INTM Installation Corrugated Eternit Roof

STATICS. STABILITY. SAFETY.
CORRUGATED ETERNIT ROOF

Installation instructions
Manufacturing and distribution: Donauer Solartechnik Vertriebs GmbH. Subject to errors and technical modications.
Version: 02/2009; contact: info@donauer.eu // www.donauer.eu
TOOLS
You require the following tools:
15 mm and 17 mm ring / open-ended wrenches (open-ended spanners)
Electric screwdriver
Screwing tool for hanger bolts or socket wrench (7 mm or 8 mm)
6 mm hexagonal socket wrench (Allen key)
Please read the safety instructions carefully before beginning in-
stallation work. Corrugated eternit roofs are usually implemented
as slightly sloping purlin roofs. You should provide a point of ancho-
rage to the substructure at every purlin. Each of these anchoring
points is always at a wave on the corrugated eternit panel. Gene-
rally, the spacing is approximately 1.15 m. As the corrugation runs
at 90 to the purlins, you must insert a hanger bolt at every point
of intersection between purlin and wave. The module rails are nor-
mally mounted from the ridge to the eaves. The modules are thus
installed landscape. This does not apply to rafter roofs, as the raf-
ters do not always run beneath a wave. In such cases, you should
add an auxiliary rafter to the side of the rafter in the proper manner,
so as to be able to position the hanger bolt.
Strong wind suction forces are to be expected near the edges and
ridges of gable roofs. Please take this into account when installing
a PV system. Figures 1 and 2 show the areas where the wind suc-
tion forces aerodynamic coeffcients are high. If you install the PV
system in these areas as well, the mounting frame must be able to
accommodate these high loads. Also note that the anti-lifting pro-
tection must be sufcient for the higher wind suction forces.
If you have any additional questions, use INTERSOLs professi-
onal and comprehensive consultation service. Our competent
construction engineers and technicians are happy to help you.
INSTALLATION INSTRUCTIONS
Corrugated eternit roof
Roof plan
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2x building height
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Wind
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Hanger bolts: at the fastening point, drill a hole into the corruga-
ted eternit roong and the wooden structure beneath. Make sure
that you always select a wave as the installation point. For the M10
hanger bolt, you require a 7 mm drill bit for the wooden structure,
and 11 mm for the eternit panel. For the M12 hanger bolt, use a
8 mm drill bit for the wooden structure, and 13 mm for the eternit
panel. Then screw in the full threaded length of the hanger bolt.
Please ensure that you adhere to the minimum anchoring depth of
8 cm (M10) or 10 cm (M12) respectively. When anchoring to the sup-
port structure, you should provide clearance of at least 3 cm (M10)
or 3.6 cm (M12) from the edge of the purlin (Fig. 3).
Generally, the product range comprises complete corrugated eter-
nit bolt connections, including accessories, such as connecting
plate, EPDM sealing and 3 nuts with interlocking (item no. 10301-
43/1 to 43/6) as well as individual components such as M10 han-
ger bolt (item no. 10301-45/140,/160,/180,/200) or M12 hanger bolt
(item no. 10301-45/300), EPDM sealing (item no. 10301-44) and the
M10 aluminium 5 mm connecting plate (item no. 10301-071) or M12
stainless steel 5 mm connecting plate (item no. 10301-46). Please
use only the M10 bolts and nuts provided on delivery for fastening
the frame, and the M8 bolts and nuts for fastening the modules to
the frame.
The following torques are to be adhered to:
M8 (A2-70 / A4-70): 20 Nm
M10 (A2-70/A4-70): 45 Nm
Please note: use a torque wrench to ensure adherence to these
torques. Align the frame or modules before tightening the bolts.
3
BOLTS
ROOF FASTENING
M10 3 cm
M12 3,6 cm
On rafter roofs, lateral reinforcement is necessary in
some cases, as the wave does not always run direct-
ly above the rafter. For inserting the hanger bolts,
you can order suitable hexagonal screwing tools
from our product range, for M10 (item no. 10301-47)
and for M12 (item no. 10301-47/1). For steel support
structures, use solar fasteners with 8 mm thread
and an M10 x 50 mm setscrew instead of hanger
bolts. Please note that the substructure must be at
least 1.5 mm thick. Pre-drill holes according to the
following table:

