Samontec Solar

Technical manual for steel structure for photovoltaics on flat roofs/ free fields

1. Photovoltaic support systems Samontec Solar

1.1 GENERAL The photovoltaic support system Samontec Solar is made from galvanized steel. The quality of the steel finish has a minimum coating of hot dip galvanization 45 microns. The purlins can be either from aluminium or galvanized steel. All of the steel accessories (bolts, nuts, etc...) are made from stainless steel A2. The system can receive the PV panels in both portrait & landscape configuration with any angle of inclination. It also offers the ability to adjust the height of the construction in order to avoid the shadow effect and to make the necessary adjustments for creating a level construction. Also the system can be used in free fields with a foundation of concrete or with concrete piles. All of the constructions are tested and can be approved for static loads by the engineers of the company.

2. Assembly of support system

The support system are customized for the individual needs of each building and are capable of making the adjustments necessary for a proper installation. The number of supports and the distance between the supports is dependant upon the requirements of each project (number of panels, inclination) and the required load combinations of the specific location.

2.1 INSTALLING THE FIRST SUPPORT Depending on the requirements of the project the support bracket can be either mounted directly to the ground or elevated by using a small front leg.

For mounting directly to the ground use the variable angle bracket (517201) which is anchored to the cement with the appropriate anchor bolt (depending on the project Fischer has the appropriate anchor bolt). Then the connector (517202) is attached to the angle bracket (517201) with a bolt (517158) and fastened with the washer (517206) and nut (517205).

517202 517205

517206

517201

517158

For mounting with an elevated front leg, choose the appropriate leg (517411/ 517412/ 517413/ 517414) which will be anchored to the cement with the appropriate anchor bolt (depending on the project Fischer has the appropriate anchor bolt). Then the connector sleeve (517202) is fastened to the leg with a bolt (517757) to the threaded holes in the connector sleeve (517202). Finally the variable angle bracket (517201) is fastened to the connector sleeve (517202) with a through bolt (517158) and fastened with a washer (517206) and nut (517205).

517205 517206 517202 517201 517206

517757

517158 Anchor bolt

517411 517412 517413 517414

2.2 INSTALLING ADDITIONAL SUPPORTS If the dimensioning of the project allows, you can use the following pre-manufactured legs (517411/ 517412/ 517413/ 517414) which are anchored to the cement with the appropriate anchor bolt (depending on the project Fischer has the appropriate anchor bolt). Then the connector sleeve (517202) is fastened to the leg with a bolt (517757) to the threaded holes in the connector sleeve (517202). Finally the variable angle bracket (517201) is fastened to the connector sleeve (517202) with a through bolt (517158) and fastened with a washer (517206) and nut (517205).
517158 Anchor bolt 517205 517202 517206 517201 517206

517757

517411 517412 517413 517414

If the pre-manufactured legs can not be used, then use the profile FUS41 (517426) or the FUS62 (517427), and cut it to the desired length. First you anchor the base SFL41 (517421) to the cement with the appropriate anchor bolt (depending on the project Fischer has the appropriate anchor bolt). Then you fasten the profile FUS41 (517426), after cutting it to the correct dimension, to the base SFL41 (517421) by using the connector FCN CLIX P (517420) and fastener bolts (517575). Afterwards, fix the connector (517202) with the profile (517426) with the bolt (517757) using the threaded slot in the connector (517202). Finally, the variable angle bracket (517201) is fastened to the connector sleeve (517202) with a through bolt (517158) and fastened with a washer (517206) and nut (517205). The area that the profile (517426) is cut, must be protected from corrosion. This is done by using the special galvanic spray (509242). Where the nut (517205) and the washer (517206) are used, they can be replaced with the flanged nut (71749).
517575

517201

517205 517158

517575 517206

517202

517206

517420

517426 517427

517421 Anchor bolt

2.3 INSTALLING GIRDER BEAM For the girder beam use the profile FUS62 with 3m length (517427), and cut it to the appropriate dimension. The girder beam is fastened to either the connector sleeve (517202) or the variable angle bracket (517201). For installing the connector sleeve (517202) use two bolts (517757) with the appropriate washers (517206) and pass them through the openings in the girder beam and fasten them to the threaded slots in the connector sleeve (517202). For installing the variable angle bracket (517201), use two bolts (517757) with the appropriate washers (517206) and pass them through the openings in the girder beam and fasten them with a washer (517206) and nut (517205).

Where the nut (517205) and the washer (517206) are used, they can be replaced with the flanged nut (71749). The area that the profiles are cut, must be protected from corrosion. This is done by using the special galvanic spray (509242).
517757 517757

517206 517206 517427 517428

517427 517428

517201 517206 517202 517205

3. Installing and aligning the support structure

The piles are placed in rows and are spaced according to the specifications of the project. Diagonal bracing is also used to reinforce the construction according to the specifications of the project. If needed the girders can be adjusted in order to insure the correct alignment.

