00MK-MA0140-EN00

Mounting System
ASSEMBLY INSTRUCTIONS

Universal and Universal Medium systems Rev.02

with fixing screws, for sloped roof November 2014
 Table of contents

General instructions 2

General safety instructions 3

Universal and Universal Medium systems with fixing screws,

for sloped roof 4

Regulations 5

Components required 6

Tools required 8

Assembly instructions 9

Notes 12

Table of contents 1
General instructions
Ensure you observe the general fitting and maintenance prescriptions. If you need any clarifications, please call immediately our
customer service at number +39 011 19870791.

1.Thesan Mounting System is constantly evolving and may 5.Follow the instructions of the manufacturer of PV modules
therefore be subject to changes; before starting, check the and the manufacturer of inverters.
version of the assembly instructions in your possession
and, if it is not up to date, send a request for an updated 6.Is necessary to provide routine maintenance on all parts
version to info@thesan.com. of the plant, on a regular basis (maximum each 6 months).
All personnel on work site must have a copy of the assem- Visual inspections:
bly instructions. Atmospheric events damages
Dirt, musk and other deposits
2.The 12-year warranty is assured by our warranty certifi- Corrosion of metal parts
cate subject to compliance with assembly instructions, Stability of the structure
general instructions and general safety prescriptions pro- Sealing of the roof cover
vided by Thesan S.p.A.
Mechanical inspections:
3.In case of non-compliance with the assembly instructions, Check the tightness of nuts and, if necessary, retighten
or are not used the parts listed, the warranty is void and the nuts to the torque given in the assembly instructions
Thesan declines all liability.
The areas under the modules are more prone to beco-
4.To disassemble the system, perform the assembly steps ming dirty, so remove all the deposits during the routine
in reverse sequence. maintenance.

General instructions 2
General safety instructions
Ensure you observe the general safety fitting and maintenance prescriptions. If you need any clarifications, please call immediately
our customer service at number +39 011 19870791.
1.Fitting and commissioning of the systems must be car-
ried out exclusively by skilled personnel who, thanks to
their specific training or professional experience, are able
to ensure that the work is performed correctly and to high
standards.
2.The existing structures on which the system is to be fitted
must be checked to ensure that the loading capacity of
the building/structures is adequate.
3.Observe all regulations and local and national building re-
gulations, and provisions relating to the environment.
4.Observe all regulations and national laws and local regula-
tions regarding health and safety, accident prevention and
the requirements of professional associations.
In particular, it is necessary :
Wear personal protective equipment: safety helmet, sa-
fety gloves , safety shoes, etc.
If the system is to be fitted on an elevated surface com-
ply with safety regulations for work at heights by using
safety harnesses, falling objects signs, etc.
General safety instructions
At least two people must be on the work site during the
fitting procedures, so that one person can provide first aid
or call emergency services in case of accident
5.Efficient grounding system is essential. If necessary, use
the lightening protection devices.
6.You can not cut the mounting rails. In the event that The-
san S.p.a. Technical Dept. requires to cut the profiles,
depending on the specific project to be carried out, you
must make sure to remove the burrson the surfaces af-
fected by the cut in order to eliminateany possible risk of
injury. Also you need to make surethat the cutted rails are
not curvy.
7.The electrical installation must be carried out exclusively
by skilled personnel who, thanks to their specific training
or professional experience, are able to ensure that the
work is performed correctly and to high standards. The
wiring of the photovoltaic modules must be made to avoid
the possible creation of loops.
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Universal and Universal Medium systems
with fixing screws, for sloped roof

FEATURES OF THE SYSTEM

Thanks to the significant reduction in the number of components, Thesan Mounting System allows a reduction of
approximately 57% in the amount of time required to fit the photovoltaic panels, compared to similar mounting
systems of key competitors.

Robustness, practicality, and reliability over time are key characteristics of the system.

Suitable for photovoltaic modules with and without frame.

Thesan is leader in guaranteeing, on request, a reliable and efficient after-sales service, which is at customers
disposal for any requirements.

All Thesan Mounting System documents

are available at:
www.thesan.com

For any need or clarification you may required, tel. 0039 011 19870791
please contact our customer service: e-mail ufficio.tecnico@thesan.com

The Universal and Universal Medium systems with fixing screws, for sloped roof, are a not pre-
assembled mounting system for photovoltaic modules.
In order to ensure safe and proper fitting of the system, each step described in these instructions must be carefully and
accurately followed. At each step, necessary materials and equipment are listed. For any inconvenience or misunderstandings
please call immediately our customer service.

