Lorenz Trapeo Manuale utente

Installation manual

LORENZ®trapeo

LORENZ®Solar module mounting system

2Welcome

Welcome to LORENZ®

Thank you for deciding to use a product from the LORENZ®fami-

ly. LORENZ®trapeo is a simple, flexible mounting system for tra-

pezoidal roofs.

Please read these instructions for mounting the system. They ex-

plain how to mount parallel systems on pitched, trapezoidal sheet

roofs in accordance with DIN 18807.

Pre-assembled mounting kits ensure rapid installation. The use of

self-tapping screws means there are no shavings and no need to

pre-drill.

Your personal LORENZ Customer Service contact will be

happy to help, should you have any questions that are not

answered by these installation manual.

+49 2234 93309-0

Questions !Please read carefully all the safety instructions (from page

10) before installing LORENZ® trapeo for the first time. Also,

please check out any new system components and functions of

our mounting system.

Four pre-drilled holes.

Suitable for use on all

trapezoidal geometries

EPDM seals

40 cm, 74 cm and 94 cm aluminium rails

Cable clip

Clamp from the

LORENZ® solo

system

• Suitable for use on all trapezoidal sheet

geometries, on roofs with a pitch of up to

60°

• Can be used with any framed modules

• Your roof is guaranteed watertight by the

pre-mounting of EPDM material

• Cables can be fed through the rails or

attached using cable clips if preferred

• Quality tested materials (10 years war-

ranty)

Self-tapping screws with seal, approved for use in

general construction work

Thread geometry designed

for rapid tightening of

screws

Tip ensures that no

shavings are produced

when screws are tightened

Seal

Sitemap

1. Planning guide

1.1 Orientation and roof pitch .................... 4

1.2 Roof layout .......................................... 4

1.3 Plan for mounting system...................... 5

1.4 Stringing plans..................................... 5

1.5 Planning for lightning

protection and equipotential ................. 6

2. Preparations

2.1 Test modules ........................................ 6

2.2 Check inverters .................................... 6

2.3 Install safety devices ............................. 6

3. Mounting

3.1 Mounting the U-shaped rails................. 7

3.2 Laying the cables ................................. 8

3.3 Mounting the modules.......................... 8

3.4 Connecting the modules....................... 9

4. Safety instructions

4.1 General safety instructions.................. 10

4.2 Observation of regulations

and standards ................................... 10

4.3 Safety regulations when

working on the roof ........................... 11

Warranty Certificate 12

Garantiezertifikat 14

Planning guide

1. Planning guide

1.1 Orientation and roof pitch

A solar system in central Europe will deliver the maximum yield

when installed at an angle of around 30° and facing south. Devi-

ations towards the south west or south east, and a roof pitch of

15° to 50° will reduce the output only slightly and can therefore

also be recommended without reservation.

1.2 Planning the roof layout

Please note that the LORENZ® trapeo system described

here is suitable only for parallel mounting. Any change in

the angle of the modules can have a detrimental effect on the

statics and is therefore not permitted.

!Before installing the mounting system, please read the

safety instructions in chapter 4.

We recommend our free of charge planning software, „LORENZplaner“.

LORENZplaner gives you a carefully constructed project overview, right from the start. Very

easy to use and totally reliable, the software leads you through the process from identifying

wind and snow load zones and how to enter your specific module layout to the complete struc-

tural engineering report, documenting in detail the load bearing capacity of edges and corners.

Planning the module field

With this system, modules can be mounted vertically or horizon-

tally. When mounting horizontally, please note the clamping re-

quirements of the module manufacturer in question. Position the

module field such that it is at least 400 mm away from the edges

of the roof, both on the right and on the left. The distance from

the ridge and the eaves should not be less than 300 mm.

For building heights of ≤ 25 m all building categories and wind

zones and all snow zones to EUROCODE 1 permitted.

When planning systems for buildings with a ridge higher than 25

m, or for buildings on sites which are more than 800 m above sea

level, please contact LORENZ Montagesysteme GmbH.

Montage der DachhakenPlanning guide

Determine the number and spacing of the U-shaped rails. The po-

sitioning of the rail sections is dependent upon the dimensions of

the modules used. You can take the details from the following illus-

tration. It is important that you always follow the module

manufacturer’s instructions when it comes to positioning the

clamps.

