CompactMETAL

TL25/38
Assembly Instructions
Version: 03
Language: English | Original language: German
Original installation instructions

Important! Read carefully before installation!

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+ + + + Legal Notice
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Subject to changes due to technical improvements. These assembly instructions correspond to the technical
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status of the delivered product and not to the current development status at the manufacturer.
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If pages or parts of the assembly instructions are missing, please contact the manufacturer's address given
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below.
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The original language of these assembly instructions is German. Any assembly instructions in another lan-
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guage are a translation of the assembly instructions in German.
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The assembly instructions are protected by copyright. Without written permission from AEROCOMPACT®
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the assembly instructions may not be copied, reproduced, microfilmed, translated or converted for storage
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and processing in computer systems, either in part or in full.
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+ + + + Copyright by © AEROCOMPACT®
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+ + + + Manufacturer
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+ + + + AEROCOMPACT® Holding
+ + + + Sonnenstraße 10
+ + + + A 6822 Satteins | Austria
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+ + + + [email protected]
+ + + + www.aerocompact.com
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Update
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This manual is subject to change without notice. This does not represent any obligation on the part of the
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manufacturer.
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TL25/38

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+ + + + Creation date
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+ + + + 01/2022
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TOC
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+ + + + About This Document 5
+ + + + Applicable Documents 5
+ + + + Explanation of Symbols 5
+ + + + Symbols in Illustrations 5
+ + + + Target group 6
+ + + + Appropriate use 6
+ + + + Liability, Warranty, Guarantee 6
+ + + + Guarantee 7
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General information on liability 7
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Systems with clamping on the short module side 7
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Safety 8
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Requirements of personnel 8
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Working safely 8
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Breakthrough protection 8
+ + + + Climbing aids 8
+ + + + Weather conditions 8
+ + + + Dangers from the environment 8
+ + + + Protection against falling objects 9
+ + + + Personal protective equipment (PPE) 9
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+ + + + System Overview 10
+ + + + Basic Components TL system 10
+ + + + Accessories 11
+ + + + Bonding and Grounding Accessories 11
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Module Accessories 12
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Installation Options 12
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Assembly 13
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Measure the area 13
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Install the trapezoidal metal sheet bridge 14
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Tighten metal screws with attached EPDM washer 14
+ + + + Install height adapter (optional) 15
+ + + + Installing the tilt adapter (optional) 15
+ + + + Installation options 15
+ + + + Installing the tilt adapter 16
+ + + + Option PS 16
+ + + + Option PM/PL 16
+ + + + Install microinverter (optional) 17
+ + + + Mount microinverter with the microinverter clamp (MA-MO) onto the module frame. 17
+ + + + Installing modules 18
+ + + + Bonding 20
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Potential equalization (not USA-compliant) 21
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Potential equalization with grounding lug and bonding jumper (USA-compliant) 21
Grounding lug installation 23
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Maintenance 25
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Complete System 25
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Fittings 25
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Dismantling 26
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Disassemble components 26
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Dismantle clamps 26
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+ + + + Appendix 27
+ + + + Declaration of Conformity TL 27
+ + + + UL Certification Notes 27
+ + + + Load Rating 28
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 About This Document

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ABOUT THIS DOCUMENT
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These installation instructions describe the procedure for installing the product. Read these assembly instruc-
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tions carefully before starting the assembly. Follow the instructions carefully to ensure correct installation of
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the product.
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+ + + + Applicable Documents
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+ + + + The following documents are a part of these installation instructions and are absolutely necessary for the
+ + + + correct assembly of the system:
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+ + + + o Project report from AEROTOOL
+ + + + o Planning documents and drawings
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Explanation of Symbols
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In order to make these assembly instructions easy to understand, uniform safety instructions, symbols, terms
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and abbreviations are used. The following symbols indicate notes which are not relevant to safety, but
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which make working with the assembly instructions easier.
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Requirements for an action are depicted with this symbol. Make sure that all requirements are met before
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you carry out the following actions.
+ + + + Action steps are depicted with this symbol. Carry out the steps in the specified order.
+ + + + The result of the action is depicted with this symbol.
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+ + + + This note provides useful information for a smooth assembly of the product.
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+ + + + Symbols in Illustrations
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+ + + + Activities
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Certain activities are required to carry out the assembly. These activities are shown in the illustrations with
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the following symbols.
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+ + + + Check AEROTOOL planning documents Visual inspection
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Activity by hand Observe right angle
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Optional component,
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optional installation method
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 About This Document

