H2300 HELIOS

Flat Roof Typologies

AS106 – AS116
TECHNICAL MANUAL

Version:12/2022 www.alumil.com, www.alumilsolar.com

 Assembly Instructions for PV mounting structures

AS106 & AS116

❖ CONTENTS
A. MATERIAL LIST .......................................................................................................................................................... 3
1. Aluminum Profiles ................................................................................................................................................. 3
2. Fasteners & other accessories. ............................................................................................................................. 4
➢ Accessories needed to mount the profiles ....................................................................................................... 4
➢ Accessories needed to mount PV panels to the structure................................................................................ 5
3. Tooling set ............................................................................................................................................................. 6
4. Nut’s torques......................................................................................................................................................... 7
5. Safety zones .......................................................................................................................................................... 7
B. ASSEMBLY INSTRUCTIONS FOR AS116 ...................................................................................................................... 8
1. AS116 .................................................................................................................................................................... 8
➢ Placing Base Plate ............................................................................................................................................. 8
➢ Placing inclined beam on piles ........................................................................................................................ 10
➢ Placing purlins on inclined beam .................................................................................................................... 13
➢ Placing core ..................................................................................................................................................... 14
➢ Mounting panel ............................................................................................................................................... 17
➢ Placing end cups for purlins ............................................................................................................................ 19
C. MAINTENANCE ........................................................................................................................................................ 20

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 A. MATERIAL LIST

1. Aluminum Profiles

BASE PLATE CONNECTOR WITH INCLINED BEAM

(8960280100) (8960950000)

PROFILE: PILES AND INCLINED BEAM

PURLIN CORE FOR PURLIN

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 2. Fasteners & other accessories.

➢ Accessories needed to mount the profiles

HEXAGON BOLT ISO4017 M10x80 A2 INOX SERRATED LOCK WASHER DIN6798-Α M10 A2 INOX NUT M10 DIN934 A2 INOX
(7622108001) (7627301001) (7628010101)

HAMMER HEAD BOLT WITH EPDM M8x22 INOX A2 SERRATED LOCK WASHER DIN6798-A M8 A2 INOX HEXAGON BOLT ISO4017/DIN933 M8x30 A2 INOX
(8969122081) (7627300801) (EX-7622803001)

SELF DRILLING SCREW 6,3x32 Α2 INOX DIN7504K HEXAGON NUT DIN6923 M8 WITH SERRATION INOX COMPRESSION PLATE SMALL 40mm
(7626703201) (8968808201) (8960260000)

END CAP FOR PURLIN-RAL1003 YELLOW

*Size of end cup depends on the purlin profile

Purlin Profile End cap

H2055 EX-8960600040
H2060 EX-8960600040
H2070 EX-8960700040
H2080 EX-8960800040
H2090 EX-8960900040

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➢ Accessories needed to mount PV panels to the structure

MID CLAMP PANEL END CLAMP LENGTH : X mm*

(EX-8960180200) *Height of end clamp depends on the thickness of the PV panel

SERRATED LOCK WASHER DIN6798-A M8 A2 INOX T-SLOT NUT M8 ALUMINUM

(EX-7627300801) (EX-8968008103)

ALLEN BOLT DIN912/ISO4762 M8x‘LENGTH INOX A2*’ CAP OF PANEL GRIP WITH 55mm LENGTH
*Length of allen bolt depends on the thickness of the PV panel (EX-8960660000)

Panel thickness (mm) End clamp Allen bolt

50 EX-8960330100 EX-7629085001
46 EX-8960430100 EX-7629084501
42 EX-8960340100 EX-7629084001
40 EX-8960440100 EX-7629084001
38 EX-8960720100 EX-7629084001
35 EX-8960450100 EX-7629083501
34 EX-8960460100 EX-7629083001
32 EX-8960621100 EX-7629083001
30 EX-8960630100 EX-7629083001

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3. Tooling set

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4. Nut’s torques

The table below represents the specific torques that should be used for fastening the screws and nut’s,
according to size (i.e. M8 or M10) and aluminum’s finishing (i.e. mill finished or anodized).

