Conergy SunTop Trapeze User manual

Conergy SunTop Trapeze
www.conergy.com
Installation manual

Table of Contents
2 Installation manual Conergy SunTop Trapeze
ENGLISH
Table of Contents
1 Introduction 1
1.1 Short description 1
1.2 Intended use 1
1.3 Standards and guidelines 1
1.4 About these instructions 1
2 Safety 2
2.1 Basic safety information 2
2.2 Information regarding working on roofs 2
2.3 Warnings 2
2.4 Operator‘s responsibilities 3
3 Technical description 4
3.1 System overview 4
3.2 Scope of delivery 5
3.3 Technical specifications 6
4 Planning the module area 7
5 Important installation information 8
5.1 Conditions of use 8
5.2 Preparation 8
5.3 Mounting aids and required tools 8
5.4 Grounding the mounting system 8
6 Install the system 9
6.1 Using the EPDMs 10
6.2 Placing and aligning the base rails 10
6.3 Positioning of the trapezoidal side fixations 11
6.4 Positioning of the trapezoidal top fixation 12
6.5 Mounting the base rails 12
6.6 Securing the base rails against excessive
slipping 14
6.7 Connecting the base rails 14
7 Mounting the modules 15
7.1 Quickstone installation 15
7.2 Anti-slip protection for portrait orientation 16
7.3 Fixing the outer modules of each row 16
7.4 Fixing the inner modules of each row 17
7.5 Installing further rows of modules 17
8 Distinctive features when installing
the modules in landscape orientation 18
8.1 Correct alignment of the base rails 19
8.2 Installation of the base rails and modules 20
Conergy SunTop Trapeze - innovative solution for metal roofs

1 Introduction
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1 Introduction
1.1 Short description
The SunTop Trapeze flat roof system is a sturdy frame sys-
tem for mounting PV modules on trapezoidal sheet metal
roofs. It consists of aluminum base rails and all necessary
small parts to install the modules to the rails and con-
necting the components to each other. Both portrait and
landscape mounting of the modules are possible.
1.2 Intended use
The on-roof system SunTop Trapeze is to be used for the
installation of PV modules only. Any other use is consid-
ered improper. Please follow the instructions in this manual
carefully. Mounting Systems is not responsible for damage
that results from improper installation. Be sure to follow the
safety and use guidelines closely.
1.3 Standards and guidelines
When planned correctly, SunTop Trapeze fulfills the follow-
ing standards and directives:
• Eurocode 9 — DIN EN 1999-1-1: Design of aluminum
structures
• Eurocode 1 — DIN 1055 — Actions on structures
• DIN 18807-3 Trapezoidal sheeting in building; trapezoidal
steel sheeting; structural analysis and design
• DIN 18807 Trapezoidal sheeting in buildings - Part 9:
Aluminium trapezoidal sheeting and their connections;
application and construction
In addition, every installation must be in compliance with
the following codes/rules:
• VDE 0100 – 712 ; IEC 64/1736. Installation of low-voltage
systems
• VDE 0185 Serie, IEC 81/335. Lightning protection
1.4 About these instructions
Subject
The purpose of this manual is to provide instructions for the
installation of the on-roof system SunTop Trapeze.
The illustrations in this manual show the installation for
framed modules in portrait orientation. The installation in
landscape orientation is dealt separately in section 8.
Users
This manual is written specifically for qualified installers
who have undergone instructions by the operator and have
basic mechanical and trade skills.
Orientation aids
The following aids will improve the readers’ understanding
when using this manual:
Symbols
Shows detail and additional information for
handling procedures.
Useful Tips
Simplifies handling procedures and contributes
to the success of the installation.