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+ + + + Tools
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Certain tools are required to carry out the assembly. These tools are shown in the illustrations with the fol-
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lowing symbols.
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+ + + + Measuring tape, measure Cordless screwdriver, screwdriver
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+ + + + Torque wrench,
Pencil, mark
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+ + + + Chalk line Drilling machine, drill
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+ + + + Target group
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These installation instructions are intended for trained personnel who are familiar with the installation of
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photovoltaic systems. The personnel should also be familiar with working on roofs and know the local reg-
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ulations regarding work safety. The personnel must also observe the instructions in the Safety chapter.
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Appropriate use
+ + + + The TL25/38 system is designed exclusively for installing PV modules on metal roofs consisting of
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+ + + + The system must be properly installed in accordance with these installation instructions.
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PV modules used with the TL25/38 system should be approved by the module manufacturer.
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AEROCOMPACT accepts no liability for loss of performance or damage of any kind to the PV modules.
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Any other use of the TL25/38 system is considered improper.
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+ + + + Liability, Warranty, Guarantee
+ + + + These assembly instructions and the project report supplied with the product are integral parts of the
+ + + + product. The information, data and instructions given in the assembly instructions were up to date at the
+ + + + time of printing. No claims can be made for products already delivered that deviate from the information,
+ + + + illustrations and descriptions.
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+ + + + The project report supplied with the system contains the static/ structural calculation related to the location.
+ + + + If the module layout on the roof changes due to local conditions, e.g. unforeseen interference areas, the
+ + + + structural analysis must be recalculated. The Aerocompact system is designed and planned with the Aero-
+ + + + tool software.
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+ + + + Aerocompact accepts no liability for damage and malfunctions caused by:
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o improper use
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o use of non-certified components.
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o unauthorized modifications to the product.
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o improper handling of the product.
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 About This Document

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o Installation errors
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o Failure to comply with the installation instructions or planning documents.
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Guarantee
+ + + + The warranty period for the system is 25 years. The warranty period for galvanized steel parts is 10 years. The
+ + + + guarantee is only valid if the installation is carried out professionally and all system components are pur-
+ + + + chased from Aerocompact. If the assembly instructions or the planning documents are disregarded, the war-
+ + + + ranty will be invalidated.
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+ + + + Photovoltaic racking systems are not maintenance-free. Carry out maintenance annually and immediately
+ + + + after unusual weather events, e.g., after heavy storms or heavy snowfall, etc. If the maintenance is not carried
+ + + + out at the specified interval, the warranty will become void.
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+ + + + General information on liability
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We point out that the product is sold within the framework of a purchase agreement. Assembly/installation
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by the purchaser or third parties is not carried out on behalf of or for Aerocompact and must be carried out
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by qualified personnel strictly in accordance with the installation instructions. The Aerocompact system
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must be designed and planned with the AEROTOOL software. Aerocompact is not responsible for the pro-
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ject-related structural integrity of the roof structure, for obtaining and documenting the roof manufacturer's
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approval for the installation of the corresponding fasteners on the respective roof (in terms of warranties),
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nor for the professional execution.
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Errors and damage as well as limited or insufficient functionality of the system due to incorrect installation
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and/or installation that deviates from the installation instructions and/or the project report (AEROTOOL)
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exclude any material defect for which Aerocompact is responsible. In the event of improper handling, the
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buyer's rights of warranty for material defects shall not longer be valid. The system warranty is only valid if
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all system components are purchased from Aerocompact.
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+ + + + Systems with clamping on the short module side
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+ + + + For a system with a clamp on the short side of the module, it is assumed that the module may also be used
+ + + + in this mounting form (clamp on the short sides of the module). This release can either be generally avail-
+ + + + able as part of the module installation instructions or can be given by the module manufacturer for specific
+ + + + projects.
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 Safety

