Installation instructions. Novotegra for Corrugated Fibre Cement / Sandwich Roofs

Transcription

1 Installation instructions Novotegra for Corrugated Fibre Cement / Sandwich Roofs I

2 CONTENTS 1 General information Novotegra: mounting system planning Solar-Planit software General information Novotegra for corrugated fibre... 2 cement/ sandwich roofs General information Hanger bolt mounting Hanger bolt mounting with wooden purlins (HP) Mounting the hanger bolt with steel purlins (SP) Horizontal module mounting - roof parallel Cross rail assembly Horizontal module mounting roof parallel Single-layer rail assembly Cross rail assembly Rail extension and expansion joints General information Rail extension Designing expansion joints using module arrays Designing expansion joints using movable bearings Module fastening Elevated mounting for north and south-facing roofs General information Roof division Module arrangement Arrangement of the C-rails Fastening the C-rails Arranging the base profiles Fastening the base profiles Module fastening and position securing Elevated mounting for east and west-facing roofs General information Roof division Module arrangement Arrangement of the C-rails Fastening the C-rails Arranging the base profiles Fastening the base profiles Module fastening and position securing Earthing the mounting system/ electrical installation Earthing the mounting system II

3 4.2 Laying the main DC line Safety instructions and warnings III

4 1 General information Check for completeness On receipt of the goods, check that your order is complete on delivery based on the enclosed delivery slip. BayWa r.e. Solarsysteme assumes no costs or guarantee for any subsequent express deliveries if it only becomes apparent that materials are missing during installation. Solar modules The data relating to the permitted pressure and suction loads for the modules and permitted mounting areas is included in the data sheets or installation instructions provided by the solar module manufacturer. In individual cases, check that the mounting system is suitable for the used modules. Mounting system All mounting systems described in these installation instructions are intended for installation on pitched roofs, with roof pitches from 0 to 60 degrees. Before installing the substructure, read the installation instructions and observe the information, specifications etc. Roof characteristics In individual cases, check whether the roof covering is suitable for the mounting system. The substructure must meet the requirements of the mounting system with regard to load-bearing capacity, support structure and condition. For example, with rafter roofs and purlin roofs, the components must be intact (no fungal growth, no rot) and as a minimum requirements should meet the C24 standard in conformance with DIN 1052, SIA 265 (for Switzerland) and ÖNORM EN 338 (for Austria). When securing the mounting system to folded seam roofs or trapezoidal sheet roofs, these statements apply accordingly. Check on-site that the roof covering is secured with sufficient retainers or trapezoidal sheet fasteners to the substructure of the building. In addition, the structural aspects regarding insulation penetrations must be observed (e.g. condensation formation). Structural analysis Structural analysis is implemented using the Novotegra Planner software (chapter 2). Novotegra has been tested and certified by TÜV Rheinland: 0

5 2 Novotegra: mounting system planning 2.1 Solar-Planit software General information As a rule, the mounting system must be designed using Novotegra Planner or by a member of the BayWa r.e. sales team. The Novotegra Planner analysis software calculates the load-bearing capacity of the Novotegra mounting system and also takes the fastening to the building into consideration (wooden rafters/wooden purlins/trapezoidal sheets etc.). This calculates the load-bearing capacities of the mounting system components in accordance with the system engineering (arrangement of the modules on the roof). On-site deviations from the planning can lead to different results. Load transfer within the building is not taken into account (structural analysis of the building). For products which are not integrated in the Novotegra Planner yet, please contact the BayWa r.e. Solarsysteme sales team for sufficient dimensioning/design. The Novotegra Planner uses the current load assumptions of DIN 1055, SIA 261 (for Switzerland), ÖNORM B and ÖNORM B (for Austria) and incorporates the division of the roof into an edge and central area as standard. The PV system can be connected flush with the verge, ridge and eaves, i.e. the uppermost modules can meet an imaginary horizontal line with the upper edge of the ridge tiles. As a result of the increased wind loads, the modules may not protrude above the edges of the roof. If the building is in an exposed location, e.g. at the edge of a slope, site categories I to IV may not be used. Instead, an increased dynamic pressure must be calculated per DIN , Appendix B. To determine the loads per SIA 261 (for Switzerland) or ÖNORM B (for Austria), the instructions of the respective standard must be taken into consideration. The limit spans and individual profile lengths are specified by the Solar- Planit taking the roof areas into consideration, and must be complied with. The remaining instructions must be observed. Rail overhangs permitted per the Novotegra Planner must be observed. All subsequent specifications and statements assume a symmetrical layout of the modules on the substructure on the longitudinal side of the modules. For example, this ensures an even load on the Novotegra rails and modules when installing the modules on tiled roofs. For installation on pitched roofs, two Novotegra rails (C-rails) per module row or column, horizontal or vertical, are fastened depending on the module mounting method (horizontal or vertical mounting). 1

