I

Installation manual

novotegra for tiled roofs

II

TABLE OF CONTENTS

1 Information .......................................................................................................... 1

2 Installation system maintenance ....................................................................... 3

3 novotegra for tiled roofs ..................................................................................... 3

4 System components, tools and work equipment ............................................. 4

4.1 Required for installation ................................................................................... 4

4.2 Installation system components – installation variants ..................................... 5

4.3 Installation system components – optional ...................................................... 5

5 Installing the substructure ................................................................................. 6

5.1 Installing the roof hooks ................................................................................... 6

5.2 Installing the rails ............................................................................................. 7

5.3 Installing the module ........................................................................................ 8

5.4 Installation variants .......................................................................................... 9

6 Warranty / product liability and disclaimer ..................................................... 12

1

1 Information

Safety information

Installation work may only be carried out by qualified expert personnel. Safety clothing in accordance with the relevant national regulations and guidelines must be worn during all work.

Installation must be carried out by at least two people so as to ensure that help is available in the event of an accident.

All relevant nationally and locally valid occupational safety regulations, accident prevention regulations, standards, construction regulations and environmental protection regulations must be observed, along with all regulations of the institutions for statutory accident insurance and prevention.

National regulations for working at height or on roofs must be complied with.

Electrical work must be carried out in compliance with nationally and locally valid regulations and guidelines and in accordance with the safety regulations for electrical work.

The earthing / potential equalization of the installation system must be carried out in line with the nationally and locally valid standards and guidelines.

Classification into hazard classes

In order to draw the user's attention to potentially hazardous situations, the following hazard classes are used, based on ANSI Z 535. The hazard class describes the risk in the event that the safety information is not observed.

Warning symbol with signal word Hazard class as per ANSI Z 535

DANGER! indicates an immediate hazard. Failure to prevent this could result in death or severe injury.

WARNING! indicates a potential hazard. Failure to prevent this could result in death or severe injury.

CAUTION! indicates a potential hazard. Failure to prevent this could result in slight or minor injury.

NOTICE! indicates a potentially damaging situation. Failure to prevent this could result in damage to the system or something in its environment.

General information

The product must be checked for completeness upon receipt using the accompanying delivery notice.

BayWa r.e. Solarsysteme GmbH shall assume no costs or guarantees for any subsequent deliveries by express delivery if missing material is only noticed during installation.

The installation system is suitable for securing PV modules with standard market dimensions. The maximum permitted module width is 1.34 m.

The suitability of the installation system for the respective project must be checked on an individual basis with respect to the existing roof covering / roof construction.

The roof covering / roof construction must meet the requirements of the installation system in terms of load-bearing capacity, load-bearing structure and condition.

Requirements for the material used in roof construction or roof covering: Wooden components (rafters/purlins): minimum strength class C24, no fungal infestation or rot Tensile strength Rm,min of trapezoidal panels: steel 360 N/mm²; aluminium 195 N/mm²

2

The user must test the load-bearing capacity of the existing roof / roof construction (rafters, purlins, trapezoidal panels, number of fasteners for folded seam roof, etc.) or have this tested.

The user must take into account structural issues with regard to insulation penetrations (e.g. condensation).

Installation instructions

The components of the novotegra installation system are intended solely for securing PV modules. Depending on the roof type of the building, installation system components that are suitable for this roof type must be used.

Strict compliance with the safety and installation instructions in this manual is required for compliance with the intended use of the novotegra installation system.

All claims for warranty, guarantee and liability against the manufacturer are rendered null and void in the event of non-intended use and non-compliance with the safety and installation instructions, non-use of associated installation components or use of third-party components not belonging to the installation system. The user shall bear liability for damages and resulting consequential damages to other components such as PV modules or to the building itself, as well as for injury to persons.

The constructor must read the installation manual prior to installation. Any open questions must be resolved with the manufacturer prior to installation. The installation sequence described in this manual must be complied with.

Please ensure that a copy of the installation manual is kept in the immediate area of the works on the construction site.

The assembly instructions (module loading, fastening, clamping ranges, etc.) of the module manufacturer must be observed and complied with.