SCREW TIGHTENING TORQUES (MILL FINISHED PROFILES)

M10 M8 M8 Allen

T = 9 - 10Nm (for thin film panels)

T=40-45 Nm T=25 Nm T =12-15 Nm (for poly panels)
SCREW TIGHTENING TORQUES (ANODISED PROFILES)
M10 M8 M8 Allen

T = 9 –11 Nm (for thin film panels)

T=50 Nm T=25-30 Nm T =14–17 Nm (for poly panels)

5. Safety zones

Safety distances of 10% roofs length should be kept from all edges of the roofs.
Installation of PV panels at zones B & C should be avoided since wind forces are very high at those zones.

WIND

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 B. ASSEMBLY INSTRUCTIONS FOR AS116

1. AS116

➢ Placing Base Plate

The process for drilling a hole on the roof according to the X1, X2, and Y dimensions is as follows:

1. Determine the X1,

X2, and Y
dimensions for the
hole. These
dimensions will
vary depending on
the specific
requirements of
the project.
2. Mark the location
for the hole on the
roof using the X1
and X2 dimensions
as reference
points.
3. Use a drill with the
appropriate size and type of bit for the material of the roof.
4. Begin drilling the hole, making sure to keep the drill level and steady. Pay attention to the drill's speed
and pressure to avoid damaging the roof material.
5. Continue drilling until the hole reaches the Y dimension.
6. Stop the drill and inspect the hole to ensure that it is the correct size and shape. If necessary, adjust
the hole as needed.

X1, X2 = Distance of horizontal according to order.

Y = Distance of vertical profiles according to order.

PART NUMBER Y
TRIANGLE (mm)
8961162510 1650
8961162550 2200
8961163010 1820
8961163100 1830
8961163700 2100

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 BASE PLATE

Place the fully threaded stud bolts M10.

THREADED STUD
BOLTS M10

Note: It is important to follow all safety guidelines and wear proper personal protective equipment when
drilling holes in a roof. Always consult the roofing material manufacturer's specifications and guidelines
before drilling a hole.

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➢ Placing inclined beam on piles

After tracing the spots on the concrete blocks where the base plates of the structure should be placed on,
connect the inclined beam with the brackets and poles by using the connector and screws M10X80.

DETAIL A

INCLINED BEAM

CONNECTOR
WITH
INCLINED
BACK BRACKET BACK PILE BEAM

FRONT PILE
FRONT BRACKET

BASE PLATE

Place the hammerhead screw on the rail and rotate clockwise to lock and use hex flange nuts M8 to fasten all
parts together.

HAMMER HEAD
BOLT WITH EPDM
M8x22 INOX A2

HEXAGON NUT
DIN6923 M8 WITH
SERRATION INOX

CONNECTOR
WITH
INCLINED
BEAM

DETAIL A

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Placing the base plate at the appropriate distance.
Tight the bolts M10x80 that connect the base plates with the poles and brackets, so that every item is stable.

PART NUMBER Y IB P
A
TRIANGLE (mm) (mm) (mm)
DETAIL B 8961162510 1650 2850 25ο 80
8961162550 2200 3150 25ο 90
8961163010 1820 2850 30ο 60
8961163100 1830 2850 30ο 35
8961163700 2100 3700 25ο 130

DETAIL C

CONNECTOR BASE PLATE

WITH
INCLINED
BEAM

HEXAGON BOLT
ISO4017 M10x80 HEXAGON BOLT
A2 INOX ISO4017 M10x80
A2 INOX

SERRATED LOCK
WASHER DIN6798-A SERRATED LOCK
M8 A2 INOX WASHER DIN6798-A
M8 A2 INOX

NUT M10
DIN934 A2 NUT M10
INOX DIN934 A2
INOX

DETAIL B DETAIL C

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Place base plate in the stud bolts M10 and tight with hexagon nut M10.

HEXAGON
NUT M10

THREADED STUD
BOLTS M10

Note:

• Inspect the entire installation to make sure that all components are securely attached and that there
are no gaps or other issues.
• It is important to follow the manufacturer's specifications and guidelines for the installation of the
inclined beam, brackets, poles, and connector, as these will vary based on the specific application and
requirements. Failure to properly install these components can result in damage or failure of the
structure.

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➢ Placing purlins on inclined beam

Place the purlins at the appropriate distances, according to the manufacturer of the PV module.

