LightX-EW and LightX-EW Alpine Installation

Manual
 Contents

1. Indroduction 3
1.1 Short Description 3
1.2 On these instructions 3
1.3 Warning notices 4
1.4 Safety 4

2. Important assembly notes 5

2.1 Application conditions 5
2.2 Assembly preparation 5
2.3 Assembling aid and required tools 5
2.4 Expansion joints 5
2.5 On the assembly descriptions 5

3. Technical description 6
3.1 System overview 6
3.2 Components 7
3.3 Technical data 8

4. Planning of the module area 9

5. Mounting steps 10
5.1 Pre-assembling back support 10
5.2 Pre-assembling front support 10
5.3 Mounting the next unit 11
5.4 Mounting the next row 12
5.5 Applying ballast 13
5.6 Mounting the modules 14
5.7 Mounting the back sheet 15

6. Light X-S Alpin Installation 16

2 LightX-EW-MA-EN-2406
1. Introduction
It is crucial to carefully read these Instructions as well as all
1.1. System Description applicable documents prior to carrying out any installation,
maintenance or disassembly work. You are provided with the
The LightX-EW ProLine & LightX-EW Alpine ProLine is a robust information required for the safe and complete installation,
framework designed for assembling photovoltaic (PV) modules maintenance and disassembly. Should you have any questions,
on flat roofs exceeding 10 m2 allowing to mount PV modules please contact Mounting Systems GmbH.
with a width of 1134 mm. This system facilitates connecting
multiple rows of modules facing south, with inclination of 10°.
User Group
It is specifically engineered for flat roofs with limited load Mounting Systems GmbH’s installation instructions are
capacity. All components are designed for easy assembly, intended for the following persons (user group):
utilizing Clickstone technology, standard preassembly, and a
thoughtful product design comprising minimal individual • Skilled personnel
parts, resulting in efficient assembly with minimal tool • Instructed personnel
requirements.
The materials used include aluminum and stainless steel, Skilled personnel
chosen for their corrosion resistance, ensuring prolonged Skilled personnel are individuals who, on the basis of
service life and enabling full recyclability. their professional training, are able to execute
installation, maintenance, and disassembly work
appropriately.

1.2. Manual Overview Instructed personnel

Instructed personnel are individuals who have been
Content instructed and taught appropriately regarding the assigned
These instructions cover assembling the LightX- EW tasks and the possible risks in the event of improper conduct.
ProLine flat roof system, including planning, components, An instructed individual must have received instructions
and safety information. The initial drawings demonstrate regarding the required safety policies, precautions, relevant
corner clamping for framed regulations, accident prevention regulations, as well as
modules. Chapter 6 provides details on procedures and operating conditions and must have demonstrated his/her
components for the Alpine version, enabling long-side clamping. competence.
The implemented work must be approved by skilled
personnel.
Applicable Documents
In addition to this manual, each MSY system includes the Orientation guide
“Installation Manual - General Information” providing The following pictograms allow for the easier orientation in
general details on standards, safety, transport, maintenance, this manual:
disassembly, and disposal relevant to the assembly site. Both
this Installation Manual and the “Installation Manual - Pictograms:
General Information” are essential components of the LightX-
EW ProLine & LightX-EW Alpine ProLine mounting system This symbol indicates important information
and must be followed for every installation. and useful tips.

This symbol indicates tips and tricks for easier

procedures.

Installation Manual LightX-EW 3

 1.4 Safety
1.3. Warning notices

The complete general safety regulations for the frame systems

The warning notices used in this Installation Manual
supplied by Mounting Systems GmbH
indicate safety-relevant information. They include:
are included in the further applicable document “Installation
Manual - General Information”. Read this document with care
• warning symbol (pictogram)
and always observe the notices contained - use the frame
• signal word indicating the hazard level
only in compliance with its intended purpose. Observe the
• information on the type and source of hazard
duties of the principal and follow the general as well as the
• information on possible consequences if hazards are
specific safety instructions.
disregarded
• measures to be taken in order to prevent
For any jobs you accomplish, the specific safety notes which
• hazards and avoid injuries or damage
precede the instruction steps in this productspecific Installation
Manual must also be observed.
The signal words of the warning notices indicate the
following hazard levels:

DANGER! DANGER!
Indicates a great and extraordinary Danger to life due to falling parts!
danger, which may result in death or
serious injury if ignored. Parts falling from the roof may cause
severe injury or death!