Prior to installation, structural analysis for the installation system must be carried out with the loads foreseen for the project in accordance with national standards. Information relevant to the installation (e.g. distance between roof hooks, screw lengths, overhangs and protrusions) is determined by the structural analysis carried out using the Solar-Planit.de design software.

The permitted roof incline for use of the installation system in accordance with this installation manual is 0 to 60 degrees.

Two module support rails must be installed symmetrically beneath each module in order to transfer the load evenly to the substructure.

The specified tightening torque values must be observed and tested on a random basis on site.

Information on structural analysis

The installation system must always be calculated for each project individually using the Solar-Planit.de design software.

The structural analysis determines only the load-bearing capacity of the novotegra installation system and also takes fastening to the building (rafters, purlins, trapezoidal panel, etc.) into account. The load transfer within the building is not taken into account (structural analysis of existing building).

The load-bearing capacity of the installation system components is determined here based on the planned module arrangement and the relevant roof data (project data collection). On-site deviations from the planning may lead to different results.

The load assumptions (load and roof partitioning) are made on a country-specific basis according to the specifications of the load standards in the Eurocode. In Switzerland, the loads to be applied are determined according to SIA 261.

The modules may not be installed above the bargeboard, ridge or eaves (increased wind load). The modules may only be mounted up to a notional horizontal line with the ridge tile at the ridge and no further than flush at the bargeboard. In the area around the eaves, the modules may only be installed up to the end of the roof covering for load-bearing reasons.

If the building is at an exposed location (e.g. exposed to wind load on a slope) or in the event of snow accumulation (e.g. dormer or roof snow fence), the user must take responsibility for observing the specifications in the load standards of the Eurocode or SIA 261 (Switzerland). The design software does not take these cases into account.

3

The structural analysis of the installation system is based on the modules being symmetrically mounted on the installation rails on the long side of the modules in order to evenly distribute the load onto the substructure.

The results calculated using the design software such as the distances between the fastening equipment (e.g. roof hooks, hanger bolts, seam clamps, etc.), the rail lengths and quantity of fastening equipment (e.g. direct fastening on trapezoidal panel), overhangs (e.g. protruding rails or roof hooks) as well as the further calculation information must be observed and complied with.

novotegra is tested and certified by MCS:

2 Installation system maintenance

The installation system must be tested annually for stability and proper functioning.

In addition to visually inspecting the components and the roof covering for damage, all screw connections must also be checked.

Components can be removed by following the work steps detailed below in the reverse order.

Maintenance work must be carried out by a specialist company with verifiable experience of electrical systems and working with installation systems.

3 novotegra for tiled roofs

The contents of this installation manual describe the installation of the substructure on roofs with clay tiles, concrete roof tiles or plain tiles roofing. These installation steps can also be used likewise for installation on roofs with slate roofing. In this case, however, covers or lead flashings must be fitted in the area where the roof hooks protrude from the roof in order to prevent water penetration. Please contact us before carrying out this kind of installation so that we can provide customer support to you.

4

4 System components, tools and work equipment

4.1 Required for installation

Image Tool Component* Product group

Roof hook set Material: V2A and aluminium Tool: Special socket 18 mm, deep

Roof fasteners and fastening equipment

Roof hook fastening screw Material: Galvanized steel or V2A Tool: Bit Torx TX 25

Roof fasteners and fastening equipment

C-rail Material: Aluminium

Module support rail

Rail connector set Material: Aluminium and V2A Tool: Special socket 18 mm, deep

Module support rail

Centre clamp set Material: Aluminium, cast aluminium and V2A Tool: Socket 8 mm

Module fasteners

End clamp set Material: Aluminium, cast aluminium and V2A Tool: Socket 8 mm

Module fasteners

Anti-slide protector set Material: V2A

Module fasteners

* The components vary depending on the requirements of the roof, the structural analysis and the choice of components and may deviate from the images above.

