ValkAce Installation Manual

Disclaimer

This installation manual must be kept for future reference. For project-specific guidelines and recommendations, it is essential to use this document in conjunction with the "Project Report" generated by the ValkPVplanner. The instructions contained within this project report must be strictly followed at all times.

The content of this installation manual has been compiled with great care. Van der Valk Solar Systems accepts no liability for the correct use of this document. Van der Valk Solar Systems reserves the right to update the content of this document without prior notice. Please visit the Van der Valk Solar Systems website (www.valksolarsystems.com) to obtain the latest version of this document.

For the warranty conditions of your system, please contact your supplier. We also refer to our General Terms and Conditions, which are available upon request.

General Installation Guidelines

General

When installing the solar mounting system, the instructions and safety precautions listed in this installation manual must be carefully followed. As stipulated in the General Terms and Conditions of Sale and Delivery of Van der Valk Solar Systems B.V., failure to comply with the installation guidelines in this document will result in the customer being unable to claim any warranty, and Van der Valk will not be liable for any damages.

The information, comments, and advice in this document are binding. Van der Valk Solar Systems reserves the right to update this document without prior notice.

Safety

The installation of the mounting system must be carried out by qualified personnel. Omitting parts can impair performance and is therefore not permitted. Avoid installation work in adverse weather conditions, especially in strong winds and on wet (slippery) roof surfaces. When planning and executing the installation, always consider possible changing weather conditions, especially strong winds or storms. Take the appropriate measures and ensure that no situation arises where solar modules have already been attached to the system, but other important parts are still missing. Always use fall protection when working on the roof and, if necessary, use safety nets and edge protection. Always wear appropriate protective clothing and gloves when carrying out installation work. Follow the guidelines in the publication "Health & safety in roof work".

Environmental Factors

Adjacent buildings or objects, such as windmills, can influence wind pressure. In such cases, seek advice from Van der Valk Solar Systems before installation. If, during installation, it is found that the project data and/or environmental factors do not fully match the project report, the project must always be recalculated first. In coastal areas, the system should be located at least 500 meters from open water to prevent accelerated corrosion due to saltwater exposure. If there are buildings between the open water and the roof, a minimum distance of 250 meters from the open water can be maintained.

Norms and Regulations

For correct and safe installation and use of the solar mounting system, always observe the applicable norms and regulations:

• EN 1990: Eurocode - Basis of structural design
• EN 1991-1-3: Eurocode 1: Actions on structures - General actions - Densities, self-weight, imposed loads and snow loads
• EN 1991-1-4: Eurocode 1: Actions on structures - General actions - Wind actions
• IEC 60364: Electrical installations of buildings
• IEC 62305: Protection against lightning
• EN 50110: Operation of electrical installations
• Working Conditions Act and Ordinance on Safe Working Conditions

Stability and Condition of the Roof and Roofing

The roof pitch should be less than 5 degrees for flat roofs and between 5 and 75 degrees for pitched roofs.

The condition of the roof must be checked beforehand for sufficient strength to support the weight of the mounting system, including the ballast of the PV modules and the wind and snow loads. Ensure that the load reserve of the roof is not exceeded anywhere.

Check the stability of the roof and adapt the roof/construction if necessary. Before installation, check whether the roofing and/or insulation is suitable for the pressure and thermal expansion of the solar mounting system. The maximum pressure is specified in the ValkPVplanner project report or can be requested from Van der Valk Solar Systems.

Buckling of the roof membrane must be prevented. This can lift the solar mounting system and lead to displacement of the mounting system or ballast. It is the installer's responsibility to prevent buckling of the roof membrane.

Factors such as bridging cranes, seismic activities, and others that affect the stability of the roof and/or building can affect the installed solar mounting system. Van der Valk Solar Systems does not take these factors into account unless they have been confirmed in writing.

The roof surface on which the solar mounting system is to be installed must be clean, dry, and level.

The roof height must not exceed 25 meters if the project was calculated in ValkPVplanner and must correspond to the roof height in the project report. For installations on roofs higher than 25 meters, Van der Valk Solar Systems should always be contacted in advance.

Roof Zones

When installing the solar mounting system, always consider the applicable roof zones according to EN1991-1-4. Placing solar modules in the edge zone of the roof (the distance measured from the roof edge, which corresponds to 1/5 of the building height) is only possible if this has been explicitly taken into account in the calculation. It is possible to position modules in the edge zone using ValkPVplanner (calculation software). Based on this, the required additional ballast or fastening points are automatically calculated. This can only be done in "Satellite" or "White Map" design mode. The edge zone is automatically calculated by ValkPVplanner based on the roof height and building footprint, in accordance with applicable regulations. If the "Simple Mode" design mode is used, the calculation always assumes that the solar modules are located only in the middle zone of the roof.

