© BISOL Production, Ltd. December 2015. All rights reserved. All information presented in this document is subject to change without prior notice.

INSTALLATION GUIDELINES: BISOL EASYMOUNT ALU BASE 125/200/300

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Table of Contents

TABLE OF CONTENTS 2

PRODUCT INFORMATION 3

LIST OF BASIC COMPONENTS 4

LIST OF REQUIRED TOOLS 6

MOUNTING INSTRUCTIONS 7

STEP 1 – ARRANGING THE PV SYSTEM AREA 7

STEP 2 – LAYING OUT THE SUPPORTING PROFILES 8

STEP 3 – EXTENSION OF THE SUPPORTING PROFILES 8

STEP 4 – ATTACHING THE A-FRAMES AND BALLAST PANS 9

STEP 5 - INSTALLING BALLAST 9

STEP 6 – FIXING THE PV MODULES WITH CLAMPS 12

STEP 7 – MOUNTING THE WINDSHIELDS 13

SAFETY AND LIABILITY 14

The aim of this installation manual is to outline the practical guidelines for the correct installation of

a specific type of BISOL EasyMount mounting system. You will benefit from top quality EU-made

solutions which offer a quick and easy installation, reductions in installation time and long time

performance. Please read the entire manual before commencing the installation work. Pay special

attention to the Safety and Liability information which can be found at the end of this manual. Our

team of experts is at your disposal for any inquiries regarding the use of BISOL products.

INSTALLATION GUIDELINES: BISOL EASYMOUNT ALU BASE 125/200/300

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PRODUCT INFORMATION

This lightweight, but sturdy mounting solution requires no roof penetration and is suitable for flat

roofs covered with bitumen, gravel or synthetic membrane. The BISOL EasyMount ALU Base is

delivered pre-assembled to simplify the installation work, as well as substantially reduce the

installation time.

Technical specifications

Application Flat roofs

Roof incline Up to 5°

Method of installation Direct laying without roof penetration

Module incline 12.5°, 20° and 30° (other angles available upon request)

Module orientation Landscape

Module frame tolerances Width: 200 - 1050 mm (7.87” - 41.33”) / Frame thickness: 35, 40

or 45 mm (1.38”, 1.57” or 1.77”) applicable to different clamp

types

Material Aluminum EN-AW 6060 T5 (ALU Rail 80) /

Stainless steel A2-70 (fastening elements)

System weight without ballast 0.015 kN/m2 (without PV module)

Snow load per system 0 – 2.40 kN/m2 (with BISOL PV modules)

Wind load (velocity) 0 – 115 km/h (71 mph)

Additional stabilization Ballast / Windshields

REQUIRED ROOF STRENGTH

(1)For use with standard size BISOL PV modules

INSTALLATION GUIDELINES: BISOL EASYMOUNT ALU BASE 125/200/300

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LIST OF BASIC COMPONENTS

Product code Components included in the set

(all components available as options for individual order)

EasyMount ALU Base 125 SEKP-EMTAB_125 EasyMount ALU Base 200 SEKP-EMTAB_200 EasyMount ALU Base 300 SEKP-EMTAB_300

EasyMount ALU Base triangle leg length 1100mm SEK-EMT_ABR_1100 (1pc)

EasyMount ALU Base triangle leg, length 230mm SEK-EMT_ABR_230 (1 pc) EasyMount ALU Base triangle leg, length 387mm SEK-EMT_ABR_387 (1 pc) EasyMount ALU Base triangle leg, length 620mm SEK-EMT_ABR_620 (1 pc)

EasyMount ALU Base middle Connector SEK-EMT_MC (1 pc)

EasyMount ALU Base front Connector 125 SEK-EMT_FC_125 (1 pc) EasyMount ALU Base front Connector 200 SEK-EMT_FC_200 (1 pc) EasyMount ALU Base front Connector 300 SEK-EMT_FC_300 (1 pc)

EasyMount ALU Base back Connector 125 SEK-EMT_BC_125 (1 pc) EasyMount ALU Base back Connector 200 SEK-EMT_BC_200 (1 pc) EasyMount ALU Base back Connector 300 SEK-EMT_BC_300 (1 pc)

Screw hammerhead M10x25 A2-7 SEK-HHS_10_25 (2 pcs)

Nut M10 flange A2-70, SEK-DIN6923 2 pcs)