Thickness of the substructure (in mm)
1,5 5,0 6,0 8,0 10
Pre-drilling diameter (in mm)
6,8 7,0 7,2 7,4
Once you have put the hanger bolt / solar fastener
in place, affx the EPDM sealing over the drilled hole
with an M10/M12 fxing nut (fig. 4). Subsequently,
install the connecting plate between 2 additional
nuts, in such a manner that a level supporting sur-
face for the cross girders is created, then install the
cross girders in a tension-free manner by placing
them on this surface (fig. 5). Now fasten the con-
necting plate by adjusting the two nuts at the head
of the hanger bolt connection.
Note: it is strictly forbidden to install a PV system
on an asbestos cement roof. Exceptions can only be
granted in individual cases by the relevant indus-
trial inspectorate, upon written application as per
20 of the german hazardous substance Ordinance
(gefahrenstoffverordnung, gefstoffV).
4 5
With the cross girders Standard type 2 and Light
type 2, the lower slot serves to accommodate M10
T-head and M10 mushroom head square necked
bolts. The upper T-shaped slot is only suitable for
fastening the modules, because only M8 square nuts
can be inserted here. The cross girder Futura 40x40
(item no. 10301-04/310, /32) can accommodate M10
bolts and nuts in both slots. Thus, the cross girders
application options are highly fexible. The upper
T-shaped slot also serves to accommodate the M8
hammerhead nut (item no. 10301-41/E) for faste-
ning modules with Allen bolts (item no. 10301-411
to -419). All 3 types of cross girder can be connected
quickly and easily with the assembly angle (item no.
10301-073). With the cross girders Standard type
2 and Futura 40x40, attach the assembly angles in
such a manner that the side piece with the 2 drilled
holes serves as a lateral arrester. With the cross gir-
der Standard type 2, the arrester is not to be situated
on the side of the cable duct. With the Light type 2
cross girder, the side piece with the 3 drilled holes is
the lateral arrester. Each assembly angle is fastened
with two M10 T-head or mushroom head square ne-
cked bolts and M10 hexagon nuts with interlocking
(item no. 10301-40/M) (fig. 6 to 8). Make sure that
the connecting joint is not situated directly at a fa-
stening point.
Please note: the maximum cross girder length
should not exceed 15.0 m, and the cross girders
should not protrude more than 300 mm beyond the
last corrugated eternit bolt connection. After 15.0
m, install an expansion joint of at least 5 cm.
End caps can be applied to the cross girders as opti-
cal fnishing. A suitable end cap is available for every
type of cross girder. For cross girders Standard type
2, you need the end cap 10301-083, for cross girders
Light type 2 the end cap 10301-082, and for cross
girders Futura 40x40, the end cap 10301-081. The
Standard type 2
cROss giRDeRs
Light type 2
6 7
M8