3.1 ADJUSTMENTS The adjustments that can be made are the following: The girder beam can be adjusted in length with the fastening bolt (517757).
517757

The variable angle bracket can rotate around 517201 the bolt (517158) changing the angle of the girder beam. The connector sleeve (517202) can be adjusted in height with the fastening bolt (517757).

Girder beam

517158

517757 517202

3.3 TABLE FOR FASTENER TORQUE Drawing Description Bolt 12x20 (517757) Bolt 12x80 (517158) Torque 56 Nm 56 Nm

4. Installing purlins
517757

The purlin is made from the profile FUS41 with a 3m length (517426) or in special cases the profile FUS62 with a length of 3m (517427). The purlin is installed over the girder beam and fastened using the connector nut FCN CLIX P (517420), which is inserted and rotated into the channel groove of the girder beam. Then the bolt (517757) and washer (517206) are inserted through the purlin and fastened to the connector nut FCN CLIX P (517420).

517206 Purlin

517420

517420

4.2.1 PURLIN CONNECTOR When the purlin is used continuously to span over several girders, then a special purlin connector (517203) is used to fasten the two purlins together. The purlin connector is fastened to the under side of the purlin with four allen screws M12x30 (517757) and washers M12 (517206). Safety nuts are not required as the connector has been threaded to directly receive the M12 bolts.

517757

517206

Purlin

517203

5. Installing the panels

The panels are fixed to the purlins with special clamps. There are end clamps that are used to fix the panels at the beginning and the end of a series, and there are middle clamps that are used between two panels. The clamps are available preassembled (with allen screw, spring, plastic grip, hammer-head nut) and are availble for every panel thickness.

The hammer head nut is inserted into the channel of the purlin and turned to lock into the desired position. Then the clamp is fastened into place with the allen screw.

Allen screw
Clamp

Hammer head nut

6. Technical data sheets

1- point load

FUS 41
Height Width Perimeter Ix Iy Wx Wy Area Weight 41 mm 41 mm 281,19 mm 5,33 cm4 7,69 cm4 2,58 cm3 3,75 cm3 L/3 L/2 L

2- point load F L/3 L F

252 mm2 2060 gr/m

2 supports - Uniformly load q

L 3 supports - Uniformly load qL qL

L
F (N) 6500 6000 5500 5000 4500 4000 3500 3000 2500 2000 1500 1000 500 0 0,5 1 1,5 2 2,5 3 3,5 4 4,5 5 5,5 6 L (m)

FUS 41

3-supports 2-supports 1 point load 2 point load

1- point load

FUS 62
Height Width Perimeter Ix Iy Wx Wy Area Weight 62 mm 41 mm 365,19 mm 17,70 cm4 12,90 cm4 5,62 cm3 6,29 cm3 L/3 L/2 L

2- point load F L/3 L F

405 mm2 3270 gr/m

2 supports - Uniformly load q

L 3 supports - Uniformly load qL qL

L
F (N) 10000 9500 9000 8500 8000 7500 7000 6500 6000 5500 5000 4500 4000 3500 3000 2500 2000 1500 1000 500 0 0,5 1 1,5 2 2,5 3 3,5 4 4,5 5 5,5 6 L (m) 1 point load 2 point load 3-supports 2-supports

FUS 62

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7. Accessories
Drawing Code Description Drawing Code Description

517201

VB PV hdg

517420

FCN CLIX P 12 hdg

517202

VB PV hdg

517421

SF L 41 hdg

517203

FUF PV 41 connector hdg Bolt 12x30 A2 hexagon head Nut M12 A2

509242

ZINC Spray 400ml

517204

517158

Bolt M12x80 A2 hexagon head Flange nut MU F M12 A2 Hammer head nut 8 6mm thick Socket screw 12x20 A2

517205

71749

517206

Washer M12 A2

517165

517411

FCA 300 hdg Cantilever Arm

517757

517412

FCA 450 hdg Cantilever Arm

517426

FUS 41/2-3m hdg Channel

517413

FCA 600 hdg Cantilever Arm

517427

FUS 62/2,5-3m hdg Channel.

517414

FCA 750 hdg Cantilever Arm

517428

FUS 62/2,5-6m hdg Channel.

1958, the beginning. 2012, world-wide.

Chemical Fixings

High Performance Steel Anchors

General Fixings

Cavity Fixings

Photovoltaic Mounting Structures

Drills and Bits

Samontec - MEP Installation Fixings

Screws

Foams, Sealants

E.W.I. / ETICS

fischer Hellas Emporiki EPE National Road Athens-Lamia (17th) & 6 Roupel str. GR - 14564 Kifissia, Athens Greece Tel.: +30 210 28 38 167, Fax: +30 210 28 38 169 info@fischer.gr

www.fischer.gr

The contents of this manual are subject to change without prior notice. Fischer Hellas Emporiki EPE is not responsible for typographical errors. PLS012 05/2012

Founded in 1958, the fischer brand is synonymous for safe, innovative and sophisticated technical solutions which set new standards in fixing engineering. The products and applications are unique fixing systems that are invented and produced by fischer. That is the reason that there exist unlimited solutions and a large range of applications, and today is recognised as the leader in the market of fixing systems.