Dilations

The maximum permissible dimensions of a coupled mounting system are 30 meters in the aluminum direction and 60 meters in the steel direction. The maximum dimensions are based on thermal expansion at a maximum temperature difference (Delta T) of 70 degrees Celsius. The coupled mounting system must not be installed over a gutter or roof ridge. If the mounting system is installed over a gutter or roof ridge, the system must be divided (dilation). When using the extra-wide module support feet for ValkPro+ with ballast, different expansion rules apply: for such installations, the coupled system may not exceed 30 meters in the steel/roof bracket direction and 15 meters in the aluminum direction.

Solar Modules

It is the installer's responsibility to determine in advance whether the selected solar module is suitable for the mounting system in terms of dimensions and load capacities. The calculated loads on the solar module are listed in the ValkPVplanner project report or are available upon request from Van der Valk Solar Systems.

Cable Management

To ensure a solid and durable electrical connection between the solar modules, it must be ensured that the cables from the junction box have sufficient length and thus do not place mechanical stress on the cable glands. Consider the thermal expansion and contraction of the cables and the mounting system. Cables and connectors must be kept away from sharp and/or abrasive parts and the roof surface by using adequate and suitable cable ties and cable trays.

Disassembly and Disposal

The components of the solar mounting system can be easily and completely disassembled at the end of their service life and separated for recycling. The systems contain only screw, bolt, and click connections; nothing is glued or welded. All materials are fully recyclable. The disposal of the components always takes place in accordance with local laws and regulations.

Tools Required for Installing ValkAce on Pitched Roofs with Tiles

• Cordless drill
• Socket wrench 13mm
• Torx bit T-30 (789530)
• Measuring tape

Materials for Installing ValkAce on Pitched Roofs with Tiles

• ValkAce Smartline Roof Hook (747502)
• Wooden board 730mm (75400730)
• Ss Torx screw 5.5x38mm (773840)
• Plastic element 3mm for Smartline roof hooks (739003)
• ValkAce Slimline Roof Hook (729505)
• ValkAce Slimline Adjustable Roof Hook (729501)
• ValkAce Strongline Roof Hook (747506)
• ValkAce Strongline Heavy Duty Roof Hook (747504)
• Ss Torx screw 5.5x58mm (773360)
• ValkAce Profile (7019…*) *see table
• Profile Lengths: 1220 mm (Art. Nr. 701901220), 2370 mm (Art. Nr. 701902370), 3520 mm (Art. Nr. 701903520), 4670 mm (Art. Nr. 701904670), 5820 mm (Art. Nr. 701905820)
• ValkAce Connector for Profiles (749502)
• ValkAce Module End Clamp (721412 - Grey, 721412ZW - Black)
• ValkAce Module Middle Clamp (721410 - Grey, 721410ZW - Black)
• ValkAce End Cap (739060)
• ValkAce Micro-Inverter Mounting Clip (739062)
• ValkAce Inverter Clamp (721440)
• ValkAce Cable and Connector Clip (739061)
• Plastic cable entry for roof tiles (739063)
• ValkAce Disassembly Tool (739065)
• Plastic pins for module alignment (733020)
• Ss. Cable clamp small (732001)
• Ss. Connection clamp (738201)

Overview of Standard Roof Construction

The ValkAce mounting system can be installed on a pitched roof with "normal" roof tiles. This manual refers to specific elements of the roof construction. The illustration below highlights these elements.

1) Purlins: The purlins are the structural beams that give the roof its shape and strength.

2) Roof Sheathing: The roof sheathing is the waterproof layer of the roof. In most cases, the roof sheathing also includes insulation.

3) Rafters: The rafters hold the layers of the roof together. The rafters are fastened through the roof sheathing into the purlins. The battens are fastened to the rafters.

4) Battens: The battens are fastened to the rafters. The battens are used as support and for fastening the roof tiles.

Overview of ValkAce Roof Hooks

Turning the Roof Hook Bracket for Installation

When unpacking, the ValkAce roof hook is not yet in the correct mounting position. Rotate the bracket by 90° to bring it into the correct position. With the help of the two alignment lips, the bracket is at a right angle to the roof hook.

