1986-12 Hexagon wood screws

Tab. 23: Technical rules and regulations for sizing and constructive implementation


DIN 1055-1 2002-06 Effects on building structures

Part 1: Weighting and surface loads of building structures


Part 3: Dead-weight and payload for building construction


Part 4: Wind loads + report version 2006-03


Part 5: Snow and ice loads


Part 100: Fundamentals of building structure planning – safety

concept and dimensioning rules

DIN 4113-1 1980-05 Aluminium structures primarily under static load

Part 1: Calculation and construction design

DIN 4113-1/A1 2002-09 Aluminium structures primarily under static load

Part 1: Calculation and construction design; modification A1

DIN 18800-1 1990-11 Steel structures

Part 1: Dimensioning and construction

DIN 18800-2 1990-11 Steel structures

Part 2: Bending bars and bar construction

51


Solar modulesSolar modulesSolar modulesSolar modules

In standards IEC 61215 and IEC 61646 are specifications for an allowed surface load of

2400 Pa (corresponds to 2.40 kN/m² or approx. 240 kg/m²). During a test of the solar

modules, an optional greater test load of 5400 Pa is permitted if it is determined that the

solar module can withstand higher snow and wind loads. This increased test load is not

mandatory however.

Our static type calculation was performed with a threshold of 5400 Pa and so covers all

currently valid applications for solar modules having a valid certificate.

NoteNoteNoteNote!!!! Only solar modules with the following certificates may be used: IEC 61215 or IEC 61646 Protection Class II / IEC 61730

Tab. 24: Technical regulations for solar modules


DIN EN 61215

(IEC 61215:2005)

2006-02 Terrestrial crystalline silicon photovoltaic (PV) modules

Construction suitability and construction approval

DIN EN 61646

(IEC 61646:2006)

2007-07 Terrestrial thin-film photovoltaic (PV) modules

Construction suitability and construction approval

NoteNoteNoteNote!!!! The maximum test load of the solar modules used (see manufacturer operating instructions) must always be used as the basis for system planning.

52


Load combinations to DIN 1055Load combinations to DIN 1055Load combinations to DIN 1055Load combinations to DIN 1055----100100100100

The effects of photovoltaic systems on supporting building structures must be determined in

accordance with the relevant technical regulations of the building industry. Since 1 January

2007, the load effects to DIN 1055 Parts 1-5 must be included in the safety concept to DIN

1055-100. Because valuable and sensitive solar modules are installed outside a protective

building and exposed to the elements, integration of loads from wind and snow are vital in

planning a photovoltaic system.

Our mounting system has been designed for a very broad range of applications. The system

can be used in all wind and snow load zones up to elevations of 1000m above sea level.

Tab. 25: Permitted snow and wind load zone combinations for GehrTec© Top

Snow load zone Snow load zone Snow load zone Snow load zone

SLZSLZSLZSLZ

Wind zone Wind zone Wind zone Wind zone

WZWZWZWZ Max. elevationMax. elevationMax. elevationMax. elevation

1 1 or 2 To 765 m above sea level

1 3 To 400 m above sea level

1a 1 or 2 To 765 m above sea level

2 1 or 2 To 1,000 m above sea level


2a 1 or 2 To 1,000 m above sea level

3 1 or 2 To 1,000 m above sea level


Listed in Table 25 are all permitted load combinations to DIN 1055 investigated in our static

calculation and approved for installation parallel to the roof.

Tab. 26: Permitted snow and wind load zone combinations for GehrTec© Top-TS

Snow load zone Snow load zone Snow load zone Snow load zone

SLZSLZSLZSLZ

Wind zone Wind zone Wind zone Wind zone

WZWZWZWZ Max. elevationMax. elevationMax. elevationMax. elevation

1 1 to 3 To 1,000 m above sea level

1a 1 or 2 To 1,000 m above sea level

2 1 to 3 To 770 m above sea level

2a 1 or 2 To 600 m above sea level

3 1 to 3 To 590 m above sea level

Listed in Table 26 are all permitted load combinations to DIN 1055 investigated in our static

calculation and approved for the Top-TS system.

