STATICS. STABILITY. SAFETY.

TILED 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:
13 mm, 15 mm and 17 mm ring / open-ended wrenches (open-ended spanners)
Electric screwdriver
6 mm hexagonal socket wrench (Allen key)
TILED ROOF
Please read the safety instructions carefully before
beginning installation work. You must always an-
chor the roof hooks in the supporting roof structure.
The substructure is usually a rafter roof. In such
cases, you must install roof hooks on every rafter.
On purlin roofs, you have to proceed differently, as
the tiles displacement usually does not correspond
to the spacing of the purlins. This means that you
cannot install the hooks on the purlins. With other
roof structures, it is usually possible to anchor the
roof hooks.
If you have any additional questions, use INTERSOLs
professional and comprehensive consultation ser-
vice. Our competent construction engineers and
technicians are happy to help you.
You can choose between roof hooks with thick-
nesses of 5 mm, 6 mm and 8 mm. These are availa-
ble as fxed or adjustable bolted roof hooks (item
no. 10301-180 to -185) or as normal or low welded
roof hooks (item no. 10301-201/2 to -206). For ex-
treme loads, you can use the 40x10 roof hook (spe-
cial article).
On tiled roofs, modules are usually installed verti-
cally. For this purpose, you must install 2 cross gir-
ders. If wind and snow loads are high, a third cross
girder may be necessary.
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 ad-
herence to these torques. Align the frame or mo-
dules before tightening the bolts.
INSTALLATION INSTRUCTIONS
Tiled roof
BOLTS
Manufacturing and distribution: Donauer Solartechnik Vertriebs GmbH. Subject to errors and technical modications.
Version: 02/2009; contact: info@donauer.eu // www.donauer.eu
Remove tiles from the roof covering and position the roof hook on
the rafter in such a manner as to enable anchoring to the substruc-
ture with at least 2 bolts, and so that an exit point can be provided
for the roof hook at the tile. You may need to cut a notch out the
tiles in the area of the roof hook. Upon delivery, 50% of the bolted
roof hooks have a left-sided arrester, and 50% have a right-sided
arrester. If it is necessary to adjust the arrester direction, you can
rotate the base plate by loosening the two hexagonal nuts on the
base plates press-ftted M8 bolts, and by moving the roof hook. In
order to set the correct installation height above the rafter, positi-
on the hook in such a manner that the side piece has a minimum
clearance of 3-5 mm from the tile (Fig. 1 and 2). For this purpose,
you may need to underlay the hook. With bolted roof hooks, you
can add 3 to 10 mm of height between the base plate and the roof
hook by means of 3 mm steel shim (item no. 10301-186) and 5 mm
steel shim (item no. 10301-187). In order to insert the steel shim,
loosen the two M8 nuts above the side piece. You can then raise the
side piece far enough to make it possible to slide in the steel shim
laterally (Fig. 2). With welded roof hooks, if it is necessary to adjust
the height on the rafter, do so by underlaying the welded roof hooks
with hardwood or MDF panels between rafter and base plate. On
roofs with an uneven surface, the adjustable roof hooks are used.
These allow you to increase the distance between the side piece
and the roof covering further, by up to 40 mm (Fig. 3).
The fastening to the substructure (rafters) is then realised with at
least 2 screws per roof hook. Here, you can choose between fat
head screws (item no. 10301-420100, -420120), which can be in-
stalled without pre-drilling, and wood screws (item no. 10301-
42/100, /120, /200), which require pre-drilling into the wooden
structure. For roofs with insulation on the outside of the roof struc-
ture, Assy Isotop bolts (special article) are used in order to fasten
the roof hooks, so as to achieve the desired anchoring in the sup-
port structure (Fig. 4).
1
ROOF FASTENING
2
3
3 - 5 mm
2,4 cm
TILED ROOF
Please note: the screws for fastening the roof
hooks must be at least 2.4 cm from the edge. As the
screws are to be guided into the wooden structure
in a straight line, the rafter must be at least 6 cm
wide if the base plate is used. We recommend 8 cm
as the minimum anchoring length.
Make sure that a support point is always provided
in the area of the side piece beneath the base plate.
This, for instance, can be realised by using an ad-
ditional batten beneath the roof hook. If you cannot
install the roof hooks side piece in the area of the
rafter, an auxiliary rafter must be added to the side
of the rafter (Fig. 5). If lateral reinforcement is not
possible, our team will be happy to help you fnd a
suitable solution.
4 5
Manufacturing and distribution: Donauer Solartechnik Vertriebs GmbH. Subject to errors and technical modications.
Version: 02/2009; contact: info@donauer.eu // www.donauer.eu
With the cross girder types Standard type 2 (item
no. 10301-03/1 to /7) and Light type 2 (item no.
10301-04/16 to /20), the lower slot serves to accom-
modate the M10 T-head bolts and M10 mushroom
head square necked bolts. The upper T-shaped slot
is only suitable for fastening the modules, because
only M8 square nuts (item no. 10301-41/M) can be
inserted here. The Futura 40x40 cross girder (item
no. 10301-04/310, /311, /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 (10301-41/E) for fastening mo-
dules with M8 Allen bolts with interlocking (item no.
10301-411 to -419). All 3 types of cross girders can
be connected quickly and easily with the assembly
angle (item no. 10301-073). With the cross girder
Standard type 2 and Futura 40x40, attach the as-
sembly angle in such a manner that the side piece
with the 2 drilled holes serves as a lateral arrester
(Fig. 6). With the cross girder Standard type 2, the
arrester is not to be situated on the side of the cable
channel. With the cross girder Light type 2, the side
piece with the 3 drilled holes is the lateral arrester
(Fig. 7). Every assembly angle is fastened with two
M10 T-head or M10 mushroom head square necked
bolts and M10 hexagon nut with interlocking (item
no. 10301-40/M). Make sure that the connecting
joint is not situated directly at a fastening point.
Please note: the maximum transverse rail length
should not exceed 15.0 m. 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 with item no. 10301-083, for
Standard type 2
CROSS GIRDERS
Light type 2
6 7
M8