WARNING! Seal off the danger zone on the ground

Indicates a potentially dangerous prior to starting assembly work in order
to prevent persons from being injured by
situation, which may result in serious
falling parts!
or medium injury or damage to the
property. Make sure to secure the parts so that they
cannot fall from the roof!

Wear the protective equipment stipulated by

law!
CAUTION!
Indicates a potentially dangerous Do not stand in the danger zone! Do

situation, which may result in minor

not work in high wind!
injuries or damage to the property if
ignored. After having completed assembly, check the
frame system and the modules whether they
are tightly secured!

ATTENTION!
Indicates potential danger, which can
result in damage to property DANGER!
Danger to life due to falling parts!

Falling from the roof may cause

severe injury or death!

Wear the protective equipment stipulated by

the law!

Secure yourself against falling!

Do not work on the roof during high wind!

4 Installation Manual LightX-EW

 2.4 Expansion joints
2. Important assembly notes
Due to thermal expansion, the frame must be designed with
2.1 Application conditions
joints which must be taken into account for the ballast plan.
The following data can be used for module design:
Ballast stones are utilized on the ground rails to sta- bilize the
installed flat roof system. Your personalized ballast plan
Basic Version :
specifies the arrangement of these stones and is included in
In North-South direction: every 10 modules In
the delivery package. The customer is responsible for
East-West direction: every 5 modules
verifying that the roof can support the extra weight of the
system and the ballast stones.
Alpine Version :
In North-South direction: every 10 modules In
2.2 Assembly preparation
East-West direction: every 5 modules

Mounting Systems GmbH recommends gathering in-

formation on the on-site conditions before placing an order
2.5 On the assembly description
but in particular, you should familiarise yourself with:

The following chapters outline the sequential steps re- quired

• The roof structure (e.g. surface material)
for planning and assembling the system. Chap- ter 5 details the
• The permissible extra load capacity of the roof
steps for corner clamping modules on the short side, while
• Ensuring the supporting structure is securely fixed to the roof
Chapter 6 covers additional steps for alpine version.
surface.

Please carefully follow these assembly steps and en- sure strict
compliance with the safety instructions.
2.3 Assembling aid and required tools

The following tools are required for the assembly of the frame
DANGER!
system :
Danger to life due to falling parts!
• Allen wrench, 5 mm
• Impact wrench with a tightening torque of min. 18
Parts falling from the roof may cause
Nm or an M13 ring spanner wrench
severe injury or death!
• Elongation for impact wrench
• Attachment for impact wrench, 13 mm nut Before starting assembly, make sure
• Chalk line that the material used meets the on-
• Spirit level site static requirements.

• Folding rule / measuring tape

• Lifting gear (e.g. roofer lift, harness)
• Plunger elevator
• Spacing template (included in the scope of delivery)
• Gloves

DANGER!
Danger to life due to damage to the
roof

Excessive load may severely damage

the roof!

Before starting assembly, make sure that the

building and in particular the roof cladding
meet the static requirements which will
increase due to the PV
system and during assembly work.

Installation Manual LightX-EW 5

 3. Technical description

3.1 System overview

The following illustration shows all crucial system parts. The

design of each system part may vary.

It depends on:

• type of roof
• type of module
• number of modules
• local conditions.

1
1

5
3

6 8

1
9

1 Front Support

2 Back Support

3 Ground Rails

4 Module Mid Clamp

5 Module End Clamp

6 Universal Ballast Tray

7 Ballast Plate

8 T-Head Bolt & Locking Nut for

Ballast Tray

9 Building Protection Mat, 370 x 150 x 8mm

(standard or coated with aluminium)

11 Ballast Stone

6 Installation Manual LightX-EW

3.2 Components

The following illustration shows all parts of the

LightX-EW frame which can be included in the
scope of delivery.