Universal and Universal Medium systems with fixing screws, for sloped roof 4
Regulations
The installation of the system have to be performed in accordance to the following regulations, or similar standards which are
being used in the region of installation. The quality level of the standards need to be equal or higher as the standards which are
mentioned.

BGV A1 Accident prevention regulations General rules

BGV A3 Power system and equipment
BGV C22 Construction work
DIN EN 62305 Lighting protection
DIN VDE 0185 Lighting protection Components
DIN VDE 0100 part 410 Grounding
DIN VDE 0100 part 712 Electrical installations of buildings
DIN VDE 0105 Operation of electrical installation
DIN VDE 0298 Application of cables and cords in power installations
DIN 18338 Roofing work
DIN 18451 Scaffolding work
DIN 4102 Fire behavior of building materials and building components
DIN 18015 Electrical installations in residential buildings
DIN 18531 Waterproofing of roofs
VDS 2023 Electrical installations in structural works with mainly flammable materials
Eurocode 1 Wind loads
Eurocode 1 Snow loads
Eurocode 3 Design of steel structures
Eurocode 9 Design of aluminum structures

Regulations 5
Components Required

Alternatives available:
ALTERNATIVE RAILS

Universal SO-AYP12L3-0000 (3,1 m)

Material: Aluminium SO-AYP12L4-0000 (4,1 m)
SO-AYP12L6-0000 (6,2 m)

Alternatives available:
Universal Medium SO-AYP11L3-0000 (3,1 m)
Material: Aluminium SO-AYP11L4-0000 (4,1 m)
SO-AYP11L6-0000 (6,2 m)

Depending on the type of roof.

Fixing screws with plate
Refer to general catalogue.
FASTENERS

Alternatives available:
Allen head screw, M8, (DIN 993) 0042-68320-0000 (M8x25mm)
Material: Stainless steel 0042-68325-0000 (M8x30mm)
0042-68330-0000 (M8x35mm)

Nut with safety fit, M8, (DIN 6923)

0042-80500-0000
Material: Stainless steel

Components Required 6
 Clamp sets Depending on the type of
for frameless modules module, refer to general
CLAMP SETS

Material: Aluminium catalogue.

Clamp sets Depending on the type of

for modules with frame module, refer to general
Material: Aluminium catalogue.

Clamps Depending on the type of

for modules with frame module, refer to general
Material: Aluminium catalogue.

Alternatives available:
CLAMPS

Hammer head screw, M8 SOST-V209-00TH (M8X30mm)

Material: Stainless steel SOST-V206-00TH (M8X36mm)
SOST-V210-00TH (M8X42mm)

Nut with safety fit, M8, (DIN 6923)

0042-80500-0000
Material: Stainless steel
SUPPORT

Support plate for clamp,

to be used with Universal Medium rail SO-AY107-0000
Material: Aluminium
OPTIONAL

Other accessories available on request.

Consult the general catalogue.

For the possible use of alternative components contact Thesan S.p.a. technical department at ufficio.tecnico@thesan.com

Components required 7
Tools Required

Wireless screwdriver

Insert n13, n17 and n19 for screwdriver

Torque wrench

Mark line cord

Metric tape measure

Level

Tools Required 8
Assembly instructions
There are different types of screws with double thread,
depending on how the roof substructure is made, for
example with concrete, with steel beams, or wooden beams.
Step 1 Preliminary checks
a. Check the design measurements on the roof on which
the system is to be fitted.
b. The system is designed for assembly of all types of
Step 2 Pre-drilling the metal sheet/fiber cement sheet
and the steel supporting structure
a. Check that the supporting structure is intact and adequa-
te before making the holes.
b. Check the position of the supporting structure joists and
mark the position for the pre-drilled holes on the roof
sheet.
Step 3 Pre-drilling the metal sheet/fiber cement sheet
and the wood supporting structure
a. Check that the supporting structure is intact and adequa-
te before making the holes.
b. Check the position of the supporting structure joists and
mark the position for the pre-drilled holes on the roof
sheet.
Assembly instructions
The difference between them is the screw thread. The
waterproofing of the roof coverage is ensured by special
seals.
modules, with or without frame.
c. Provide a minimum distance of the rails from the edge of
the roof of 500 mm.
c. Pre-drill the hole both in the roof sheet and in the suppor-
ting structure. The two hole diameters are identical, refer
to the table below.
d. The support points of the mounting rail on the fixing screw
plate must be at the same height to ensure the mounting
rails are aligned.
e. The number of fixing screws and the relative application
distance will be determined by Thesan Technical Dept. (or
Thesan configuration software) depending on the specific
project to be carried out.
In case of different assembly solutions the warranty is
void.
c. Pre-drill the hole both in the roof sheet and in the sup-
porting structure. The hole diameter in the metal sheet/
fiber cement must always be larger than the diameter of
the fixing screw. Consult the table below.
d. The support points of the mounting rail on the fixing screw
plate must be at the same height to ensure the mounting
rails are aligned.
e. The number of fixing screws and the related application
distance will be determined by Thesan Technical Dept. (or
Thesan configuration software) depending on the specific
project to be carried out.
In case of different assembly solutions the warranty is void.
9
Table of reference hole diameters