2 Safety
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Indicates a severe and unusual risk
that, if ignored, could lead to seri-
ous injury or death.
Indicates a potentially hazardous
situation that could lead to serious
or moderate bodily injury and prop-
erty damage.
Indicates a potential hazard that
could lead to property damage.
2 Safety
2.1 Basic safety information
The following basic safety information and warnings are an
important part of this manual and needed for safe handling
of this product:
• Ensure that the product meets local code requirements
prior to mounting and installation.
• Ensure the building must meet the increased code
requirements resulting from the PV unit prior to mounting
and installation.
• Comply with the relevant safety regulations.
• Wear a hard hat, protective gloves and safety shoes.
• A second person must be present during the entire in-
stallation, to provide assistance in the case of accident.
• Keep a copy of this installation manual in the immediate
vicinity of the system.
2.2 Information regarding working on roofs
When working on roofs:
• Always follow accident prevention regulations, and if
necessary, install guards to protect against falling com-
ponents.
• Accident prevention regulations require a safety harness
or protective scaffolding be used.
• Observe valid local safety regulations.
• Test and verify the load-bearing capacity of all relevant
components prior to walking on the roof.
• Use fall protection equipment.
• Use protective equipment, even for simple and quick
tasks.
• Always use appropriate lifting equipment. Never carry
material up the ladder.
2.3 Warnings
The warnings listed in this manual indicate safety-relevant
information. They include:
• Warning symbols
• Key words to indicate the risk level
• Information about the type and source of the risk
• Information about possible consequences if the danger
is ignored
• Measures for avoiding risk and preventing injuries or
property damage
The key words in the warnings always indicate one of the
following risk levels:
WARNING
CAUTION
DANGER

2 Safety
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2.4 Operator‘s responsibilities
The system operator must fulfill the following safety-related
obligations:
• Ensure that only persons with basic mechanical and
trade skills should be installing this system.
• Ensure that responsible persons must be able to recog-
nize and assess all possible dangers involved in the work
assigned to them.
• Ensure that the responsible persons are familiar with all
system components.
• Ensure that the installation manual is readily available
during the assembly. These installation manual is an
integral part of this product.
• Ensure that a project related design layout exists.
• Ensure that the installation manual and especially the
warnings are read and understood by the responsible
persons prior to assembly.
• Ensure that the permissible conditions of use (see sec-
tion 3.3) have been upheld. Mounting Systems will not be
responsible for damage which results from a violation of
these conditions.
• Ensure that the roof construction has the required load-
bearing capacity.
• Ensure that the durability of the mounted connections
and the roof attachments are guaranteed.
• Ensure that appropriate lifting equipment must be used
for the mounting work.
• Ensure that Mounting Systems components are to be
used, both for the initial installation and for eventual
maintenance or repair later on, otherwise all guarantees
will be void.

c
f
e
b
d
a
3 Technical description
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3 Technical description
3.1 System overview
All system components are listed below. The design of the
individual system components may vary.
They are dependent on:
• roof type
• module type
• number of modules
• the onsite conditions
Please note:
This illustration shows the portrait orientation of the
PV modules. Base rails that are 40 cm long are used for
landscape orientation.
In addition, the system overview shows the possibility of
fastening the base rails on the side and on the top on the
high beads of the corrugation.
a Base rail
b Trapezoidal side fixation
c Trapezoidal top fixation
d Inter-module clamp
e Module end clamp
f EPDM

b
e
h
c
f
i
a
d
g
3 Technical description
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3.2 Scope of delivery
Following the descriptions of all
SunTop Trapeze components that may
be included in delivery are listed.
The exact delivery contents and the
quantities of the individual system
components are based on your order.
a Base rails
b Trapezoidal side fixation with
Alu-Fixband seal
c Trapezoidal top fixation
d Drilling screw with gasket (6x25 mm)
e Splice preassembled for framed
modules
f EPDM 80 mm (trapezoidal top fixation) or
40 mm (trapezoidal side fixation)
g Z -Module end clamp
h Inter-module clamp
i Grounding clip (Weeb clip)