Planning the distance between rails

Option 1 : short/short (standard)

1.3 Planning the mounting system

The U-shaped rails are available in 3 different lengths:

139511000

U-shaped trapeo rail 25x46x400mm.Set (Standard)

139511200

U-shaped trapeo rail 25x46x740mm.Set (for 5“ modules)

139511400

U-shaped trapeo rail 25x46x940mm.Set (for 6“ modules)

The following different options are possible:

The distance between the rows of modules should be 2-20

mm. The module clamps are to be fitted in the space bet-

ween the screws.

Montage der Dachhaken

1.4 Planning the stringing

Before mounting, plan the string cabling between the solar

modules and inverters. Lay out the plus and minus cables as

close to each other as possible in order to avoid overvoltage

coupling. Make sure that the gap between the cables is kept to a

minimum.

The cabling should not rest on the roof. Make sure that all

cables and cable connectors are fitted in accordance DIN VWE

0100-712.522.8.1 (protection against earthing and short

circuits). Use a duct or a disused chimney flue to route the

cabling down to the basement of the building. By laying cable

ducting on the outside of a building, it is possible to avoid any

building works inside. Either way, make sure fire safety is not

compromised.

Attach connectors to the ends of the DC cables. LORENZ Monta-

gesysteme GmbH supplies crimping pliers and mounting tools

from a variety of suppliers for this purpose.

Measuring the open-circuit voltage

Preparatory work

1.5 Lightning protection and equipotential

planning

Fit an equipotential bond to avoid over-voltage. The equipotenti-

al between the mounting system and the trapezoidal sheet roof is

ensured, in accordance with DIN/VDE standards, by using thin

sheet metal screws. Should the building have lightning protection,

the solar system should be taken into account. In such cases, we

recommend that you work with a specialist lightning protection

company. Please follow European standard DIN EN 62305 (VDE

0185).

2. Preparation

2.1 Testing modules

Check the functionality of the solar modules before mounting.

Measure the open-circuit voltage of each individual module.

Always test one module at once, not a complete string. There

could be dangerously high voltages. Note the serial number of

each module and its position in the module field.

2.2 Check the inverters

Before installing each inverter, check the type of protection it has

(e.g. IP54), the recommended ambient temperature and the noise

level. For external applications, the equipment must be protected

against dust and moisture. Please note that only specialist electri-

cal companies are permitted to connect the device to the grid.

2.3 Use of safety equipment

Note: You must install all necessary safety equipment on the roof

before beginning work. Read the instructions given in Chapter 4

of this manual.

Planning the stringing

Montage der Dachhaken

3. Installation

3.1 Mounting the U-shaped rails

If necessary, clean the roof before starting any mounting work.

Start by installing the outside U-shaped rails on the lowest row.

We recommend that you use a piece of string to mark the positi-

on. Lay the U-shaped rail together with the sealing strip horizon-

tally across two high points.

Position the U-shaped rail in such a way that one of the drilled holes

is in the middle of the two high points.

Screw the U-shaped rail into place, using the screws supplied, until it

is tight enough to create a secure seal (recommended torque

max. 3 Nm).

Make sure that all U-shaped rails are running in the same direc-

tion. Align the rails using the piece of string.

Fit all the other U-shaped rails in the way described.

Arrange the U-shaped rail horizontally

Centre the U-shaped rail

Installation

Secure the seal

Position the U-shaped rail

Install the rail

Tools required

Components required

Cordless screw-

driver

Bit, 8 mm

Folding rule

String

U-shaped trapeo

25x46xxxxmm.Set

13 951x000

Cable ties (optional)

4,8x200mm (100

pcs.)

26 3549510

Soloclip (optional)

13 9486700

Montage der Dachhaken

Fitting the end clamps

Positioning the end clamp

Installation of the module

Clicking the central clamp into place

3.2 Laying the cables

!Please make sure that the string cabling is laid before

mounting the modules.

Prepare the cable entry into the roof, extending the module circuit

cable if necessary. When mounting the solar modules, it should

simply be a question of connecting them. Fit the cabling inside or

alongside the rail using cable ties or cable clips so that the cables

do not sag or rest on the roof. Click the solo clip into place on the

rail, as required.

3.3 Mounting the modules

!Always follow the mounting instructions provided by

the module manufacturer in order to ensure that any war-

ranty rights are protected.

This is particularly important when it comes to the positioning of

fixings. Do not under any circumstances stand or put any weight

on the modules. There is a risk that they might break. Install the

modules with the junction box at the top to avoid the risk of

moisture ingress.