Caution: Ensure that the bracket is not pressed down before attaching the profile to the roof hook. This will cause the spring action to be lost. If this happens, you can fix it by loosening the screw-nut connection and re-tensioning the bracket. This will not affect performance.

ValkAce Smartline Roof Hooks

The ValkAce Smartline roof hook is fastened to the roof construction with screws. First, a wooden board is mounted on the purlins of the roof, then the roof hook is attached to the board.

It is important that the Smartline roof hook has a 3 mm gap to the underlying roof tiles. If this is not the case, special yellow plastic elements (739003) can be placed between the wooden board and the roof hook (see illustration below).

ValkAce Slimline Roof Hooks

The Slimline roof hooks are placed over the roof tile and the batten that supports the tile. If you use the adjustable hooks, make sure the roof hook is set to the correct thickness (see illustration on the next page). Ensure that the roof hooks are correctly aligned so that the profile can be mounted correctly.

Check the ValkPVplanner project report for the required number of roof hooks and the maximum distance between the roof hooks.

The adjustable Slimline roof hook can be set to the desired thickness (tile + batten). Ensure that the roof hook fits snugly around the tile and the batten. If not, adjust the roof hook to increase tightness. Once you have determined the correct fit, adjust the remaining roof hooks to the correct thickness before mounting them on the roof.

Strongline (Heavy Duty) Roof Hooks ValkAce

The Strongline (Heavy Duty) roof hook ValkAce is mounted on the purlins of the roof. Use the holes in the mounting plate and the adjustable position of the hook to bring the hook into the correct position. The Strongline (Heavy Duty) roof hook must be fastened with at least 2 screws.

It is important that the roof hooks have a 3 mm gap to the roof tiles. This prevents the roof tile from breaking under heavy load (see illustration below).

Installation and Connection of ValkAce Profiles

ValkAce Profiles

Once the roof hooks are in place, the profiles can be mounted. The profiles are inserted into the steel brackets at the top of the roof hooks. The profiles can be mounted in a horizontal or vertical direction, depending on the desired orientation of the solar modules. When the profile is in the correct position, you can fasten it to the bracket by tightening the screw on the underside of the bracket (use Torx T30).

Solid Line (Blue) - Profile in vertical position for landscape orientation of solar modules.

Dashed Line (Green) - Profile in horizontal position for portrait orientation of solar modules.

Once the aluminum profile is correctly aligned, it can be fastened to the remaining roof hooks with the screws on the underside. The required torque range is 12-14 Nm.

Dilations

To ensure the mounting system has sufficient play to expand and contract due to temperature fluctuations, the system has limits for the maximum coupled lengths of the profiles. A "dilation" is required every 30 meters. The minimum gap between the profiles at the dilation is 150 mm.

Connection of ValkAce Profiles

Two ValkAce Profiles can be connected using the steel connection profile (749502). The connector can be inserted into both ends of the aluminum profiles, after which the aluminum profiles are pushed against each other. The connector has a stop on the underside, so that the coupling profile has the same length in both profiles to ensure maximum strength.

If a gap of no more than 3 mm occurs between the profiles after attaching them to the roof hook, a correct connection is still guaranteed.

Cable Management

ValkAce Cable and Connector Clip (739061)

The ValkAce cable and connector fastening clip (739061) can be used for the safe and clean fastening of cables and connectors. Each fastening clip provides space for the following items:

• 4x Cable Ø 6.5mm
• 1x Cable Ø 10mm
• 1x Cable Ø 12mm
• 2x MC4 connectors

The fastening clip can be clicked onto the ValkAce profile in any desired position.

Plastic Cable Entry for Roof Tiles (739063)

The plastic cable entry (Art. 739063) allows for clean and safe routing of cables through roof tiles. It protects the cables from sharp tile edges and keeps the cables separate. The cable entry can be hung behind the tile, and the cables can then be pushed into the grooves. The cable entry provides space for:

• 2 cables - Ø6mm
• 1 cable - Ø4mm

Micro-Inverters

ValkAce Micro-Inverter Clip

Attaching micro-inverters to the ValkAce system is quick and easy. The mounting clip (739062) made of stainless steel is positioned on one side over the profile and then pressed down on the other side. See illustration for reference. The "click" sound ensures that the clip is correctly positioned. The clip can be attached at any desired point on the profile.

The mounting plate of the micro-inverter can then be inserted under the nose of the mounting clip and is secured with a "click".

ValkAce Inverter Clamp (721440)

Inverters can be mounted directly onto the ValkAce profile using the inverter clamp (721440).

