Conergy SunTop Trapeze, Installation Manual

Page 1: ...Conergy SunTop Trapeze www conergy com Installation manual ...

Page 2: ...ding 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...

Page 3: ...n 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 01...

Page 4: ...he 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 ...

Page 5: ... 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 roo...

Page 6: ...ype 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...

Page 7: ...sted 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 Gro...

Page 8: ...y 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 lan...

Page 9: ... 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 ver...

Page 10: ...elines 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 he...

Page 11: ...its between the base rail and the module frame The 4 noses protrude into the rail channel 6 Install the system The following pages contain all the operations for installing the SunTop Trapeze in the correct order Trapezoidal fixa tions are used for the assembly of the base rails They can be fixed either to the side of the high bead of the corruga tion or on the high bead itself Define and mark the...

Page 12: ... to interpret and define the possible cuts The connected series of rails should not exceed a length of 12 m The required total railway length is determined by the width of the module area see point 4 Make sure that the maximum cantilever of 17 5 cm is not exceeded if necessary cut rails or use splices The spacing of the rails to each other is defined by the size of the PV module see section 4 Base...

Page 13: ...terial damage due to incorrect assembly Incorrectly assembled trapezoidal side fixations may rip out When fastening the trapezoidal side fixations al ways make sure that the fixation is seated correctly in the channel CAUTION The following points must be considered when installing the trapezoidal side fixations till the verge of the roof It is not possible to place the trapezoidal side fixation se...

Page 14: ...al fixation on the side or top with the supplied 6x25 mm drilling screws with gaskets Do not over tighten the screws The torque setting of the cordless screwdriver is depend ent on the thickness and the material of the trapezoidal sheet metal Positioning of the trapezoidal top fixations for bead heights 20 mm Positioning of the 6x25 mm drilling screw with a gasket Correct fit of the trapezoidal to...

Page 15: ...dal top fixation the EPDM fits correctly underneath Material damage due to incorrect assembly Incorrectly installed drilling screws may rip out Do not over tighten the drilling screws CAUTION CAUTION Damage to the building and the PV system through incorrect frame installation Incorrect spacing of the trapezoidal fixation can cause damage to the building and the PV system When fastening the base r...

Page 16: ...ixations are used to secure the base rails Screw the drilling screws into the side of the base rail to the right and left of the trapezoidal fixation at a distance of approx 2 cm Ensure that the use of the module clamps or splices is not impeded by the drilling screws 6 7 Connecting the base rails A splice is provided for connecting individual rail series They can also be used for grounding indivi...

Page 17: ...NGER 7 Mounting the modules The modules are successively installed onto base rails It is recommended to start on one side of the module field The Modules in the bottom row can be equipped with anti slip protection Inter module clamps and module end clamps are used to fasten the modules The module end clamps can each are used to hold one module The inter module clamps are positioned between two mod...

Page 18: ...the module Place the first module of the bottom row so that the anti slip protection sits in the rail channel of the lowest rail row 7 3 Fixing the outer modules of each row Installation Insert the Quickstone of the module end clamp Z mod ule end clamp here in the example in the rail channel of the base rail When positioning the Allen bolt must not protrude past the underside of the Quickstone Ins...

Page 19: ... module clamp and tighten the Allen bolt tightening torque 8 Nm 7 5 Installing further rows of mod ules Installation Align the modules of the top row with the bottom row being sure to keep the space between them even TOOL You may use a inter module clamp for example as a spacing gauge You will obtain identical spacing horizontally and verti cally using this technique Fasten the modules with the mo...

Page 20: ...nstalling the modules in landscape orientation Here you must be careful to maintain the correct spacing between the base rails Accuracy is a must Mounting Systems recommend using a spacing template to maintain the correct spacing Precise rail align ment must be maintained Take into account that the rail row near to the roof ridge is mounted always turned by 180 8 Distinctive features when install ...

Page 21: ...Align the profiled rails as follows During the alignment the wider flat surface of the base rail with the nose can be used as an orientation aid Position the top row of base rails as shown in figure 1 The wider flat surface of the base rail can be used as an orientation aid It must face the direction of the roof ridge The other rows of rails are mounted with the wide flat surface facing down Upper...

Page 22: ...es Installation Mark the positions of the base rails Apply the EPDM on all necessary high beads Align use a spacing template and fasten the base rails with the trap ezoidal fixation Installation of the modules For landscape mounting the Quick stone must be place in the channel at the side of the profile It is not pos sible to insert the Quickstone into the channel from the top ...

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Page 24: ...Conergy SunTop Trapeze_IM_ENG_201110 For further information www conergy com Subject to technical modifications without notice 2011 Conergy ...