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SAFETY
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+ + + + Requirements of personnel
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The person must be physically and mentally fit. Under no circumstances must the installation personnel be
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under the influence of medication, alcohol or drugs.
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Persons who are not healthy and fit must not work on roofs.
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+ + + + Personnel who are in training must only carry out work under the supervision of qualified personnel who
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Working safely
+ + + + The company carrying out the installation is responsible for ensuring that the local regulations for work
+ + + + safety and accident prevention are observed.
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+ + + + Breakthrough protection
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Roof windows, skylights, large ventilation flaps etc. often cannot withstand the weight or impact of a person.
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Such objects must be secured in a similar way as the edge of the roof.
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Corrugated fibre cement roofs can be prone to breakthrough over the entire surface. Define walking routes
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and secure them with load distribution measures.
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On roofing or roof structures that do not have sufficient load-bearing capacity (e.g. thin sheets, corrugated
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fibre cement), always work with load distribution aids.
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+ + + + Climbing aids
Only use suitable, intact and tested ladders. Set up and secure ladders according to instructions.
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+ + + + Separate rules apply to mechanical climbing aids (lifts, lifting platforms, ...).
+ + + + Never use the PV mounting system as a climbing aid.
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Weather conditions
In case of unsuitable weather conditions, work on the roof must not be continued any longer than neces-
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sary - or not started at all.
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Never carry out assembly work in strong winds. Strong wind exerts enormous forces on the large-area PV
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modules. There is a risk that a module could be torn off the roof and people could be injured.
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Never work in wet conditions or at temperatures below the freezing point. Depending on the roof pitch
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there is a risk of slipping.
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+ + + + Dangers from the environment
+ + + + Keep sufficient distance from overhead electrical lines. The following distances must be observed:
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 Safety

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+ + + + 1 m to 1,000 V
+ + + + 3 m: 1,000 to 11,000 V
+ + + + 4 m: 11,000 to 22,000 V
+ + + + 5 m: 22,000 to 38,000 V
+ + + + > 5 m: if the voltage is unknown
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+ + + + Protection against falling objects
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Areas below the roof on which work is being carried out must be protected from any falling objects. Where
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this does not succeed, affected areas must be closed to the public.
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+ + + + Persons involved in the construction project must wear safety helmets.
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Personal protective equipment (PPE)
+ + + + Personal protective equipment is required to prevent injuries during assembly work.
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Wear protective goggles when drilling.
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+ + + + Wear safety boots.
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+ + + + Wear cut-resistant work gloves during assembly.
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Helmets are required for all persons involved on the construction site.
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+ + + + Use fall protection.
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 System Overview

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SYSTEM OVERVIEW
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+ + + + Basic Components TL system
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1 Mid-Clamp | CLM10
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2 End-Clamp | CLE10
+ + + + 3 Metal Sheet Screw* | EJOT JF3-2-5,5x25 E11
+ + + + 4 Trapezoidal Metal Sheet Bridge at 9.8" (250 mm), at 15.0" (380 mm) | TL25, TL38
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+ + + + * This component is intended for single use.
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 System Overview

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Accessories
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+ + + + 1 Height Adapter 1.3 in (33 mm) | EL05 Elevation
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2 Height Adapter 3.3 in (83 mm) | EL10 Elevation
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3 Safety Bolt | LSP
+ + + + 4 Front Tilt Adapter 0.8 in (20 mm) | PS Pitch
+ + + + 5 Rear Tilt Adapter 3.9 in (100 mm) | PM Pitch
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6 Rear Tilt Adapter 7.0 in (180 mm) | PL Pitch
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Bonding and Grounding Accessories
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1 Grounding Clamp 8 - 10 mm | WCL8-10
+ + + + 2 Aluminium Wire 8 mm for Grounding | AWR8 (please use properly sized copper wire in the USA)
+ + + + 3 8" Bonding Jumper (follows UL 476 or UL 2703 requirements) | BJ8
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4 Grounding lug with T-bolt (follows UL 476 or UL 2703 requirements) | GL18T
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 System Overview