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Screw M8x16 button head, SEK-DIN7380_8_16 (16 pc)

Nut M8 flange A2-70, SEK-DIN6923_8 (16 pcs)

Clamp end EasyMount SEKP-EMEC25 Clamp end EasyMount, 'colour'(2) SEK-EMEC25_(2)

Clamp end EasyMount, SEKP-EMEC25 (1 pc)

Screw Inbus M8x25 A2-70, SEK-DIN912_8_25 (1 pc)

Spring EasyMount, SEK-EMS_40 (1pc)

Consoles for ballast side mounting, set SEKP-EMT_BPN

Ballast pan EasyMount, SEK-EMT_BPN (1 pc)

Screw hammerhead M10x25 A2-7, SEK-HHS_10_25 (1 pc)

Nut M10 flange A2-70, SEK-DIN6923 (1 pc)

EasyMount ALU Rail 80 x 5850 mm SEK-EMRL80_5850

Connector set for EasyMount Rail 80 SEKP-EMCRL80

Connector for EasyMount Rail 80 SEK-EMCRL80(1 pc)

Screw hammerhead M10x25 A2-7 SEK-HHS_10_25 (2 pc)

Nut M10 flange A2-70 SEK-DIN6923 (2 pc)

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Load concrete plate 40/40/4 cm (15 kg) SEK-LOAD_CP15 Load concrete plate 50/50/5 cm (36 kg) SEK-LOAD_CP36

Windshield 12.5 1700x200 white SEK-TWS125_1720W Windshield 20 1700x340 white SEK-TWS200_1734W Windshield 30 1700x500 white SEK-TWS300_1750W

Screw self-drilling 5.5x25 with washer SEK-DIN7504_5525

(2)BISOL EasyMount end and middle clamps are available in a variety of colours (black, RAL 1036, RAL 4007, RAL 4004, RAL 6003, RAL 6009, RAL 7011, RAL 8017) for use with BISOL Spectrum coloured PV modules.

LIST OF REQUIRED TOOLS

Open-end wrench (size 8, 13, 17)

Tape measure

Hexagon wrench (size 6; torque range 5 Nm – 20 Nm)

Electric drill with drill bit for aluminum

(size 11)

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MOUNTING INSTRUCTIONS

STEP 1 – ARRANGING THE PV SYSTEM AREA

Calculate the distances between rows by taking into consideration the incident angle of the sun at a specific location. The suggested distances in the table below are for indicative purposes only.

ALU Base 125 ALU Base 200 ALU Base 300

h(3) 285 mm 415 mm 575 mm

Incident angle of the sun in the winter (A)

B C B C B C

17° 693 mm 1,870 mm 775 mm 2,040 mm 1,413 mm 2,777 mm

18° 646 mm 1,823 mm 709 mm 1,974 mm 1,305 mm 2,669 mm

19° 604 mm 1,781 mm 651 mm 1,916 mm 1,209 mm 2,573 mm

20° 567 mm 1,744 mm 597 mm 1,862 mm 1,122 mm 2,486 mm

25° 422 mm 1,599 mm 549 mm 1,814 mm 787 mm 2,151 mm

30° 323 mm 1,500 mm 393 mm 1,658 mm 559 mm 1,923 mm

35° 295 mm 1,472 mm 253 mm 1,518 mm 390 mm 1,754 mm (3)When using standard size BISOL PV modules.

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STEP 2 – LAYING OUT THE SUPPORTING PROFILES

The ALU Rail 80 supporting profiles must be positioned in parallel at a distance 40 mm wider

than the dimension of the long side of the PV module.

EasyMount ALU Rail 80 x 5850 mm SEK-EMRL80

STEP 3 – EXTENSION OF THE SUPPORTING PROFILES

The extension of ALU Rail 80 profiles can be achieved using connectors which are delivered pre-assembled with screws and flange nuts.

Insert the hammerhead screw of the preassembled connector into the top slot of the ALU Rail 80 profile and rotate by 90°. Tighten the two hexagon flange nuts applying a torque of 22 Nm.

Nut M10 flange A2-70 SEK-DIN6923_10

Connector for EasyMount ALU Rail 80 SEK-EMCRL80

Screw hammerhead M10x25 A2-70 SEK-HHS_10_25 EasyMount ALU Rail 80x5850 mm SEK-EMRL80

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STEP 4 – ATTACHING THE A-FRAMES AND BALLAST PANS

Fix the hammerhead screw and the nut part of the preassembled A-frames to the supporting profiles.