Dead loads to DIN 1055Dead loads to DIN 1055Dead loads to DIN 1055Dead loads to DIN 1055----1111

Because accurate inclusion of bolts and small parts would normally be associated with

unreasonable overhead, they are usually neglected. Please refer to the manufacturer data

sheets for the dead loads of solar modules. The dead loads to be applied are between

g=0.12–0.20 kN/m² depending on element used. Assumed in our static calculations is a dead

load of solar power system and supporting structure of g=0.20 kN/m².

53


Snow load zones to DIN 1055Snow load zones to DIN 1055Snow load zones to DIN 1055Snow load zones to DIN 1055----5555

DIN 1055 Part 5 applies for determining the snow loads to be applied. In the general

method, the snow load zone (SLZ) for the location of the photovoltaic system is taken from

the snow load zone map of the Federal Republic of Germany (Fig. 56). The elevation above

sea level is also required in addition to the snow load zone.

Fig. 56: Snow load zone map to DIN 1055 Part 5

54


Wind zones to DIN 1055Wind zones to DIN 1055Wind zones to DIN 1055Wind zones to DIN 1055----4444

DIN 1055 Part 4 applies for determining the wind loads to be applied. The wind zone (WZ)

for the location of the photovoltaic system must be taken from the wind zone map for the

Federal Republic of Germany (Fig. 57).

Fig. 57: Wind zone map to DIN 1055 Part 4

Wind zones are valid for domestic installation under normal conditions and classification by

wind zone and building height. Stronger winds can be expected near the coast and in

exposed areas (summits and plains).

If in any doubt, calling in a planning expert is recommended.

55

DisclaimerDisclaimerDisclaimerDisclaimer

General Terms and Conditions of Gehrlicher Solar AG apply.

The content of these instructions are subject to continual revision and are amended as

required from time to time. Discrepancies may nevertheless occur. We provide no guarantee

for completeness. The most up-to-date version is available in the Internet from our website

at www.gehrlicher.com and through the usual sales channels.

Because Gehrlicher Solar AG has no control over the conditions and methods used for

installation and mounting, or the use and maintenance of photovoltaic components,

Gehrlicher Solar AG explicitly disclaims liability for losses, damages and costs arising as a

result of unprofessional mounting, installation, initial use, usage and maintenance.

Guarantee and liability claims in the event of damage of any kind are excluded if

attributable to one or more of the following causes:

o Transportation damage

o Improper use of the product or non-intended use of the product

o Use of the product in a non-intended environment

o Use of the product whilst failing to comply with relevant legal safety regulations at the

place of installation

o Failure to comply with warning and safety instructions in all documents relevant to the

product

o Use of the product in deficient safety and protective conditions

o Modifications to, or repair of, the product or the software also supplied

o Malfunction of the product due to the effects of connected or adjacent equipment that

are not within legal thresholds

o Emergencies and force majeure

Warranty conditionsWarranty conditionsWarranty conditionsWarranty conditions

The most up-to-date warranty conditions can be downloaded from our website at

(www.gehrlicher.com) and are available in paper form from the usual sales channels.

Should relevant damages occur within the warranty period, please contact the complaints

department at Gehrlicher Solar: [email protected]

56

CCCContactontactontactontact

Munich Munich Munich Munich OOOOffice (ffice (ffice (ffice (AAAAdministration)dministration)dministration)dministration)

Gehrlicher Solar AG

Max-Planck-Str. 3

D–85609 Dornach / Munich

Tel +49 89 420792 – 0

Fax +49 89 420792 – 8540

[email protected]

CCCCoburg oburg oburg oburg OfficeOfficeOfficeOffice ((((HeadquartersHeadquartersHeadquartersHeadquarters))))