6 3 Novotegra for corrugated fibre cement/ sandwich roofs 3.1 General information The following chapter contains instructions on how to mount the Novotegra mounting system for corrugated fibre cement/sandwich and trapezoidal sheet roof coverings. In principle, the mounting system can be used for roof coverings on purlin roofs on which direct attachment of the mounting system on the roof cladding is either not possible (e.g. corrugated fibre cement), not permitted (e.g. sandwich profiles, aluminium trapezoidal sheets) or not desired. When mounting photovoltaic systems on asbestos cement roofs (e.g. old corrugated fibre cement coverings), the appropriate regulations must be observed. The mounting system is connected to the roof structure via hanger bolts. The hanger bolts must be screwed into the purlins through the raised beading of the roof covering. When mounting the Novotegra mounting system to corrugated fibre cement/sandwich roofs, you will need the following tools, depending on the roof structure material: Wooden purlins: Tool Mounting system component HP hanger bolt set M10 I M12 Electric screwdriver Torque wrench Drill (long) 7,5 I 9mm Pre-drilling of the wooden purlin Drill 14 I 16 mm Pre-drilling of the roof cladding Hanger bolt for screwing in or Bit Torx HP hanger bolt set 30 Open-ended wrench SW 18 Locking nut via EPDM Special socket, SW18 deep Locking nut Bit Torx 30 Module clamps (roof parallel mounting) Special socket, SW8 Module fastener set and fastening sets (elevation) Steel purlins: 2

7 Tool Electric screwdriver Torque wrench Drill 6,8 / 7,0 / 7,2 / 7,4 mm (long) depending on the material thickness of the steel purlin Allen screw bit SW 5 Open-ended wrench SW 17 Socket SW17, deep Bit Torx 30 Mounting system component Drilling open of the roof cladding and pre-drilling of the steel purlin SP hanger bolt set Lower nut (below) Self-locking nut (above) Module clamps (roof parallel mounting) Special socket, SW8 Module fastener set and fastening sets (elevation) 3.2 Hanger bolt mounting Hanger bolt mounting with wooden purlins (HP) Components of the hanger bolt set HP Units Hanger bolt M 12 M10 I M12 1 EPDM sealing M10 I M12 1 Locking nuts M 12 M10 I M12 3 Pre-screw the wooden purlin in the fastening point of the hanger bolts through the roof covering using a drill with a diameter of 9 mm. The depth of the drill hole in the wooden purlin must be greater than 80 mm. Here, an edge distance of 36 (M12) or 30 (M10) mm from the drill axis to the edge of the purlin must be maintained. The 36 or 30 mm-edge distance results in a minimum purlin width of 72 or 60 mm. Then, carefully drill out the roof covering with a diameter of 16 (M12) or 13,5 (M10) mm. Use a sufficiently long drill to do so. Screw in the hanger bolts with a Torx 30 drive or with the screwing-in tool. The minimum screw-in depth of 80 mm must be maintained. When the correct hanger bolt length is selected (Table 1), the metric thread should protrude by 60 to 100 mm over the roof covering after being screwed in (height adjustability with rail mounting Figure 7: Mounting the hanger bolt with wooden purlins and mounting the EPDM seal). The following HP hanger bolt set M10 or M12 must be used, depending on the roof construction: Height H t of the covering Hanger bolt length up to 60 mm 200 mm mm 250 mm mm 300 mm Table 1: Hanger bolt length depending on the roof construction In order to seal the roof penetration, guide the EPDM seal over the metric thread and carefully press it against the roof cladding using a locking nut. In doing so, guide the EPDM seal over the shaft until the upper part of the EPDM seal is still just within the area of the metric thread, i.e. the larger part of the EPDM seal lies in the area of the shaft. When the locking nut is carefully tightened, the part of the EPDM seal which is still in the area of the thread is pushed downwards, and is pressed against the roof cladding, or the 3

8 taper of the EPDM seal is pressed into the hole which has already been drilled in the roof cladding (Figure 1). Figure 1 Mounting the hanger bolt with wooden purlins and mounting the EPDM seal Ensure that the EPDM seal is not compressed too tightly to avoid destroying the seal Mounting the hanger bolt with steel purlins (SP) Components of hanger bolt set SP Units Hanger bolt 8.0 / M 10 1 EPDM gasket 19 mm 1 M10 nut 1 Washer 2 Self-locking nut M10 1 Calottes are not included in the SP hanger bolt set Available calottes are listed in Figure 2: Angle and top chord width Table 4 Pre-drill the steel purlin through the roof covering at the fastening point of the hanger bolt. The drilling diameter depends on the thickness of the steel purlin, and is given in Table 2. Drill right through the flange of the steel purlin. The drilling axis should be as central as possible in the flange. Ensure that you drill at right-angles to the roof cladding. The roof covering may not be drilled open over a larger area. Use a sufficiently long drill for drilling. Place a calotte in position before mounting the hanger bolt. Screw in the hanger bolt with an SW 5 Allen bolt drive tighten without a torque. Screw the hanger bolts fully into the steel purlins, until the EPDM sealing disc is lightly compressed and lies on the calotte. In order to obtain a securely supporting, rain-proof attachment, screw the hanger bolts at right-angles to the roof surface. The hanger bolt may only be mounted in combination with a calotte. The length of the hanger bolt depends on the thickness of the roof covering, and is given in Table 3. 4