M10
M8

M10
TILED ROOF
cross girders Light type 2 the end cap with item no. 10301-082, and
for cross girders Futura 40x40, the end cap with item no. 10301-
081. The end caps are affxed on the underside with an M10/16 he-
xagon bolt (item no. 10301-40/ A) and a serrated M10 hexagon nut
without interlocking (item no. 10301-41).
Installing modules portrait: if installing modules portrait, fasten the
cross girder to the roof hooks. You can use the cross girder Stan-
dard type 2, Light type 2, or Futura 40x40. The cross girders are fa-
stened to the upper side piece of each roof hook with an M10 T-head
or M10 mushroom head square necked bolts and an M10 hexagon
nut without interlocking. You can insert the T-head bolt anywhere
in the lower slot of the cross girder. Insert the M10 mushroom head
square necked bolts into the slot at the end of the rail, and slide
them to the desired position (Fig. 8 and 9).
If the cross girder Standard type 2 is selected, you must ensure that
the cable channel is uppermost, so that the cables cannot fall out of
the channel. The cross girders should not protrude more than 300
mm beyond the last roof hook.
Please note: the tiles dimensions form a pattern for the spacing
of the roof hooks / cross girders. The permissible mounting areas
are described in the data sheet, or in the installation instructions,
of your selected module.
Installing modules landscape: if installing landscape, you should
check whether the manufacturers specifcations permit fastening
of modules on the short side. If this option is possible, proceed as
for portrait installation. However, if the fastening points are situated
only on the long sides of the module, a cross rail system is necessa-
ry. For more detailed information in this regard, refer to the specifc
installation instructions Cross rail system.
8
9
Manufacturing and distribution: Donauer Solartechnik Vertriebs GmbH. Subject to errors and technical modications.
Version: 02/2009; contact: info@donauer.eu // www.donauer.eu
10 11
Installing modules portrait or landscape: now pre-
pare the end clamps (item no. 10301-1532 to -1551) /
end clamps for frameless modules 2-parts (item no.
10301-98) and central clamps (item no. 10301 14 and
-141) / central clamp for frameless modules 2-parts
(item no. 10301-97) for fastening the modules to the
module rails.
Please note: 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,
the clamps are provided with M8 serrated Allen bolts
with interlocking and M8 square nuts. Slide the re-
quired number of clamps into the upper slot of the
cross girders. With the cross girder Futura 40x40, an
M8 hammerhead nut is used instead of the M8 square
nut. Here, the clamps can be inserted 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 (Fig. 10).
To fasten the module on the other side, place another
module, and fasten both to the central clamps (Fig.
11). Continue in this manner, and lock off the fnal
module with end clamps (Fig. 12).
MODULE FASTENING
TILED ROOF
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.
L
Manufacturing and distribution: Donauer Solartechnik Vertriebs GmbH. Subject to errors and technical modications.
Version: 02/2009; contact: info@donauer.eu // www.donauer.eu
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
TILED ROOF
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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!