3 Technical description
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3.3 Technical specifications
1 Not suitable for sandwich roofs.
2 After contacting Mounting Systems and a verification of the codes, thinner sheet metal thicknesses may be possible.
3 In case of a very low bead height (below 20 mm) a holder can be screwed on top of the trapezoidal sheet, alternative to the
trapezoidal side fixation, which is fixed laterally.
4 Depending on the location, building, selected fixing devices and the module type, other values may vary. With the SunTop Trapeze design tool,
you can calculate the permissible maximum values for any system quickly and easily.
5 Because of the expected thermal expansion due to temperature differences and the resulting stress on the rails, we recommend a
maximum length of 12 m per module row.
Application areas Pitched roof – on-roof
Roof covering Trapezoidal sheet metal 1
Min. sheet thickness 0,63 mm 2
Min. bead height Free 3
Roof pitch Up to 20° 4
Height of building Up to 20 m 4
PV module Framed
Module alignment Portrait, landscape
Size of the module field Free 5
Position of the module field Free
Possible height leveling Up to 5 mm
Distance between rail fixation Depending on the load situation (automatic verification by the design software)
Standards Eurocode 1 – DIN 1055 – Actions on structures
Eurocode 9 — Design of aluminum structures
Profiles Extruded aluminum profiles (EN AW 6063 T66)
Rail fixation Aluminum (EN AW 5754)
Small parts Stainless steel (V2A)
Color Aluminum, cold pressed

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1
3
4
5
4 Planning the module area
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4 Planning the module area
The following gives the spacing of the roof mounts for in-
stalling modules that are in a portrait orientation. The spac-
ing for landscape orientation can be found in section 8. The
trapezoidal fixation must be mounted at specific distances
depending on the material, thickness of the trapezoidal
sheet metal, the spacing of the high bead of the corruga-
tion, consideration of the edge area and the further general
conditions* (a tool is used for the design).
Taking the above mentioned points into consideration,
the trapezoidal fixation must be placed so that they are as
close as possible to the module clamps.
When positioning, please note that
• the given dimensions are guidelines.
• the dimensions of the trapezoidal sheet metal and the
high bead of the corrugation define the true horizontal
spacing.
* A design in accordance with the local conditions according to
Eurocode 1-DIN 1055 / Eurocode 9-DIN EN 1999-1-1 is required.
1. Height of the module field: number of modules in the vertical x module height
2. Width of the module field: Number of modules in the horizontal x (module width + 19 mm) + 50 mm
3. Spacing of the guide rails in the vertical (in accordance with the clamping points defined by the module manufacturer): approx. the quarter
points of the modules = 1/2 x module height
4. Spacing of the trapezoidal fixations in the portrait orientation: according to the plan, depending on the trapezoidal sheet metal and the
structural analysis*
5. Spacing between the modules = 17 – 19 mm

5 Important installation information
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5.3 Mounting aids and required tools
You will need the following tools to mount the frame
system:
• 6 mm Allen key
• Cordless screwdriver
• Attachment for cordless screwdriver, hexagonal
8 mm bit
• Angle grinder with metal disk
• Chalk line
• Spirit level
• Folding rule/measuring tape
• Lifting device
(e.g. attachable work platform, shoulder straps)
• Suction cup tool
• Spacing template if applicable
(for landscape installation)
5.4 Grounding the mounting system
The potential equalization between the individual system
components must follow the respective country-specific
regulation. A possibility of grounding the SunTop Trapeze
system is shown in the following picture. The cable gauges
as well as the general grounding concept are not included
in this guide and must be calculated and/or created by the
installer in accordance with the applicable standards and
guidelines. Professional grounding methods other than the
ones given here are also possible.
5 Important installation information
5.1 Conditions of use
The on-roof system SunTop Trapeze with its different rail
and roof mounting variations is designed for different
maximum loads in accordance with Eurocode 1: Actions on
structures.
The suitability of the material must be checked for each
system, with the help of the SunTop Trapeze design tool.
5.2 Preparation
Mounting Systems recommends that you familiar-
ize yourself with the local conditions prior to ordering
SunTop Trapeze.
Pay special attention to the following:
• the roof configuration (e.g. high corrugation bead spacing
and bead height)
• the thickness as well as the material of the trapezoidal
sheet metal
• the quality and the condition of the trapezoidal sheet
metal
• the adequate fixation of the trapezoidal sheet metal to
the substructure
CAUTION
Material damage due to inadequate fastening
Inadequate fastening of the trapezoidal sheet metal roof to the substructure can lead to material
damage.
• Check to see whether the fastening of the trapezoidal sheet metal to the substructure is adequate.