Clamps for Module Mounting

ValkAce Module End Clamp

Each end of the module row is secured with the end clamps (721412). The end clamps can be easily clicked onto the profile. The end clamps have a range for module frame thickness of 25-40 mm.

When you release the clamp from its lock, it can be clicked onto the profile even more easily. Adjust the end clamp to the correct height by inserting the upper element of the clamp into the slot that corresponds to the frame thickness of the panel. See illustration below.

Fasten the clamp with the screw (Torx T30) with a torque of 6-7 Nm.

ValkAce Module Middle Clamp

The middle clamps are mounted in the same way as the end clamps, only the height of the middle clamp is not fixed to a specific height. Click the middle clamp onto the profile and place the module frames against it. Once the modules and middle clamps are correctly attached, fasten them with the screw (Torx T30) (Torque 6-7 Nm).

Mounting End Caps ValkAce

The ValkAce end caps (729505) are placed over the ends of the aluminum profiles. The end caps cover both the end of the profiles and the sides of the end clamps. To mount the end caps correctly, the profile must have the correct length: the end of the profile must be 30-60 mm long, measured from the side of the module frame to the end of the profile.

Mounting of Additional Components

Van der Valk Solarsystems for pitched roofs offers a comprehensive range of components that make installation and use easier and even better. A selection of these components can be found below.

Module Alignment Pin (733020)

The module alignment pins can only be used for installations where the mounting profiles are mounted horizontally. The module alignment pins must be pre-assembled on the module frame (two per module). Once the alignment pins are attached, the solar module can rest on the aluminum profile during installation. This way, you have both hands free to attach the module clamps without having to hold the module simultaneously.

Ss. Cable Clamp Small (732001)

This cable clamp can be attached to the frame on the underside of the solar module. The cable clamp can hold 1 DC cable.

Ss. Connection Clamp (738201)

The connection clamp (738201) can be mounted on the module frame on the underside of the solar module. The clamp features a patented design that allows the clamp to be mounted in two directions (at an angle of 0 or 90 degrees). This means that the MC4 connector can always be attached in the preferred direction for the cables, reducing the risk of cable damage. The connector clamp can accommodate one MC4 connector per clamp.

ValkAce Grounding Clamp (739064)

The ValkAce system can be grounded by attaching the grounding clamp (739064) to the ValkAce profile. Ensure that the grounding clamp is tightened correctly so that the insulation of the grounding wire is definitively severed. Also, ensure that the grounding wire runs straight through the two cutting blades.

ValkAce Disassembly Tool

The ValkAce middle/end clamps can be disassembled with the disassembly tool (739065). Lift the clamp slightly on one side with your thumb, so that it can be easily released from the profile with the disassembly tool.

It can also be used for a variety of other purposes:

• MC4 connector fastener/loosener
• ValkAce middle/end clamp disassembly
• Beer opener
• MC4 connector fastener/loosener
• MC4 connector decoupler
• MC4 connector decoupler
• Power cable thickness: 4mm²
• Power cable thickness: 4mm²

Van der Valk Solar Systems

Van der Valk Solar Systems has been one of the fastest-growing companies in the solar industry since 2009 and focuses entirely on the development and production of solar mounting systems for pitched roofs, flat roofs, and open areas. Van der Valk Solar Systems also maintains an office and warehouse in the United Kingdom and an office in Spain and Sweden and is currently active in 13 countries.

Our mounting systems are developed and manufactured at our own production facility in the Netherlands and are characterized by their versatility, extremely fast assembly, and high quality. They have been developed in accordance with the latest European regulations, thus meeting the requirements for solar installations from credit institutions and insurance companies.

Van der Valk Solar Systems is part of the family company Van der Valk Systemen, which has made a name for itself worldwide in the field of movable systems and mounting components since 1963.

Our entire company complex covers 35,000 m² of office and operational space. Thanks to a modern machine park and the latest technologies, products and systems can be developed, produced, and tested quickly and precisely here.

Solar Mounting Systems & Cable Management

Flat roofs | Pitched roofs | Gestión de cables | Cocheras

Contact Details

Van der Valk Solar Systems B.V.
Westernesse 18, 2635 BG Den Hoorn, Nederland
+31 174 25 49 99
sales@valksolarsystems.nl

Valk Solar Systems UK Ltd
+44 1304 89 76 58
sales@valksolarsystems.co.uk

www.valksolarsystems.com

Valk Solar Systems Ibérica SL
+34 910 787 616
ventas@valksolarsystems.es

Valk Solar Systems Nordics AB
+46 8 55 82 86 26
sales@valksolarsystems.se

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