Lorenz trapeo User manual

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.
[phone]
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

3
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
4
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.

5
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
6
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

7
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
8
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

9
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

10
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