Image Work equipment

Use for tool Use

Cordless screwdriver

Bit Torx TX 25 Socket 8 mm

Component connections, clamp assembly

Torque key up to at least 50 Nm

Special socket 18 mm, deep Rail assembly

Torque key up to at least 12 Nm

Socket 8 mm Clamp assembly

Chopsaw --- Cutting rails

Angle grinder --- Work on tiles

Bit extension Bit Torx TX 25 Roof hook assembly

5

4.2 Installation system components – installation variants

Image Tool Component** Product group

Cross rail connector set Material: Cast aluminium and V2A Tool: Special socket 18 mm, deep

Roof fasteners and fastening equipment

Floating bearing set* Material: Aluminium and V2A Tool: Special socket 18 mm, deep

Module support rail

Anti-slide protector for horizontal installation Material: Aluminium and V2A Tool: Special socket 18 mm, deep

Module fasteners

** Required components depending on construction of substructure (e.g. cross rail configuration), system expansion (e.g. using floating bearings) or module arrangement (e.g. horizontal module installation).

4.3 Installation system components – optional

Image Tool Component*** Product group

Cover cap for C-rail Material: Aluminium and V2A Tool: Special socket 18 mm, deep

Optional items

Cover for C-rail 2,000 mm Material: Aluminium

Optional items

Earthing connection 18 mm set Material: V2A Tool: Special socket 18 mm, deep

Optional items

Self-locking cable ties Optional items

Cable clip d = 10 mm Optional items

*** Optionally available installation system components, e.g. for improving the aesthetics of the system, cable routing or earthing of the installation system.

6

5 Installing the substructure

Prior to installation, the module array must be measured out on the roof and the position of the fastening equipment (e.g. roof hooks, hanger bolts, seam clamps, etc.) determined, taking the structural analysis into account. The individual installation steps for vertical module installation are described below. References are made to installation variants (IV) for the various design possibilities. The associated work steps are described at the end.

5.1 Installing the roof hooks

Exposing the rafters

Expose the rafters by removing the tiles.

Scaffolding must be constructed in accordance with the relevant regulations.

Positioning the roof hook

Insert the roof hook so that the hook lies in the trough of the roof tile. The position of the roof hook on the rafter must be determined taking into account the structural specifications (IV 4). Mark the roof tile and the tile beneath (if present) at the point where the roof hook protrudes. For plain tile roofing, proceed according to IV 2 + IV 3.

Recessing the tile

Grooved tile roof / concrete roof tile: Carefully cut a recess in the area where the roof hooks protrudes using an angle grinder. Plain tile: Cut the recess either continuously along the side or else notched to fit the thickness of the hook.

Observe the accident prevention regulations, avoid damage to objects!

Recess: notched or continuous

7

Recessing the slate

Carefully cut a recess in the area where the roof hooks protrudes using an angle grinder. The recess regards to the installation variant of the base profile (V1 / V2) and has to align to the base profile and the used cover or lead flashing. For slate recovering proceed according to IV 3.

Observe the accident prevention regulations, avoid damage to objects!

Observing the gap

Adjust the height of the roof hooks using the thread in the base profile. After fastening, the gap between the hook and the tile beneath must be 6 mm.

Not observing this gap can lead to the tile being damaged under loading.

Fastening the roof hook

Fasten the roof hooks to the rafter using wood screws (IV 4). The length of the screws depends on the roof construction and is determined by the design software. If the roof hook is installed on counter battens on the rafters or on over-rafter insulation, the base profile of the roof hook must be lined on both sides of the counter batten to at least the width of the rafter.

The wood screws used in the system are approved by construction authorities. The use of own or non-equivalent wood screws renders the structural analysis invalid.

5.2 Installing the rails

Installing the rail

Place the C-rail on the lower locking bolt, align the rail and tighten using the upper locking bolt. The roof hook can also be connected to the joint area of the rail connector. If installing in a cross rail configuration, the upper rail is fastened using cross rail connectors (IV 5).

Tightening torque for locking bolts: 50 Nm.

6 mm gap

V1 V2

8

Connecting the rails

Push the ends of the rails tightly together, place the rail connectors centrally and screw together using the screws contained in the set. The connector and the number of screws depend on the rail (IV 6). Maximum uninterrupted rail length 13 m, after this expansion joints or installation of floating bearings (IV 7).

