ESDEC EVO ClickFit Solar Panel Mounting Systems Instruction Manual

**ESDEC EVO ClickFit Solar Panel Mounting Systems Instruction Manual

**

INTRODUCTION

ABOUT THIS DOCUMENT
In this manual you will find the installation instructions for the ClickFit EVO mounting system for solar panels on pitched standing seam roofs.
The system is suitable for mounting solar panels in portrait and landscape orientation.
These instructions are addressed at qualified technical personnel.
You can download the latest version of this manual from www.esdec.com.

OTHER RELEVANT DOCUMENTS
When installing the ClickFit EVO mounting system, you will need the following documents:

• The project plan, which you can create in the calculator at https://www.esdec.com/en/calculator.
• The installation manuals for the solar panels, inverters and any other components.

During the installation of the mounting system, it is important to adhere to the installation manual, the installation manual of the components, and the accompanying standards to prevent accidents. Pay special attention to (local) standards, regulations and legislation (among others):

EARTHING AND BONDING
Our ClickFit EVO systems are VDE certified for corrosion and bonding. According to the electrical standard HD-IEC 60364 – chapter 712, functional bonding for inverter’s isolation check is necessary.
In the Esdec ClickFit EVO Series functional bonding is achieved through the EVO universal module clamp for the module frames and EVO rails. The final functional bonding connection is made by proper mounting of a separate bonding cable onto the EVO rail and an adequate bonding connection with the inverter or earthing contact.
For detailed instructions on grounding and bonding, consult the electrical standard HD-IEC 60364 and any local regulations.
Please, follow the instructions of the inverter’s manual. This operation needs to be done by a certified electrician.

SYMBOLS USED IN THIS MANUAL

Warning!
Failure to follow this instruction could result in serious injury or major damage to the product.

Caution!
Failure to follow this instruction could result in personal injury or damage to the product.

Note
Emphasises an instruction.

WARRANTY AND LIABILITY

WARRANTY
Esdec extends a 20 year product warranty. The warranty is subject to the warranty terms and general terms & conditions of Esdec BV. These can be found on the www.esdec.com website.

LIABILITY
The manufacturer accepts no liability for damage or injury caused by the failure to comply (strictly) with the safety guidelines and instructions in this manual, or by negligence during installation of the product and the accessories listed in this document.
Esdec BV reserves the right to change this document without notice.

PRODUCT INFORMATION

INTENDED USE
The ClickFit EVO mounting system is designed for mounting solar panels on pitched standing seam roofs. With this mounting system, solar panels can be positioned on the roof either with the short side at the bottom (portrait) or with the long side at the bottom (landscape).

IMPROPER USE
The mounting system is not suitable for use on types of roof other than the one specified.

COMPATIBLE SOLAR PANEL FLANGE DIMENSIONS
The universal module clamp is suitable for solar panels with a frame height between 29-50mm and a frame width of at least 12mm, where a sufficient clamping force can be applied.
Check the documentation of the solar panel supplier if the intended solar panel can withstand the loads and clamping force.

SPECIFICATIONS

15m per segment
Rail protrusion range| 90-350mm
Roof type| Pitched roof with seams, except copper roofs

Roof pitch

| 5-60°
At an inclination angle of <10º, the self-cleaning effect of the panel is affected.
Maximum roof height|  Subject to Eurocode guidelines and national additions. Use the calculator to calculate the possibilities of your project.
Edge zone| 30cm distance to the ridge, 30cm to the side of the roof and 30 cm to the gutter.

1. Ensure that the module frame is compatible with the ClickFit EVO clamps before installation.
2. Always consider the right measures related to fire spread and compartmentalization. This might influence the modules segment size.

 Enter the data in the calculator, so you are sure of choosing the right system for the terrain category, snow loads and wind zone that applies to your project.
 Depending on the roof and the result obtained from the calculator, you can lay several segments with solar panels next to each other. Always leave a minimum of 12mm of space between segments to allow for expansion of the roof.
 If your project has different specifications than these, please contact Esdec.

SYSTEM AND APPLICATION

COMPONENTS

Check that the correct components are present in the required numbers according to the project plan generated by the calculator.

APPLICATION

SEAM CLAMP

|

|

|

---|---|---|---
Article number| 1008035| 1008033| 1008031
Suitable for| Single-folded standing seam roof Snap seam roof| Double-folded standing seam roof| Round standing seam roof
Seam opening| 14mm| 9mm| ø23mm
|

Fixing| Directly on the seam
|

Click connection| Rotatable for horizontal and vertical mounting of rails

Use the calculator to determine the correct rail orientation for your project. The calculator takes into account, for example, the type of roof covering and the structure supporting the roof.

HORIZONTAL RAIL ORIENTATION

VERTICAL RAIL ORIENTATION

Mounting solar panels in portrait orientation in combination with vertical rail orientation is not recommended. This mounting method is also not supported by the calculator.