BISOL EasyMount ALU Base A-frame SEKP-EMTAB_125 SEKP-EMTAB_200 SEKP-EMTAB_300 Ballast pan EasyMount for ALU Rail 80, double-sided SEK-EMT_BPNRL

Ballast pan EasyMount, set

SEKP-EMT_BPN

EasyMount ALU Rail 80 x 5850 mm SEK-EMRL80

STEP 5 – INSTALLING BALLAST

To ensure appropriate stability ballast should be used in most locations. We recommend fixing the ballast pans and placing the concrete plates prior to mounting the PV modules.

Place the concrete load plates into the ballast pans as shown in the image below. Maximum dimensions of the ballast plates that can fit into the ballast pans are 500 x 600 mm.

Load concrete plate 40x40x4 cm (15 kg) SEK-LOAD_CP15

Load concrete plate 50x50x5 cm (36 kg) SEK-LOAD_CP3

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BALLAST REQUIREMENTS FOR DIFFERENT WIND ZONES:

Wind zones in the UK:

Source: http://www.nef.org.uk/renewableenergy/pv-wind.htm

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Wind zones in Germany:

Source: http://www.sciencedirect.com/science/article/pii/S016761050200257X

Wind zones in France:

Source: NF EN 1991-1-4/NA. March, 2008

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Wind zones in Belgium:

Source: http://www.wtcb.be/homepage/index.cfm?cat=publications&sub=bbri-contact&pag=Contact28&art=421

STEP 6 – FIXING THE PV MODULES WITH CLAMPS

Place the PV module between two adjoining A-frames. The two bottom connectors which will keep the module in place and prevent it from sliding of the A-frames. Insert the M8 threaded plate part of the pre-assembled clamp into the top slot of the ALU Rail 80, and fix

the clamps applying a torque of 15 Nm.

Clamp end EasyMount 25 mm, preassembled

SEKP-EMEC25

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STEP 7 – MOUNTING THE WINDSHIELDS

Wind protection requirements are project specific and must be calculated based on specific location, elevation and the presence of parapet walls. The image below shows the general guideline which requires the windshields to be installed on the two back rows and each two

outermost PV modules on the side edges of the PV system.

with windshields without windshields

Fix the metal windshields to the back leg of the A-frame with four 5,5x25 self-drilling screws.

Screw self-drilling 5.5x25 with EPDM washer SEK-DIN7504_5525

¸ Windshield 12.5 1700x200 white SEK-TWS125_1720W

Windshield 20 1700x340 white SEK- TWS200_1734W Windshield 30 1700x500 white SEK- TWS300_1750W

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SAFETY AND LIABILITY

The sole purpose of this installation manual is to demonstrate the installation of BISOL EasyMount mounting systems, therefore PV module installation guidelines and related safety precautions are not a part of this manual. For guidelines on how to safely and effectively install BISOL PV modules please refer to the www.bisol.com manual. All installation work must be carried out by a specialized company with qualified personnel. Strict safety and accident prevention measures as defined by relevant regulations must be carried out and should be known to the installer. Appropriate protective equipment for work at height must be used throughout the installation process. The installer carries all responsibility for PV system dimensioning, static calculations of the roof, weather and environmental conditions at location, proper selection and use of components and their mounting. The installer is responsible for the mechanical durability and water tightness of the installed interface connections at the building surface. All safety warnings outlined in this manual are to be closely considered. Although electrical connections are strictly not part of this manual, some safety warnings are in place. PV modules and mounting structure must be grounded even when the site is already equipped with lightning protection. PV modules are under high voltage and generate electrical current even in low light conditions. When modules are connected in series, life-threatening voltage is present at the end of the terminals. Open circuited branches can cause electric arc when in touch with conductive surface. Electrical installations must not be carried out in case of dampness. BISOL Production, Ltd. does not accept responsibility and expressly disclaims liability for loss, damage, or expense arising out of or in any way connected to PV system design and dimensioning, installation work, operation, use or maintenance. The information in this manual is based on BISOL Production’s knowledge and experience; but such information including product specification (without limitations) and suggestions do not constitute a warranty, expresses or implied. BISOL Production, Ltd. reserves the right to change the installation manual as well as product specifications without prior notice.