H2300 HELIOS Flat Roof

Typologies for Flat Roof installation

AS-161
TECHNICAL MANUAL

Version:01/2019 www.alumil.com , www.alumilsolar.com

 Assembly Instructions for PV mounting structure

AS161

General characteristics:
- Triple pole system
- 3 Portrait for 72cell panel alignment
- Aluminum mounting system

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 A. MATERIAL LIST

1. Aluminum profiles

BRACKETS AS161
1 EX-8960321000 BRACKET H2132_L=750mm

2 EX-8960321070 BRACKET H2132_L=1075mm

3 EX-8960321200 BRACKET H2132_L=1120mm

4 EX-8960323300 BRACKET H2132_L=1252mm

5 EX-8960321400 BRACKET H2132_L=1400mm

6 EX-8960321510 BRACKET H2132_L=1510mm

Inclined Beam H2190

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 Purling H2216

2. Fasteners & other accessories

- needed for mounting brackets on the ground & with inclined beams

Bracket-Incl. M10 nut with

Hex Bolt M10X80
Beam Connector serration

Hammer Head M8 nut with Concrete Ground

Bolt M8X22 with serration Support Plate
EPDM
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 - needed for mounting purlings on inclined beams

Purling-Incl. Beam Hammer Head M8 nut with

Connector Bolt M8X22 with serration
EPDM

- needed for mounting PV panels on purlings

Allen bolt M8X T-Slot Aluminum Grover M8 Mid clamp End clamp
‘Length’ Nut

*Length depends on the thickness of the PV panel

- needed for mounting cores on purlings

Slice Core for Self-Drilling Screw

H2216

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3. Tooling set

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4. Nut’s torques

Find below a table with the specific torques that should be used for fastening the screws
and nut’s, according to size (i.e. M8 or M10) and aluminum’s finishing (i.e. mill finished or
anodized).

SCREW TIGHTENING TORQUES (MILL FINISHED PROFILES)

M10 M8 M8 Allen
T = 9 - 10Nm (for thin film panels)
T=40-45 Nm T=25 Nm T =12-15 Nm (for poly panels)
SCREW TIGHTENING TORQUES (ANODISED PROFILES)
M10 M8 M8 Allen
T = 9 –11 Nm (for thin film panels)
T=50 Nm T=25-30 Nm T =14–17 Nm (for poly panels)

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 B. ASSEMBLY INSTRUCTIONS

1. Ramming Ground Support Plates on the ground

Ram the Ground Support Plates according to Y1, Y2 dimensions. Distance
between 2 consecutive Ground Support Plates is according to dimension X.

*Dimensions Y1, Y2, X are all depicted in shop drawings of every project, depending on the structural study.

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 2. Mounting Brackets with Ground Support Plates

Connect the Brackets with ground support plates using Hex Bolt M10x80 and M10
nut with serration according to the shop drawing. Do not tighten the screws, just
place the screws and nuts at the appropriate holes, in order first to adjust the
Inclined Beam at the appropriate angle, according to Shop Drawing.

3. Mounting Inclined Beam – Bracket-Incl. Beam Connector

Mount the Bracket-Incl. Beam Connector on the Inclined Beam using Hammer
Head Bolt M8X22 with EPDM and Hex Nut M8 with Serration (2pcs. per connector),
according to Shop Drawing.

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 4. Mounting inclined beam with brackets

- Connect the connectors of the inclined beam with each bracket. Use one bolt
M10x80 and one M10 nut with serration to screw them.
- Check all bolts that are screwed with the right torque.

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 5. Mounting Purlings on Inclined Beam – Purling Connectors

Step 1 : Place the purlins on the inclined beam by using the connectors
8962406000 (H2216).
Screw the connectors on the inclined beam by using M8 screw.

*Dimensions X1, X2, are all depicted in panel’s installation manual

Caution: in case you have to place horizontal beams, whose length is smaller than the span between
two successive triangles, you should avoid placing it in the beginning or at the end of each table.
Instead, you must place it over a triangle, that is not the first or the last in a row.

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6. Connecting Purlings together by using cores

After triangle-bases installation, horizontal beams are placed. In their meeting point,
the connection should be done with the help of the core accessory. Core is used to
connect two identical profiles, while it helps the absorption of thermal expansions due
to temperature changes. The core (total length 300mm) enters by 140mm in the first
horizontal beam and 140mm in the next beam. Make sure to keep a gap of about 1-
2cm at the connection point. The mounting method of core depends on the length of
the table.

Step 1 : Insert the core inside the two consecutive purlings.

Core (Slice)

Step 2 :
Connect each core with the 2 consecutive purlings by using 2 Self-Drilling-Screws
5,5x19mm, one on each purling-side.

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In tables longer than 40m, leave always the core ’’free’’, that means fix it with one
Self-Drilling screw on the purling. The rest of the cores are fixed normally by using
two screws.

Important : The ’’free’’ core must not be located below the panel. In other
words there must not be a panel mounted on two consequtive purlings, which
are connected with a ’’free’’ core. Additionally, the ’’free’’ core must be located at
a distance from the inclined beam no longer than 1/3 of the span of the
triangles. Maximum length of the tables is 60m.

8. Placing the caps on the end of the tables

Place also the yellow plastic cap at the end of the rails:

- 6 pcs. for one side of the table and 6 pcs. for the other side of the table in case of 3 Portrait
alignment.

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 9. Mounting panels on the purlings

i) Materials
Allen bolt M8

Grover M8

End Clamp Mid Clamp

T-Slot
Aluminum
Nut
Use End clamp, Allen bolt M8X ‘Length’, Grover M8 and T-Slot Aluminum Nut to mount the edge
panels on the purlings. For mounting 2 intermediate panels on the purlings, use Mid Clamp, Allen
bolt M8X ‘Length’, Grover M8 and T-Slot Aluminum Nut.

K
DETAIL K
Mid Clamp

End Clamp Allen bolt

M8
End Clamp

Mid Clamp

Grover M8
T-Slot
Aluminum
Nut

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 C) MAINTENANCE

PV mounting structures of Alumil S.A are designed according to the European

Mid(Eurocode
Standards Clamp 1, 3, 9) and they do not need any special core. Additionally,
ALUMIL provides certified aluminium PV mounting structures with toughness
aluminum alloy (Al 6005Τ6).
However, a periodic maintenance of structures is recommended to ensure the high
quality and long duration.
L
During in-situ audit, it is strongly recommended to focus on some points (joints, holes
etc.). Specifically, it is recommended to focus on the following:

* A check of bolted joints (once per year). In case you notice bolt corrosion, it is
strongly recommended to replace them with new ones.
* A periodical check of torque to the bolted joints (1 – 2 years).
* A periodical check of torque on the panel clamps, every 6-9 months or after severe
winds and storms to make sure the installation and the torque settings remain correct.
* Torque is assigned in installation manual.
* A check of aluminum parts for obvious deformations. If it is necessary, please
replace the deformed parts with new ones (once per 2 years).
* In case of short distance from sea level (<150m), you should keep the structures
clean with water (no pressure) to avoid salt corrosion (once per year).
* In case of snowing you must clean the panels in maximum 2 days after the moment
they are fully covered with snow (remove the snow without letting it freeze).

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