1 Front Support
1 2

2 Back Support

3 Ground Rails

4 Module Mid Clamp

3 4

5 Module End Clamp

6 Universal Ballast Tray

5 6
7 Ballast Plate

8 T-Head Bolt & Locking Nut for

Ballast Tray

9 Building Protection Mat, 370 x 150 x 8mm

7 8 (standard or coated with aluminium)

10 Cross Connector 1/22

9 10

Installation Manual LightX-EW 7

 3.3 Technical data

Application Flat roof 1

Roofing For all roof coverings (except green roof) 1

Roof inclination Up to 5°

Building height Max. 25 m

(Depending on wind loads on site) 2

Module width 1134 mm

Module length Up to 2300 mm

Module inclination 10°

Standards Eurocode 0 and national annex

Eurocode 1 and national annex
Eurocode 9 and national annex

Supporting profiles Aluminium (EN AW 6063 T66)

Sheet metal components Galvanised steel (DX51D+ZM310)

Small parts Stainless steel (V2A)

Color Aluminium: Natural

Warranty 10 Years 3

1
Attention: For any project, please check the static suitability of the building!
2
Official assesible static calculation available on request, at extra cost.
3
Please find the exact terms in the Mounting Systems GmbH warranty document.

8 Installation Manual LightX-EW

4. Planning of the module area

Before you can start assembly, the following tasks must

be accomplished:

• Clean the roof surface.

• The first row must always be mounted towards the front
roof edge (south).
• Align the installation area because roof areas are not
always at right angles.
• Apply, for example, a chalk line at the first row to align
the front side.

We require using building protection mats

in order to avoid damage to the waterproofing of the
roof. Depending on the surface structure of the
roof, we recommend the following building protection mats:

Roof Building protection mat

Bitumen-coated Standard

Foil roof Coated on one side with

aluminium

Gravel-covered Optional

Two building protection mats for each elevation must be

placed under each ground rail (one each under every front
foot and every back support). If additional ballast support
components such as ballast tray or ballast plates are used,
additional building protection mats are required.

The following calculation applies:

• Ballast profile: one additional building protection mat

for every two ballast profiles

• Building protection mats are cut out such that safety

tabs can be fold out in order to prevent lateral
slipping (for example caused by thermal expansion)

Make sure that the building protection mat protrudes from

both ends of the ground rail by approx. 50 mm and the
safety tabs are be unfolded. This is to ensure optimal
protection for the roof surface.

Installation Manual LightX-EW 9

 5. Mounting Steps 1

5.1 Pre-assembling back support

1 Place the back support on the ground rail, by

measuring a distance of 1068 mm from the front
edge of the ground rail. And then fasten with M8 T-
head bolt nut applying 16 Nm force. Place the
second support seamlessly at 180 degrees to the
first one.

The length of ground rail of the first assembly has

to be selected as 2393 mm for first and middle units
and connection rail length in between is 410 mm.

5.2 Pre-assembling front support

The front support serves as both a connection point

between the rails and for aligning the modules.
The natural coloured nut must face the front (south)
direction.

Assembly steps:

1 Preassemble the short ground rails (60 mm) with 1

the front support only for the “Front Row” with a
force of 16 Nm.

ATTENTION!
The first screw has to be tightened
which is indicated by the vertical slot

2 Slide preassembled front support to the base rail,

ensuring no clearance and the rails are fully
touched to each other . Then nut has to be
tightened with a force of 16 Nm.

10 Installation Manual LightX-EW

 ATTENTION!
Pay attention to the screws not yet
tightened which is indicated by the
vertical slot

5.3 Mounting the next unit: Screw not tightend Screw tightend

Assembly steps: 1

1 At this stage, the installer should have

2393 mm Rail
completed the preassembly of units that
consists of ground rail, front and back
supports.

2 Following this, the preassembled rail units need to

be joined together by securing the front supports
60 mm Rail
of each unit, which face each other, are connected
by a 410 mm ground rail piece. Front (1st) Unit
Pay attention to front support so that it does not 1

get out of place or rotate when being tightened.