Gehrlicher Solar AG

Austraße 101b

D–96465 Neustadt n. Coburg

Tel +49 9568 / 896609 – 0

Fax +49 9568 / 896609 – 999

[email protected]

Board of Directors: Klaus Gehrlicher (CEO)

Chairman of Supervisory Board: Christoph Nadler

Registered office: Neustadt n. Coburg

HR Coburg Dept. B no. 4377, VAT no. DE 202 435 014

www.gehrlicher.com

57

List of tablesList of tablesList of tablesList of tables

Tab. 1: Safety and information symbols ............................................................................................................................. 5

Tab. 2: Risks and measures ......................................................................................................................................................... 6

Tab. 3: Technical rules and regulations for lightning and overvoltage protection............................... 9

Tab. 4: Tools ......................................................................................................................................................................................... 11

Tab. 5: Additions for the individual clamp types ........................................................................................................ 14

Tab. 6: Minimum distances from roof edge ................................................................................................................... 14

Tab. 7: Maximum overall length of mounting rails connected together .................................................... 15

Tab. 8: Overview of wood screws with wheel head .................................................................................................. 17

Tab. 9: Overview of hanger bolts ........................................................................................................................................... 19

Tab. 10: Pre-drilling diameter in mm for profiled tiles and substructure ................................................. 21

Tab. 11: Overview of type Z solar fasteners for steel substructures .......................................................... 22

Tab. 12: Overview of type A solar fasteners for timber substructures ...................................................... 22

Tab. 13: Overview of fastening elements ......................................................................................................................... 23

Tab. 14: Overview of distances in relation to module width ............................................................................. 29

Tab. 15: Overview of the bolts for the Top-TS module clamp (part no. Z3340016) ....................... 31

Tab. 16: Components required to attach a solar module ................................................................................... 31

Tab. 17: Overview of the different clamp holders ..................................................................................................... 32

Tab. 18: Overview of hammerhead nuts and bolts ................................................................................................... 34

Tab. 19: Overview of the bolts for module centre clamp 1 (part no. Z3120001) ............................. 36

Tab. 20: Overview of the bolts for module centre clamp 2 (part no. Z3120010) ............................. 36

Tab. 21: Technical regulations for materials.................................................................................................................. 49

Tab. 22: Technical rules and regulations for nuts and bolts ............................................................................ 50

Tab. 23: Technical rules and regulations for sizing and constructive implementation ................... 50

Tab. 24: Technical regulations for solar modules ..................................................................................................... 51

Tab. 25: Permitted snow and wind load zone combinations for GehrTec© Top ................................ 52

Tab. 26: Permitted snow and wind load zone combinations for GehrTec© Top-TS ........................ 52

58

Revision listRevision listRevision listRevision list

Document: 90320051

RevisionRevisionRevisionRevision DateDateDateDate ChangeChangeChangeChange PagePagePagePage

R1.0 12.08.2009 Initial release All

R1.1 26.07.2010 Application aligned

Attachment bolts for roof hook mounting

Drill hole diameter changed

45 mm module end clamp added

Table of contents added

10

16

23

32

48

R1.2 06.08.2010 System part images aligned 38

R1.3 14.02.2011 GehrTec© Top-TS 24ff

R1.4 28.09.2011 Specific information, item numbers updated

Trapezoidal sheet mounting, Top-TS installation

Logo change

All

59

NotesNotesNotesNotes

60

PublisherPublisherPublisherPublisher

Gehrlicher Solar AG

Max-Planck-Str. 3

D-85609 Dornach / Munich

Editing, desEditing, desEditing, desEditing, design and coordinationign and coordinationign and coordinationign and coordination

Andreas Freyer

IllustrationsIllustrationsIllustrationsIllustrations

Leonhard Büttner Graphic Design

Munich

Documents

UserManual gehrtec TOP vs-1-4-en - gehrlicher.comgehrlicher.com/fileadmin/content/pdfs/GehrTec/usermanual-GehrTec-TOP-EN.pdf · protection and roof protection walls as anti-fall protection