Begin by mounting the top row of modules. To do this, fit the

clamps into the U-shaped one side and press down on the other

side of the clamp until you hear the click.

Make sure the clamp is in the right position.

Lay the solar module onto the U-shaped rail and fix into place

using the end clamps.

Then click the central clamps into place and slide them onto the

fixed module.

Installation

Fastening the cable using a clip

Montage der Dachhaken

Place the next module in position and fasten both modules using

the central clamps.

Mount all the other modules in the same way. Put an end clamp

on the end of each module row.

The M8 screws should be tightened to a torque of 16 Nm. Please

avoid any distortion of the module frame and the potential dama-

ge to the module that could result from this.

Make sure that the gap between the side of the module frame and

the module clamp is not larger than 1 mm. Otherwise there is a

risk that the module could work loose from the clamp when hea-

vily loaded.

Module fixed using clamp

Installation

Screw torque

16 Nm

Gap between frame and clamp

End clamp

RHxxx.Set

13 92 3xx 00*

Components required

Central clamp RH35-50.Set

13 92 1xx 00*

3.4 Electrical connection of the modules

Attention: Even with low levels of radiation, the modules will re-

ach their full voltage. Depending on the number of modules in

one string, several hundred volts coud be achieved. This could

put life at risk.

Connect the solar modules to each other using the connection

cables provided. Check that the polarity is correct.

!Make sure that the cable insulation is not damaged by

any sharp edges. Once the work is complete, please check

that the open circuit voltage is correct in the string cables.

These instructions provide information on the correct

way to install the LORENZ®-mounting system, including

the mounting of modules. They are not a replacement

for the specialist knowledge required when planning

and installing photovoltaic systems in accordance with

all the relevant regulations and directives.

The manufacturer accepts no responsibility for damage

arising from the incorrect handling of the parts deliver-

ed, from construction using components which do not

form part of this system, or from incorrect installation.

Responsibility for securely fixing the mounting system to

the roof surface and for ensuring that the roof remains

watertight, lies with the installer.

Liability

No misuse of components

All parts should be used only for the fitting of solar modules. The

fitting of roof ladders, roof treads and the construction of safety

equipment such as catch nets is not permitted using LORENZ II

components.

Protection against sharp corners and edges

Should you wish to cut the rails on site or whilst installing, remove

any burrs from the cut edges in order to avoid the risk of injury

from sharp edges and corners.

4.2 Compliance with regulations and standards

Observe in particular the safety instructions provided by the fol-

lowing regional directives:

• Standards and regulations relating to the installation of

power plants and low voltage systems

• Standards and regulations relating to lightning protection

• Standards and regulations relating to self-generation systems

connected to the low voltage network

• Accident prevention regulations for working on rooftops and

for working with electricity

!All installaton activities are governed by the accident

prevention regulations of the building industry trade asso-

ciations.

4. Safety instructions

In this chapter, we provide an overview of the key safety informa-

tion. Please observe the following instructions for the mounting of

modules together with any other relevant directives for safe and

professional working practices, both in the interests of your own

safety and for the protection of others.

4.1 General safety instructions

!Please read all safety instructions and follow the

guidelines provided. Failure to do so can lead to injury and

other damage. Please keep these safety instructions close to

hand.

The need for professional planning

Before starting to construct the solar module mounting system,

make sure that the photovoltaic system has been professionally

planned in terms of the roof orientation, the layout of the modules

and the mounting system, the electrical design and the clarifica-

tion of all information relating to the building.

Installation by qualified professionals

Ensure that all installation work is carried out exclusively by peo-

ple with the necessary qualifications.

Survey of the roof construction

The installation of a photovoltaic system will change the static load

on a roof construction. Existing buildings should therefore have a

survey carried out in accordance with current local standards.

Instructions for the installation of the mounting system

In this installation manual, you will find an explanation of

everything you need when installing a mounting system and

mounting modules. It should be clear that these are not instruc-

tions for the installation of the system as a whole.

Fire protection

The installation of a PV system can affect the fire safety of a buil-

ding. It is important that nothing is built on top of the fire walls of

any building. Please observe the fire safety regulations for the

local area. To avoid the risk of fire, we recommend that PV pro-

ducts are only fitted to flame-proof materials. The PV system

should not be installed close to flammable gases or vapours (e.g.

petrol stations, gas containers), open flames or inflammable ma-

terial.

Catch net with safety barrier

2 m

permissible

working area

2 m

> 3 m

Safety instructions

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