M10
M8

M10
futura 40x40
M8/M10

M10
end caps are affxed on the underside with an M10/16 bolt and a
M10 hexagon nut without interlocking (item no. 10301-41) (Fig. 9).
Installing modules portrait: for portrait module alignment, you
should check whether the manufacturers specifcations permit fa-
stening of modules on the short side. If so, you can either proceed
in the same manner as for landscape installation, or you can select
a fastening option which uses a cross rail system. However, if the
fastening points are situated only on the long sides of the module,
you must use a cross rail system. For more detailed information in
this regard, refer to the specifc installation instructions Cross rail
system.
Installing modules landscape: usually, the supporting roof struc-
ture will be a purlin roof. Therefore, lay the cross girders so that
they run from the ridge to the eaves. Here, you can use the cross
girders Standard type 2, Light type 2, or Futura 40x40. Fasten the
cross girders to the hanger bolts connecting plate with an M10 T-
head or mushroom head square necked bolt and an M10 hexagon
nut with interlocking. You can insert the T-head bolt anywhere in the
8
lower slot of the cross girder. Insert the mushroom
head square necked bolts into the slot at the end of
the rail, and slide them to the desired position (Fig.
10 and 11). If, on the other hand, the substructure
is a rafter roof, please check whether the wave run
directly above the supports. If this is not the case,
you should reinforce the supports laterally, so that
you can install the hanger bolt in a vertical line at
the wave.
Elevated mounting: if you choose a fastening option
with elevated mounting, you need to use a Futura
40x40 as the base rail, in order to fasten the trian-
gular supports. For more detailed information, refer
to the specifc installation instructions Pitched roof
elevated mounting frame.
Now prepare the end clamps (item no. 10301-1532
to -1551) / end clamps for frameless modules (item
no. 10301-98) and central clamps (item no. 10301-14
and -141) / central clamps for frameless modules
(item no. 10301-97) for fastening the modules to the
module rails. The mounting areas prescribed by the
manufacturer of your module can be found in the
module data sheet. For the cross girders Standard
type 2 and Light type 2, attach M8 Allen bolts with
interlocking and M8 square nuts to the clamps. Slide
the required number of clamps into the upper slot of
the module rails. With the cross girder Futura 40x40,
MODule fAsteNiNg
10 11 9
use an M8 hammerhead nut instead of the M8 square nut. Here,
you can insert the clamps directly into the slot of the cross girder
at any location. Now place the frst module on the cross girder, with
at least 30 mm clearance from the edge. Slide the end clamps onto
the modules frame, and tighten the bolts. To fasten the module on
the other side, place another module, and fasten both to the central
clamps. Continue in this manner, and lock off the fnal module with
end clamps (Fig. 12 to Fig. 13).
In order to secure the modules against theft, you can insert a star-
shaped anti-theft device (item no. 10301-80) into the M8 Allen bolt
and fasten it with a centre punch. This means that the hexagonal
socket wrench can no longer be inserted, and the Allen bolt cannot
be loosened.
14
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PRODuct liAbility:
the technical documentation constitutes part of the product. Donauer solartechnik Vertriebs gmbh is not liable for
damages caused by failure to observe the installation instructions, particularly the safety instructions, or caused by
inappropriate use of the products.
We recommend that you read the following information carefully, as it
is of great importance when handling the product. Please also inform
yourself of the safety regulations which pertain to the other system
components.
ou should adhere to these instructions precisely, whenever working
on the PV system. Installation, commissioning, maintenance and re-
pairs may only be performed by appropriately qualifed and authorised
persons.
Please observe the applicable regulations and safety instructions.
you must observe the following accident prevention regulations:
BGV A 1 General regulations
BGV A 2 Electrical systems and equipment
BGV C 22 Construction work (personal fall protection equipment)
The trade association health and safety at work rules (BGR 203 Wor-
king on roofs) and DIN EN 516 Equipment for accessing roofs
The trade association regulations regarding work clothing and work
safety
you must adhere to the following DiN standards:
DIN 18299 General rules for all kinds of building works
DIN 18338 Roof covering and roof sealing works
DIN 18360 Metal construction and locksmith works
DIN 4102 Fire behaviour of building materials and building compo-
nents
Only authorised personnel may carry out work on Donauer Solartech-
nik Vertriebs gmbh systems. the operator of the system has the fol-
lowing safety-related obligations:
Performance of regular annual maintenance work, e.g. inspection of
cabling, bolt connections, and the roof skin.
The frame may only be installed by persons with suitable qualifca-
tions, technical skills, and knowledge of the fundamentals of me-
chanics.
It must be ensured that the assigned persons can assess the work
allocated to them, and can identify possible dangers.
The installation instructions are part of the product, and must be
available during installation.
It must be guaranteed that the installation instructions, and particu-
larly the safety instructions, have been read and understood by the
assigned personnel before installation.
The trade association regulations, the local work safety regulations,
and the technical regulations must be adhered to.
Suitable hoisting equipment and ladders are to be used for the ins-
tallation work. No leaning ladders may be used.
It is necessary to arrange for a qualifed construction engineer to as-
sess the buildings existing static loading characteristics with regard
to the additional loads of a PV system.
Any general load reduction measures specifed by Donauer Solar-
technik Vertriebs GmbH (e.g. the need to clear snow, so as to limit
the snow load) are to be observed.
PRODUCT LIABILITY / COMMERCIAL GUARANTEE
(LIABILITY EXCLUSION IF APPLICABLE)
The dimensioning information included in these instructions merely
represents information gathered in practice. Binding static loading
characteristics for mounting frames can be compiled upon request.
As the installation company, you are responsible for correct executi-
on of installation work.
Donauer Solartechnik Vertriebs GmbH is not liable for the dimensi-
oning information included in commercial system proposals.
As the installation company, you are responsible for the mechanical