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Module Accessories
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+ + + + 1 Microinverter T-Bolt Assembly for Top Rail-Channel | MA-RA
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2 Microinverter Clamp for Module Frame | MA-MO
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+ + + + 3 Cable Tie Clip for Module Frame | CLP-M
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Installation Options
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Installing the modules directly on the trapezoidal metal sheet bridge
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+ + + + Installing the modules on the EL05/EL10 height adapter
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Installing the modules on the PS, PM/PL tilt adapters
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 Assembly

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ASSEMBLY
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+ + + + Measure the area
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+ + + + The trapezoidal metal sheet bridge is installed across two peaks. . The distance between the rails
+ + + + depends on the width of the modules and the distance between the peaks.
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Take the dimensions of the array field from the Aerotool planning documents.
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Determine module size.
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Determine the distances between the peaks.
+ + + + Determine and mark the positions of the short rails.
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 Assembly

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Install the trapezoidal metal sheet bridge
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For exact alignment of the trapezoidal metal sheet bridges, use a rail or similar aid as a guide.
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Position the trapezoidal metal sheet bridges according to the markings.
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Use the appropriate holes depending on the distance between the peaks.
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Fasten each trapezoidal metal sheet bridge with 4 metal sheet screws.
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Tighten the screws until the gasket bends equally all around (see picture below). Do not over-tighten.
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+ + + + Tighten metal screws with attached EPDM washer
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Mount metal screws with EPDM washer always with mechanical depth stop.
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Ensure sealing: Tighten the screws until the seal is compressed evenly all around. The seal should be com-
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pressed by approx. 30 %.
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+ + + + correct
+ + + + screw is tightened too tight
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screw is not tightened enough
+ + + +
screw is tightened unevenly
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 Assembly

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Install height adapter (optional)
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Use height adapters to achieve a greater distance between the roof surface and the modules.
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Depending on the module size, determine the exact position of the height adapter on the trapezoidal
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metal sheet bridge.
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+ + + + The height adapter may only be mounted in the area between the metal screws.
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+ + + +
+ + + +
+ + + + Install the height adapter on the trapezoidal metal sheet bridge:
+ + + + Place the T-Bolt into the mounting channel.
+ + + + Tighten the screws with 15 Nm or 11 ft lb.
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Installing the tilt adapter (optional)
+ + + +
+ + + + Installation options
+ + + +
+ + + + Using the Pitch products, modules can have an additional tilt of 5° to 15°.
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 Assembly

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Front: EL05 height adapter with PS tilt adapter
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+ + + + Rear: EL05 height adapter with PM/PL tilt adapter
+ + + +
+ + + + The height of the elevation must not exceed 300 mm.
+ + + +
+ + + +
+ + + + Installing the tilt adapter
+ + + +
+ + + + The tilt adapters are only installed in combination with the EL05 height adapter.
+ + + +
+ + + + Option PS Option PM/PL
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+ + + + Attach tilt adapter to EL05 height adapter as required.
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 Assembly

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+ + + +
+ + + + Attach the safety bolt.
+ + + +
+ + + + The LSP safety bolt is attached to each back
+ + + + EL05 height adapter (1 x per module), where a
+ + + + module end clamp is mounted.
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Use the safety bolt to secure each tilt adapter to the height adapter on the starting and ending rows of an
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array.
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+ + + +
+ + + + Install microinverter (optional)
+ + + +
+ + + +
+ + + + Mount microinverter with the microinverter clamp (MA-MO) onto the module frame.
+ + + +
The microinverter is installed directly onto the module frame.
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 Assembly