DETAIL D

HEXAGON NUT
DIN6923 M8 WITH
SERRATION INOX

COMPRESSION
PLATE SMALL
40mm

BEAM

HEXAGON BOLT
ISO4017/DIN933
M8x30 A2 INOX

HAMMER HEAD
BOLT WITH EPDM
M8x22 INOX A2

COMPRESSION
PLATE SMALL
40mm

BEAM

HEXAGON NUT
DIN6923 M8 WITH
SERRATION INOX

DETAIL D

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➢ Placing core

After bases installation, are placed. In their meeting point, the connection should be done with the help of core
accessory. Core is used to connect two identical profiles, while helping in the absorption of thermal expansions
due to temperature changes.

DETAIL E

Place the core in the 2 successive profiles and mount with 2 self-drilling screw.

PURLIN

SELF DRILLING CORE

SCREW 6,3x32 Α2
INOX DIN7504K
DETAIL E

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In tables with a total length less than 40m, fix with 2 self-drilling screws all the cores on the beans.

In tables with a total length more than 40m, leave one core free, fix with a self-drilling on one beam.

The rest of the cores fixed normal using two self-drilling screws.

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The "free core" must not be located below the panel or in other words, there should not be a panel mounted
on two successive beams, which are joined by "free core". Even the "free core" must be located no more than
1/3 of the opening of the triangle.

The maximum length of the table is 60m.

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➢ Mounting panel

The process for fixing the photovoltaic (PV) modules with clamps after fixing the purlins is as follows:

1. Gather all necessary tools and materials, including the PV modules, clamps, and any other necessary
hardware.
2. Locate the purlins that have already been fixed in place.
3. Place the clamps loosely on the purlins, making sure that they are spaced evenly and positioned in a
way that allows them to be used to secure the PV modules.
4. Begin with the placement of the PV modules on the purlins. Start by positioning the end clamps at the
start and end of a line, and then place the middle clamps at all other locations along the line.
5. Secure each PV module in place by tightening the clamps, making sure that each module is securely
fastened to the purlins.
6. Repeat the process of placing and securing PV modules along each line, making sure that each module
is properly aligned and that all clamps are tightened securely.
7. Inspect the entire installation to make sure that all components are securely attached and that there
are no gaps or other issues.

DETAIL F
DETAIL G

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Mount the edge panels onto the purlins using an End Clamp, an M8 Allen Bolt of specified length, a M8 Grover,
and a T-Slot Aluminum Nut.

CAP OF PANEL
GRIP WITH
55mm LENGTH

ALLEN BOLT M8

SERRATED LOCK
WASHER
DIN6798-A M8
A2 INOX

END CLAMP

T-SLOT NUT
M8 ALUMINUM

DETAIL F

To mount two intermediate panels on the purlins, use a Mid Clamp, an M8 Allen Bolt of specified length, a M8
Grover, and a T-Slot Aluminum Nut.

CAP OF PANEL
GRIP WITH
55mm LENGTH

ALLEN BOLT M8

SERRATED LOCK
WASHER
DIN6798-A M8
A2 INOX

END CLAMP

T-SLOT NUT
M8 ALUMINUM

DETAIL G

Note: It is important to follow the manufacturer's specifications and guidelines for the installation of the PV
modules, clamps, and other components, as these will vary based on the specific application and requirements.
Failure to properly install these components can result in damage or failure of the system.

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➢ Placing end cups for purlins

Install the yellow plastic caps at the end of the rails, with four caps for one side of the table and four caps for
the other side.

END CAP FOR PURLIN-

RAL1003 YELLOW

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 C. MAINTENANCE

The PV mounting structures of ALUMIL S.A are designed in accordance with the
European Standards (Eurocode 1, 3, 9) and do not require any special attention.
ALUMIL also offers certified aluminum PV mounting structures made from
durable aluminum alloy (Al 6005Τ6).
However, regular maintenance is recommended to maintain the high quality
and longevity of the structures.
During site inspections, it is advisable to pay close attention to areas such as
joints and holes. Specifically, the following checks are recommended:

• Inspect bolted joints annually and replace them if bolt corrosion is detected.
• Periodically check the torque of bolted joints (every 1-2 years).
• Verify the torque on panel clamps every 6-9 months or after severe weather
conditions to ensure the installation and torque settings remain accurate.
Torque specifications can be found in the installation manual.
• Inspect aluminum and plastic components for any deformations and replace any
deformed parts as needed (every 2 years).
• For locations close to sea level (<150m), it is important to clean the structures
with water (no pressure) to prevent salt corrosion (annually).
• If snow accumulates, the panels must be cleared within 2 days of being fully
covered to avoid freezing. Remove the snow without allowing it to freeze.

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