SAFETY

PERSONAL PROTECTIVE EQUIPMENT

SAFETY WARNINGS AND REGULATIONS

Warning!

Installation work should always be carried out by at least two skilled people.
 Do not use components from other mounting systems.
 Do not leave out parts.
 Always work according to the current regulations for working on roofs.
 Do not perform the installation in strong winds, or when the roof is slippery or wet.
 Always work on the roof with fall protection and, if necessary, with safety nets and edge protection.
 Never stand on or in the gutter.
 Make sure that an aerial platform or ladder does not rest on the seams.
 Always use a lifting aid or hoisting device when moving heavy equipment.
 Always place ladders on a strong, stable surface.

Caution!

 Walk as little as possible on the roof. Use an aerial platform, ladder or other solution.
 Never walk on the system or on the solar panels.

INSTALLATION

PREPARATION

INSPECT THE ROOF

• The roof is in good condition.
• The roof construction has sufficient bearing capacity to support the installation, taking into account wind and snow loads.

CHECK THE PROJECT PLAN AND COMPONENTS.

• Check the project plan. Is there no project plan? Then create one in the online calculator before starting installation.
• Check that all components are present (page 5).

MAKE SURE ALL THE REQUIRED TOOLS ARE AT HAND.

TIGHTENING TORQUES

Always use a torque wrench. Make sure that the bit is correctly and completely inserted in the screw head when tightening, in view of the high tightening torque.

Tightening torque for steel standing seam roofs with material thickness > 0.7mm| 18-20 Nm
ClickFit EVO MLPE Clip Heavy Weight| 8-12 Nm

CLEAN THE ROOF SEAMS

DETERMINE THE POSITION OF THE SOLAR PANELS ON THE ROOF

Consider the (local) fire regulations for photovoltaic installations. To mitigate the risk of fire spread, the fire compartments of the object must be respected. The PV system should not be placed over fire partition walls and a minimum distance of 30 cm must be kept. Likewise, it is wise to keep space in relation to skylights, lighting globes, corners and potential fire hazards.
 Develop a project plan using the ESDEC calculator and adhere to its guidelines. Access the calculator at calculator.
eu.esdec.com.
 The distance from the edge of solar panels to both the ridge and the gutter must be at least 30cm.
 The distance from the solar panels to the side of the roof must be at least 30cm.
 Take into account sunlight and shade over the whole year. If necessary, use a power optimizer or micro inverter to get the most out of your installation.

DRAW THE LINES AND END POINTS FOR THE MOUNTING RAILS

 Consult the project plan to determine the position of the mounting rails for your panel.
 For pitched roofs, we recommend a horizontal mounting. This is more durable and often creates a neater finish.
 Rail lengths can be found in the project plan.
For mounting in landscape orientation, the mounting rails should be placed at around ¼ of the short sides of the panel.
For mounting in portrait orientation, the mounting rails should be placed at around ¼ of the long sides of the panel.

MARK THE POSITION OF THE SEAM CLAMPS

If you can see the position of the standing seam clips, mount the seam clamps at least 50mm away.
 Consult the project plan to determine the position of the seam clamps for your project.

PREPARING AND SIZING MOUNTING RAILS

1. CONSULT THE PROJECT PLAN FOR THE OVERALL LAYOUT OF THE SOLAR PANEL SEGMENTS.
2. CALCULATE THE FULL LENGTH OF THE SOLAR PANEL LAYOUT, ACCOUNTING FOR GAPS AND/OR SPACING.
3. CALCULATE THE NECESSARY MOUNTING RAIL EXTENSIONS AND ADJUSTMENTS

Measure the solar panels and add 12mm between each solar panel for the universal module clamp (20mm for the ClickFit EVO 60mm clamp). Add 20-35mm on each side for mounting the end clamp and end cap (50 70mm for the ClickFit EVO 60mm clamp).

USE COUPLERS TO CONNECT THE MOUNTING RAILS, IF NECESSARY

IF THE OVERHANG IS GREATER THAN 250MM: EXTEND THE MOUNTING RAIL TO THE NEXT FLANGE.

CUT THE MOUNTING RAILS TO SIZE.

a. If the calculated overhang of the solar panel is more than 250mm beyond the marked position of the last flange clamp, mark the position of an extra flange clamp on the nearest flange. Extend the mounting rail to 50mm beyond the extra flange clamp.

The additional 50 mm extension allows for proper fitting of an end cap (art. no. 1008066(-B)) to the mounting rails.

b. If the calculated overhang is less than 250mm beyond the marked position of the last seam clamp, keep 20-35mm rail length overhang for mounting the end cap (art. no. ) (>40mm for the ClickFit EVO 60mm clamp).