Tightening torque for locking bolts: 50 Nm.

Observe the accident prevention regulations when sawing.

5.3 Installing the module

Securing the module

Prior to installing the module, the anti-slide protectors must be mounted on the holes in the frame above the upper or lower rail side (IV 8a/b).

Clamping the module

Following this, fasten the modules to the rails using end and centre clamps.

Installing the end and centre clamps

Insert the end or centre clamps into the rail cavity from above at the clamping position. Next, turn the rail nut in the rail and push the module clamps onto the module frame.

9

Space requirement for end and centre clamps

The end clamp can also be installed flush with the rail end. Push the modules fully to the rail nuts of the centre clamps.

Tightening torque for centre clamps: 12 Nm, tightening torque for end clamps: 8 Nm.

5.4 Installation variants

Explanation of the installation variants depending on the roof construction or design variants (e.g. horizontal module installation or cross rail configuration). IV 1 – Roof hook set variants

Roof hook set flex / double roof hook set flex:

- For roof tiles / concrete roof tiles and beavertail roofing

- Base profile height 30 or 40 mm - Hooks M10

Roof hook set PT: - For plain tile roofing - Base profile height 18 or 25 mm - Hooks M10

IV 2 – Positioning the roof hook for Plain Tile roofing

Install the roof hook above the rafter and the upper batten. The hook should be positioned roughly centrally above the tile beneath, observing the protrusion on the side (IV 4). An additional screw (5.0 x 20mm) has to be screwed in above the hook into the batten.

IV 3 – Covering the roof hook for plain tile / slates roofing

1. Install the plain tiles around the roof hook. 2. Install the recessed plain tile. 3. Cover the roof hook with a plain tile.

1.

End clamp: Centre clamp: 13 mm to 12 mm clearance rail end to module

Hook roughly central above the lower tile

1. 2. 3.

10

Install the recessed slates around the roof hook. 2. Install cover and seal foam or lead flashing 3.s Install the recessed slate above the cover or the lead flashing.

IV 4 – Installing the roof hooks

The permitted protrusion of the roof hook beyond the rafter can be taken from the project structural analysis. The wood screws must be screwed in without pre-drilling observing the distances to the edge of the rafter. The wood screw along the hook axis must be screwed in as close to the hook as possible. An additional wood screw (5.0 x 20mm) is needed when using PT roof hook and screwed in above the hook into the batten (IV2). If using the double roof hook set, the same instructions apply and should be applied similarly. Distances to edge: Screw d = 6 mm D = 18 mm

The roof hook may only be installed on over-rafter insulation using wood screws d = 8 mm.

IV 5 – Installing the cross rail connectors

Cross rail installation: Fasten the upper rails to the lower rail using cross rail connectors.

Tightening torque for cross rail connectors: 40 Nm.

IV 6 – Installing the rail connectors

Rail connectors: C-rail 47 (left): Connect the adjacent rail ends with a screw and locking bolt on each end. C-rail 71 and C-rail 95 (right): Connect the adjacent rail ends with two screws, washers and locking bolts on each end.

Tightening torque for locking bolt: 50 Nm.

2 screws

4 screws

1. 2. 3.

Protrusion

Distance to edge

Distance to edge

Close to hook

11

IV 7 – Installing floating bearings on C-rails

Position the rail ends on the gap, put the rail connector in place and connect to the rail using the fastening screws on the fixed and moving sides. The screws on the fixed side must be tightened firmly. The screws on the moving side are painted red and must be loosened again after tightening (approx. ½ turn). Max. rail length with floating bearing 40 m, plan for proper expansion joint after this.

Tightening torque for locking bolt on fixed side: 50 Nm. Distance between adjacent rail ends C-rail 47: 20 mm C-rails 71 and 95: 40-50 mm

IV 8a – Installing anti-slide protector on module frame

Push the nut over the screw and screw the thin sheet screw into the module frame without pre-drilling.

Do not overtighten the thin sheet screw.