Repeat these steps until the mounting frame row is

complete. 2393 mm Rail

Mid Unit

3 Connecting ground rail piece with the

410 mm rail.

4 Place the protection mats underneath the

rails

Installation Manual LightX-EW 11

 5.4 Placing the next row:

Assembly steps:

• All the preassembled units are aligned alongside the

application area on the roof with a certain distance in
between.
• The distance between the rows corresponds approxi- mately
to the module length.
• It is recommended to precisely realign this distance when
assembling the modules.

Distance X between rails is calculated by below formula: Module

Length - (2x20 mm)

Distance X

12 Installation Manual LightX-EW

5.5 Applying ballast

Before finally mounting the modules, ballast must

be applied. Depending on the amount of the ballast, there
are two variants for applying ballast to the LightX-EW
ProLine system. Both variants as well as their assembly are
presented in this chapter.

Applying ballast with additional ballast plates.

Assembly steps:

• Simply insert the ballast profiles in the ground rail. This

variant also offers the option of using 30 x 30 x 4 cm paving
stones in addition to the ballast stones.
• It is mandatory to apply building protection mats under the
ballast plates!
• When inserting the ballast plates, make sure that both outer
lugs of the ballast profiles are positioned in
the outer channel of the ground rail.
• Depending on pitch and module width, only a certain
number of ballast stones can be applied (see ballast plan in
calculation tool).

Configuration Number of paving stones on the

ground rail and ballast profiles

10° max 5 (approx. 40 kg)

Applying ballast with with universal ballast tray.

Assembly steps:

• Prepare the T-head bolts/nuts for one end of the tray for
proper fixing, while utilizing bottom clamps (cross
connector) for the other end.
• The ballast tray on the back support aligns perfectly with
the back support.
• Depending on the ballast calculation, only a certain number
of ballast blocks can be used (Pleae refer to the ballast plan in
calculation tool.)

Configuration Number of paving stones under

the module

10° max 15 (approx. 120 kg)

Installation Manual LightX-EW 13

 5.6 Mounting the modules

Clickstones are used for mounting the modules. Click- stones

are special clips for fitting the module clamp in the rail
channel. You only need an Allen key (5 mm)
for assembly. You can insert the Clickstone into the rail channel
from above. Each module end clamp can hold one module. The
module clamp is positioned between two modules.

Assembly steps:

• Insert the Clickstone into the rail channel at a slightly

slanted position.
• Press down the Clickstone and engage it in the rail until you
hear a clicking sound.
• Tighten the hexagon socket screw with a torque of 8 Nm.

The lugs at the inside of the Clickstone are designed such that
any mechanical release is ruled out once the screw has been
tightened. So if you want to remove the Clickstone from the
rail by pressing it together and lifting it up, you must first
unscrew the screw to
above the lug.

NOTE!
The shape of the Clickstone
corresponds exactly to the profile of
the rail channel.
It has been consciously con-
structed not to run easily in order
to prevent unintentional slipping in
vertical rail tracks. To move the
Clickstone, press lightly on the
bolt, from above, and move the
stone with a little pressure along
the rail channel.

14 Installation Manual LightX-EW

6. Light X-EW Alpine Installation

If the project location experiences heavy snow loads,

supplementary third leg per module must be added, to
prevent bending of the module. With this modification, the
module will be supported with an additional whole set of
ground rail including front and back support.

The only addition to the system is adding a

preassembled third set

Preassambled third Leg

Installation Manual LightX-EW 15

 Module Clamping on Alpine Version

16 Installation Manual LightX-EW

Installation Manual LightX-EW 17
Rangsdorf 1 Rangsdorf 2 Cologne Sales
Headquarters & Production Warehouse & Production Office

Mounting Systems GmbH Mounting Systems GmbH Mounting Systems GmbH

Mittenwalder Straße 9a Maulbeerstraße 13 Rolshover Straße 524
D-15834 Rangsdorf, Germany D-15834 Rangsdorf, Germany D-51105 Cologne, Germany

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[email protected]
www.mounting-systems.com

Subject to technical changes 2024 © Mounting Systems GmbH