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Install the microinverter onto the module according to the module manufacturer's instructions.
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+ + + +
+ + + + Installing modules
+ + + +
+ + + + Depending on the accessories used, the following options are available:
+ + + + Installing the modules on the trapezoidal metal sheet bridges.
+ + + + Installing the modules on the height adapters.
+ + + + Installing the modules on the tilt adapters.
+ + + +
+ + + + When installing the modules, make sure that the module clamps are placed as centrally as possible on
+ + + + the adapters.
+ + + +
+ + + + Do not enter the modules under any circumstances.
+ + + +
+ + + + Spans and cantilevers need to be in accordance with the structural design as issued in the AEROTOOL
+ + + + report. Refer to the AEROTOOL report for the exact positions of the module clamps.
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Attach end-clamps to the edge of the module field.
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 Assembly

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+ + + + Place the module .
+ + + + Tighten the screws of the end-clamps with 15 Nm or 11 ft lbs.
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+ + + + After the first module, attach the mid-clamps .
+ + + + Place the next module .
+ + + + Tighten the screws of the mid-clamps to 15 Nm or 11 ft lbs.
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 Assembly

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Continue placing the modules row by row.
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Make sure that the modules are installed in a line.
Tighten the screws of the end-clamps with 15 Nm or 11 ft lb each.
+ + + +
+ + + +
+ + + + Reposition / replace clamps
+ + + +
+ + + +
Demount clamp: Unscrew the screw at the clamp completely.
+ + + +
Depending on the mounting situation, squeeze the clamp laterally and pull it out or pull it laterally out of
+ + + +
the rail.
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+ + + +
+ + + + Bonding
+ + + +
+ + + +
+ + + + For bonding, AEROCOMPACT provides the bonding wire clamp as an accessory (NOT
+ + + + VALID IN THE USA). These are each mounted on the support rails.
+ + + +
TL25/38

+ + + + Dependent on the mounting setting, each module row is bonded by the module clamps with grounding
+ + + + pins.
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 Assembly

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+ + + + Potential equalization (not USA-compliant)
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+ + + + Bonding modules through module clamps with grounding pins
+ + + + Bonding the individual module rows
+ + + +
Grounding the array by terminating to on-site ground
+ + + +
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Attach the T-Bolt Assembly to the rail.
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Place the grounding wire onto the rails.
+ + + +
Attach the clamp and tighten with the nut.
+ + + +
Tighten the nut with 15 Nm or 11 ft lb.
+ + + +
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Connect the wire to the on-site ground.
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Potential equalization with grounding lug and bonding jumper (USA-compliant)
+ + + +
+ + + + Depending on the installation, the modules per row are connected to each other by the module clamps.
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 Assembly

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Bonding modules through module clamps with grounding pins
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Bonding the individual module rows
+ + + +
+ + + + Grounding the array by terminating to on-site ground
+ + + +
+ + + + For grounding and bonding, use components conforming to UL 467 or UL 2703 (bonding jumper,
+ + + + grounding lug, copper wire).
+ + + +
The detailed assembly of the bonding jumper is described in the manufacturer's assembly instructions.
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+ + + +
+ + + +
+ + + + Bonding module rows with a bonding jumper .
+ + + + Terminate the array to on-site ground with the Grounding Lug .
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 Assembly

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+ + + +
+ + + +
+ + + +
+ + + + Grounding lug installation
+ + + +
Attach the T-Bolt Assembly to the rail.
+ + + +
Connect the Grounding Lug as shown.
+ + + +
Tighten the nut with 15 Nm or 11 ft lb.
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+ + + + Potential equalization during maintenance
+ + + +
+ + + + Heads up!
+ + + + In case of a module removal, a temporary grounding lug and wire will be required to attach the remain-
+ + + + ing modules with each other and maintain an appropriate bonding path.
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 Assembly

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 Maintenance

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MAINTENANCE
+ + + +
+ + + +
+ + + +
To prevent personal injury and property damage, the system must be inspected regularly by qualified per-
+ + + +
sonnel. The operator of the equipment must perform the following maintenance items once a year.
+ + + +
+ + + +
A test of the system is necessary after severe weather events (e.g. wind storm, snow, hail, etc.) as well as after
+ + + +
extreme events such as a hurricane or earthquake.
+ + + +
+ + + + Complete System
+ + + +
+ + + + Check all components of the system for damage.
+ + + + Replace damaged components as soon as possible.
+ + + +
+ + + +
+ + + + Fittings
+ + + + Check all screw connections.
+ + + + Tighten loose screw connections. Confirm the tightening torque according to the assembly instructions.
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+ + + +
 Dismantling