stability of the installed interface connections at the building envelo-
pe, and in particular for their leak-tightness. The components from
Donauer Solartechnik Vertriebs GmbH are designed for this purpo-
se, according to the expected loads and the current state of techno-
logy. To this end, within the scope of the query / order, you must pro-
vide Donauer Solartechnik Vertriebs GmbH with written notifcation
of all general technical framework conditions on the project data
collection sheet (details of the support structure, snow load zone,
building heights, wind loads etc.).
Donauer Solartechnik Vertriebs GmbH is not liable for incorrect
handling of the installed parts.
Use in the vicinity of the sea is prohibited, due to risk of corrosion.
Donauer Solartechnik Vertriebs GmbH grants a 2-year product gu-
arantee on the service life and stability of the mounting systems,
subject to correct handling, dimensioning in accordance with the
static loading conditions, normal environmental conditions, and nor-
mal ambient conditions. This applies within the generally prevalent
weather conditions and environmental conditions.
Material and workmanship guarantee: Donauer Solartechnik Ver-
triebs GmbH grants a 12-year material and workmanship guarantee
on the materials used. Consult the specifc guarantee conditions for
more detailed information.
stANDARDs AND guiDeliNes
All standards and guidelines listed are issued for germany, and are to be applied for germany, in the respective valid
version. Outside germany, you must also observe the relevant national standards and guidelines.
NOTES ON ELECTRICAL INSTALLATION WORK
Only if you are a qualied electrician, may you perform any electrical
work. The applicable DIN standards, VDE regulations, VDEW guideli-
nes, VDN guidelines, accident prevention regulations and the regulati-
ons of the local utility company are authoritative in this regard.
DIN VDE 0100 (Installation of high voltage systems with nominal vol-
tages up to 1000 V)
VDEW guideline for parallel operation of domestic power-generation
systems with the low voltage grid of the utility company
VDI 6012 sheet 2, guideline for decentralised energy systems in buil-
dings: Photovoltaics
Leafet for VDEW guideline Domestic power-generation systems on
the low voltage grid
VDN guideline Domestic power-generation systems on the low vol-
tage grid
DIN/VDE regulations, DIN/VDE 0100 Installing high voltage systems
with grid voltages up to 1000 V, in particular VDE 0100, Part 410,
Protection against direct and indirect contact (Direct current > 120
V, < 1000 V direct current) and the Accident prevention regulations
of the commercial trade associations VBG4 Electrical systems and
equipment
DIN VDE 0100-540 Selection and installation Earthing, protective
conductors and equipotential bonding conductors
DIN 57185 VDE 0185 Installation of a lightning protection system and
VDS 2010
IMPORTANT WARNINGS
Solar modules generate electricity as soon as they are exposed to
light. There is always a voltage present. The fully insulated plug con-
tacts provide a level of contact protection but when dealing with solar
modules, the following points must be observed:
Do not insert electrically conductive parts into the plugs or sockets.
Do not install solar modules and wiring using wet plugs or sockets.
Exercise utmost caution during all work on the wiring.
Do not carry out any electrical installation work in damp conditions.
Also with low lighting, connecting solar modules in series causes
very high DC voltages to occur, which can be life-threatening upon
contact. In particular, note the possibility of secondary damage in the
event of electric shocks.
The inverter can produce high touch voltages, even when not connec-
ted:
Exercise utmost caution when working on the wiring and inverter.
After switching off the inverter, it is essential to wait for the time
interval specifed by the manufacturer before beginning any further
work. This allows the high voltage components time to discharge.
Please also observe the inverter manufacturers installation regula-
tions.
When breaking a connected string of modules (e.g. when disconnec-
ting the Dc line from the inverter under load), a lethally strong electric
arc can occur:
Never disconnect the solar generator from the inverter while the in-
verter is connected to the mains grid.
NOTES ON THE INSTALLATION OF MOUNTING
FRAMES
For installation in roof areas, you must observe the currently appli-
cable construction engineering regulations, especially the require-
ments formulated in the DIN standards and in the Regulations of the
german Roofng industry (Regelwerk des Deutschen Dachdecker-
handwerks).
Check whether all bolt connections are tight.
Adhere to the specifed torques.
Regardless of verifable static loading conditions, you must ensure
that the product complies with the static loading requirements on
site, as per DIN 1055, before every installation.
DIN standard 1055 Actions on structures
Part 1: Densities and weights of building materials, structural ele-
ments and stored materials
Part 4: Wind loads
Part 5: Snow load and ice load
Part 100: Basis of structural design Safety concept and design rules
The mounting frame is dimensioned as per DIN 4113 Aluminium
constructions under predominantly static loading and DIN 18800
Structural steelwork; dimensioning and construction or the rele-
vant Eurocode EC1, EC3, EC9.
Make sure that the substructure is appropriate with regard to load
capacity (dimensioning, state of maintenance, appropriate material
specifcations), supporting structure, and any other layers which it
affects (e.g. insulation layer).
Make sure that the rainwater runoff is not impeded.
Pay attention to the physical construction aspects (e.g. possible con-
densation problems caused by penetration of insulating layers).
SAFETY INSTRUCTIONS AND WARNINGS
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STATICS. STABILITY. SAFETY.
STILL HAVE QUESTIONS?
We will be happy to provide you with more information.
Distributed by
Donauer Solartechnik Vertriebs GmbH
Zeppelinstr. 10
82205 Gilching
Germany
Telephone +49 (0)8105 / 77 25 - 0
Fax +49 (0)8105 / 77 25 - 100
info@donauer.eu // www.donauer.eu
you can also visit us online at:
www.intersol.eu
If you still have unanswered questions or suggestions, you are welcome
to call us. You can reach our competent consultants, who will answer
all your questions regarding products, planning and installation, at
+49 (0)8105 / 77 25 - 0. Here, you can also obtain information on the in-
stallation systems for all other roof types.
Just get in contact with us!

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STATICS. STABILITY. SAFETY.

CORRUGATED ETERNIT ROOF

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