IV 8b – Installation of anti-slide protector with horizontal module

Screw the anti-slide protector to the end of the rail with a gap of approx. 5 mm using a fastening screw, a washer and a locking bolt.

Tightening torque for locking bolt: 50 Nm.

Fixed side

Moving side

Gap depending on C-rail

Thin sheet screw

Nut M6

Rear side Module frame

5 mm gap

12

6 Warranty / product liability and disclaimer

In addition to the aforementioned regulations and safety instructions, the installation company must observe the valid regulations and standard engineering practice.

The installation company is responsible for dimensioning the novotegra installation system.

The installation company is responsible for connecting the interfaces between the installation system and the building. This also includes the seal tightness of the building envelope.

On flat roofs, the installation company is responsible for the on-site assessment of the roof seal with regard to the sealing membrane material, durability, ageing, compatibility with other materials, general state of the roof seal and the need for a separation membrane between the roof seal and the installation system. The installation company must take the required and necessary measures and/or precautions for protecting the roof seal for the installation of the PV system substructure, if necessary with the involvement of a specialist. BayWa r.e. Solarsysteme GmbH shall bear no liability for incorrect or insufficient measures and precautions for protecting the roof seal.

The installation company is responsible for the on-site testing of the coefficient of friction used in the calculation for verification of the anti-slide protection for PV systems on flat roofs. Coefficients of friction calculated on site can be taken into account and must be provided to BayWa r.e. Solarsysteme GmbH for the calculation. BayWa r.e. Solarsysteme GmbH shall assume no guarantee for the correctness of the assumed values and shall bear no liability in the event of damages caused as a result of the use of incorrect values.

The instructions of the module, cable and inverter manufacturers must be observed. In the event of instructions that contradict those in this installation manual, be sure to contact your BayWa r.e. Solarsysteme GmbH sales team prior to installation or else the relevant manufacturer for components not supplied by BayWa r.e. Solarsysteme GmbH.

Local conditions are not always sufficiently well known by our sales representatives when preparing quotations for novotegra. This may result in deviations from the quoted parts quantities during installation. These deviations mostly relate to the quantity of fastening material to the building envelope (such as roof hooks). In this case, the additionally required components must be installed in accordance with the dimensioning.

BayWa r.e. Solarsysteme GmbH shall bear no liability for incorrectly or incompletely filled-in data survey sheets. Completely filled-in and error-free data survey sheets are essential for correct dimensioning.

The information in the installation manual, the warranty conditions and the disclaimer information must be observed.

13

NOTES:

14

Subject to errors and amendments. Date: November 2014/ASC, version 3.0 Copyright BayWa r.e. Solarsysteme GmbH

BayWa r.e. Solarsysteme GmbH Eisenbahnstrasse 150 D-72072 Tübingen Phone +49 7071 98987-0 Fax +49 7071 98987-10 solarsysteme@baywa-re.com

www.baywa-re.com solarsysteme.baywa-re.com

Sales office Tübingen Sales office Munich Sales office Nuremberg

Welzenwiler Strasse 5 Beethovenplatz 4 Wiesentalstrasse 32-34

D-72074 Tübingen D-80336 Munich D-90419 Nuremberg

Phone +49 7071 98987-300 Phone +49 89 386670-0 Phone +49 911 216646-0

Fax +49 7071 98987-139 Fax +49 89 386670-10 Fax +49 911 216646-10

tue.solarsysteme@baywa-re.com mue.solarsysteme@baywa-re.com nue.solarsysteme@baywa-re.com

Sales office Duisburg Sales office Braunschweig BayWa r.e. solar systemer ApS

Philosophenweg 21 Packhofpassage 3 Kullinggade 31E

D-47051 Duisburg D-38100 Braunschweig DK-5700 Svendborg

Phone +49 203 348596-0 Phone +49 531 6094012-0 Phone +45 62 21 10 00

Fax +49 203 348596-10 Fax +49 531 6094012-10 Fax +45 62 21 10 04

dui.solarsysteme@baywa-re.com bsg.solarsysteme@baywa-re.com solarsystemer@baywa-re.com