FIXING THE SEAM CLAMPS

PLACE THE CLAMP ON THE SEAM

TIGHTEN THE SCREW

ROTATE THE CLICK CONNECTION INTO THE CORRECT ORIENTATION

ATTACHING THE MOUNTING RAILS

PLACE THE MOUNTING RAIL INTO THE CLICK CONNECTION AND ALIGN THEM

CLICK IN THE MOUNTING RAILS

FOR VERTICAL MOUNTING: SECURE THE MOUNTING RAILS TO THE CLICK CONNECTIONS

 First secure the bottom click connection with a self-drilling screw. Skip two click connections and then screw down the fourth click connection. Repeat until the top click connection.

OPTIONAL: ATTACHING THE MLPE CLIPS

CLICKFIT EVO MLPE CLIP LIGHT WEIGHT

1. CLICK THE LIGHT WEIGHT MLPE CLIP ONTO THE RAIL
2. CLICK THE OPTIMISER ON THE LIGHT WEIGHT MLPE CLIP

Use one MLPE clip per solar panel.

With vertical rail orientation you have to fix the MLPE clip by bending the edge of the mounting rail with adjustable pliers.

CLICKFIT EVO MLPE CLIP HEAVY WEIGHT

1. ATTACH THE OPTIMISER TO THE HEAVY WEIGHT MLPE CLIP
2. CLICK THE HEAVY WEIGHT MLPE CLIP ONTO THE RAIL

 For larger optimizers (equipped with 2 slots), it is essential to use two Heavy Weight MLPE clips.
With vertical rail orientation you have to fix the cable clip by bending the edge of the mounting rail with adjustable pliers.

MOUNTING THE FIRST PANEL

1. OPTIONAL: CLICK THE AUXILIARY SET ON THE PANEL

2. OPTIONAL: CLICK THE CABLES OF THE PANEL FIRMLY INTO THE CABLE CLAMP.

3. CLICK THE UNIVERSAL MODULE CLAMP ON THE RAILS.

4. SLIDE THE END CAPS ONTO THE RAILS.

5. ROTATE THE UPPER PART OF THE MODULE CLAMP OVER THE END CAP.

6. OPTIONAL: GUIDE THE CABLES OF THE SOLAR PANEL THROUGH THE CLICK CONNECTIONS.

7. PLACE THE PANEL ON THE RAILS.

8. SLIDE THE PANEL AGAINST THE CLAMPS.

9. SCREW THE CLAMPS ONTO THE PANEL. APPLY A TORQUE OF 4.5 NM.

10. CLICK THE UNIVERSAL MODULE CLAMP ON THE RAILS.
     Install the module clamp with the drainage channel of the module clamp pointing downwards.

MOUNTING THE FOLLOWING PANELS
Optional: Repeat steps 1.1. and 1.2.: Click the Auxiliary set on the panel and Click the cables of the panel firmly into the cable clamp.
Repeat step 1.7. Place the panel on the rails.

11. SLIDE THE PANEL AGAINST THE CLAMPS

12. SCREW THE CLAMPS ONTO THE PANEL. APPLY A TORQUE OF 4.5 NM.

MOUNTING THE LAST PANEL

• Optional: Repeat steps 1.1. and 1.2.: Click the Auxiliary set on the panel and Click the cables of the panel firmly into the cable clamp.
• Repeat step 2.7. Place the panel on the rails.
• Repeat step 2.11. Slide the panel against the clamps.

1. OPTIONAL: SAW THE MOUNTING RAILS TO SIZE
    If the overhang is smaller than 250 mm, keep a minimum of 20 mm to a maximum of 35 mm rail length overhang for mounting the end cap (art. no.1008060(-B)).
    If the outer panel edge is more than 250 mm outside the first/last seam, extend the mounting rail to 50 mm beyond the previous/next seam and provide a seam clamp here for attachment. The extra 50 mm facilitates sufficient length to accommodate the mounting rails of the end cap (art. no. 1008066(-B)). At the location of the end clamp, you must provide the end clamp support (art. no. 1008065(-B)).

2. CLICK THE UNIVERSAL MODULE CLAMP ON THE RAILS.

3. SLIDE THE END CAPS ONTO THE RAILS.

4. ROTATE THE UPPER PART OF THE MODULE CLAMP OVER THE END CAP.

5. SCREW THE CLAMPS ONTO THE PANEL. APPLY A TORQUE OF 4.5 NM.

MOUNTING MULTIPLE ROWS

1. MOUNT EACH NEXT ROW AGAINST THE PREVIOUS ROW
   Always keep a minimum of 12 mm between each row of panels in the case of horizontal rails, or each panel column in the case of vertical rails.
   Always follow the project plan from the calculator.

REMOVAL AND RECYCLING

GENERAL

Always follow local laws and regulations when dismantling the mounting system and disposing of it.

Esdec
Londenstraat 16
7418 EE Deventer
The Netherlands

+31 850 702 000
[email protected]

www.esdec.com

References

• Esdec - Building value for solar professionals
• Esdec - Building value for solar professionals
• Calculator - Esdec

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