Pre-drilling Diameter in mm,

corrugated sheet metal and Supporting Structure thickness in mm
supporting structure

Supporting Material Steel Timber

Material thickness in mm 1,5...< 5,0 5,0...< 7,5 7,5...< 10 10 32 40

Pre-drilling Diameter in mm for corrugated sheet metal + supporting structure

Solar panel fixing screw

6,8 mm 7 mm 7,2 mm 7,4 mm
for steel 8 mm
Solar panel fixing screw
5,5 mm 5,5 mm
for Timber 8 mm

Pre-drilling Diameter in mm for fibre cement sheets

Solar panel fixing screw

In corrugated sheet 11 mm 11 mm
for Timber 8 mm

In timber supporting structure 5,5 mm 5,5 mm

Step 4 Positioning the Universal or Universal Medium mounting rails

a. Fasten the mounting rail to the brackets using allen head

screw M8 and nut with safety fit.
The allen head screw must be inserted into the bottom of
the rail.

Bottom side

b. Tighten the nut with safety fit with a tightening torque of

35 Nm.
c. If necessary, use the external joint connectors to join two
or more profiles in line. When using the external joint con-
nectors, observe precautions to avoid thermal expansion.
To avoid any problem of thermal expansion it is recom-
You can use two different kind of rail:
mended not to exceed the overall lenght of 24,8 m, or
- Universal 4 profiles size 6,2 m aligned, aligned with each other.
- Universal Medium Beyond such length leave a minimum distance of 2 cm
The kind of rail will be determined by Thesan Technica Dept. from the next profile.
(or Thesan configurator software) depending on the specific d. Insert plastic protective plugs in the ends of the mounting
project to be carried out. rails.

Assembly instructions 10
Step 5 Positioning and fixing the photovoltaic modules

c. If the PV module is mounted landscape on the Universal

Medium rail, you must use the appropriate support plate
for the middle clamp and terminal clamp:

d. Position the photovoltaic module and fully tighten the nut

with safety fit to a torque of 14Nm.
e. Ensure the correct position of the clamp compared to the
frame of PV module. The vertical walls of the clamp must
adhere perfectly to the frame of the module:

Attention: Follow the instructions of the manufacturer of

the PV modules. Middle and final clamps
Module
for PV module
with frame Rail

a. If pre-assembled clamp sets are used, insert the hammer

head screw into the specific opening in the upper side of
the mounting rail, press the clamp gently to turn the screw Pre-assembled middle
of 90 clockwise. and final clamps Module
for PV module Rail
Make sure that hammer head screw is in an orthogonal with frame
position respect to the rail, and that the spring of the
clamp makes completely adhere the hammer head screw
to the rail. f. The cable lock and the cable lock with rings should be
If the clamps you are using are not preassembled, in- used to clipping the PV module wires, and they may be
sert the hammer head screw in the specific opening in clipped everywhere on the bottom side of the Universal
the upper side of the mounting rail, turn the screw of 90 rail.
clockwise, position the clamp and partially tighten the nut The PV module wires must be placed in the zones illustra-
with safety fit. ted below.
Please note that the electrical installation must be carried
out exclusively by skilled personnel who, thanks to their
Upper side specific training or professional experience, are able to
ensure that the work is performed correctly and to high
standards.

Upper side
Bottom side

Bottom side

Positioning area for PV module wires

b. If the PV module is mounted landscape, the long side of

the clamp must be in longitudinal position respect the
mounting rail, if instead the PV module is mounted por-
trait, the long side of the clamp must be in orthogonal Cable lock
Cable lock
position respect the mounting rail. with rings

Assembly instructions 11
Step 6 Grounding system

a. Efficient grounding system is essential.

b. Fastened with a screw the ground wire at any point on
the aluminium rail, using only stainless steel fasteners and
components.
c. Tighten the screw securely.

Assembly instructions 12
Notes

Notes 13
 www.thesan.com

Thesan S.p.A. - Via Torino 25 - 10050 Chiusa di San Michele (TO) Italy - tel. +39 011 19870791 - info@thesan.com

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