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+
DISMANTLING
+ + + +
+ + + +
+ + + + Disassemble components
+ + + +
Disassembling the system: Carry out the assembly steps in reverse order.
+ + + +
+ + + +
+ + + + Dismantle clamps
+ + + +
+ + + + Completely unscrew the screw on the
+ + + + clamp.
+ + + + If clamps are re-installed:
+ + + + Make sure that the O-ring is not lost.
+ + + +
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+ + + +
 Appendix

+ + + +
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+
+
+
+
APPENDIX
+ + + +
+ + + +
+ + + + Declaration of Conformity TL
+ + + +
+ + + +
+ + + +
Manufacturer: AEROCOMPACT®
+ + + +
Metal roof system
+ + + + Designation:
CompactMETAL trapezoidal metal sheet
+ + + +
bridge
+ + + +
+ + + + Identification code: CompactMETAL TL
+ + + + Harmonised stand-
EN 1090
+ + + + 21 ard: To the declaration
+ + + + Certification body: 2397 of performance
+ + + +
+ + + +
+
+
+
+
+
+
+
+
UL Certification Notes
+ + + +
+ + + +
+ + + + The CompactMETAL system is certified by SolarPTL, LLC for grounding/bonding, fire classification, and
+ + + + mechanical loading. SolarPTL, LLC is a Nationally Recognized Testing Laboratory (NRTL).
+ + + +
+ + + +
The CompactMETAL grounding method conforms to ANSI/UL 2703, and is approved for use with photo-
+ + + +
voltaic modules listed under ANSI/UL 1703 and/or ANSI/UL 61730, whichever applies, and complies with the
+ + + +
National Electrical Code, ANSI/NFPA 70. The individual parts within the solar array need to be electrically
+ + + +
bonded to existing DC ground paths via the use of a UL 467 approved grounding lug and via UL 467
+ + + +
approved bonding jumpers. The conductor size, type and temperature rating should be selected in accord-
+ + + +
ance with NEC 690.45 and NEC 250.122.1. The primary evaluation for grounding and/or mounting was per-
+ + + +
formed with the PV module type(s) listed below.
+ + + +
o VSUN330-72P
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+ + + +
+ + + +
Specific evaluations of other modules can be provided upon request and at cost (a minimum of two mod-
+ + + +
ules are required). In addition, more than four attachment points per module can be set to account for wind,
+ + + +
snow, and other types of loading.
+ + + +
+ + + +
For the fire rating / testing requirements for metal roofs, there is an exception in ANSI/UL 2703 section 11.1
+ + + +
that exempts fire testing and provides a Class A rating when the following conditions are met:
+ + + +
+ + + + o Type 1, Type 2, or Type 3 modules as defined by UL 1703 or UL 61730-2;
+ + + + o 98% by weight of the racking is non-combustible per ASTM E136;
+ + + + o Installed over a Class A roof assembly of non-combustible roof covering, such as clay tile, concrete
+ + + + tile, metal panels made from steel, minimum 28 Ga ferrous panels or shingles.
+ + + +
+ + + +
+ + + + CompactMETAL meeting the above conditions shall be identified as having a Class A fire rating.
+ + + +
+ + + +
+ + + +
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+ + + + www.aerocompact.com 27
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+ + + +
 Appendix

+ + + +
+ + + +
+ + + +
+ + + +
+ + + + Load Rating
+ + + +
The CompactMETAL system design load ratings for a 72 cell PV module are:
+ + + +
a) Upward: 50 psf / 2.4 kPa
+ + + +
b) Downward: 71 psf / 3.4 kPa
+ + + +
c) Down-slope 10 psf / 0.48 kPa
+ + + +
+ + + +
Tested loads:a) Upward: 75 psf / 3.6 kPa
+ + + +
b) Downward: 106.5 psf / 5.1 kPa
+ + + +
c) Down-slope: 15 psf / 0.72 kPa
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