9 The calottes should be selected depending on the sandwich or trapezoidal sheet profile. As a standard, calottes are available from BayWa r.e. in an Alu blank colour with vulcanised EPDM seal in accordance with Table 4. Select the correct calotte using the Novotegra Planner. If you require calottes which are not listed in Table 4, contact the sales division at BayWa r.e. GmbH. Pre-drill as follows, depending on the material thickness of the steel purlin flange: Material thickness Drill diameter 1.5 < 5 mm 6.8 mm 5.0 < 8.0 mm 7.0 mm 8.0 < 10 mm 7.2 mm 10 mm 7.4 mm Table 2: Drill diameter depending on the material thickness The following SP hanger bolt set must be used, depending on the roof construction: Height H t of the covering Hanger bolt length up to 60 mm 140 mm mm 185 mm mm 220 mm Table 3: Hanger bolt length depending on the roof construction Available calottes: Name Angle Top chord width W 36/ mm W 17/ mm W 27/ mm W 15/ mm Table 4: Calotte name Figure 2 Angle and top chord width 5

10 3.3 Horizontal module mounting - roof parallel Cross rail assembly For cross rail assembly, 2 rail levels must be laid. The following describes rail mounting on wooden purlins with the HP hanger bolt set. When mounting on steel purlins with the SP hanger bolt set, replace the lower locking nut with the M10 nut and washer. For the upper locking nut, use the second washer and selflocking nut. Before mounting the first rail layer, screw the lower locking nut (corrugations facing upwards) onto the hanger bolt. Then place the rails vertically onto the hanger bolts (elongated holes below). The upper locking nut is lightly tightened (corrugations facing downwards) in order to lightly hold the rails in position. Finally, affix the C-rail 50 Nm torque after adjusting the height. The second rail layer is mounted at an offset of 90 (horizontally) and onto the first rail level using the cross rail connecter 40 Nm torque (Figure 4). Figure 3 Schematic diagram vertical module mounting with cross rail assembly 6

11 Ensure that the maximum length of the vertically and horizontally running rails does not exceed 8.5 m. For longer rails, expansion joints with a gap width of at least 20 mm should be used. For information on extending the C-rails and providing expansion joints, see chapter 3.5. Figure 4 Cross rail assembly The permitted overhangs of the rails are specified by the Solar-Planit software. Component Orientation Arrangement Hanger bolt Every purlin Lower rail Vertical Hanger bolt axis Module support rail Horizontal Symmetrically below the module 3.4 Horizontal module mounting roof parallel Single-layer rail assembly The following describes rail mounting on wooden purlins with the HP hanger bolt set. When mounting on steel purlins with the SP hanger bolt set, replace the lower locking nuts with the M10 nut and washer. For the upper locking nut, use the second washer and self-locking nut. Figure 5 Schematic diagram horizontal module mounting with single-layer rail assembly 7

12 Before mounting the rail, screw the lower locking nut (corrugations facing upwards) onto the hanger bolt. Then place the C-rail vertically onto the hanger bolts (elongated holes below). The upper locking nut is lightly tightened (corrugations facing downwards) in order to lightly hold the rails in position. Finally, affix the C-rail 50 Nm torque after adjusting the height. The permitted overhang of the rail over the last hanger bolt is 0.4 times the maximum span width of the respective roof area. Component Orientation Arrangement Hanger bolt Every purlin Module support rail Vertical Symmetrically below the module Also ensure that the maximum rail length does not exceed 8.5 m. With larger rail lengths an expansion joint of at least 20 mm must be provided. See chapter 3.5 regarding extension of the C-rails and creation of expansion joints Cross rail assembly For cross rail assembly, 2 rail levels must be laid. The following describes rail mounting on wooden purlins with the HP hanger bolt set. When mounting on steel purlins with the SP hanger bolt set, replace the lower locking nuts with the M10 nut and washer. For the upper locking nut, use the second washer and self-locking nut. Before mounting the first rail layer, screw the lower locking nut (corrugations facing upwards) onto the hanger bolts. Then place the rails horizontally onto the hanger bolts (elongated holes below). The upper locking nut is lightly tightened (corrugations facing downwards) in order to lightly hold the rails in position. Finally, affix the C-rail 50 Nm torque after adjusting the height. The second rail layer is mounted at 90 (vertical) to the first rail level using the cross rail connectors and tightened to a torque of 40 Nm (Figure 4). Component Orientation Arrangement Hanger bolt Every purlin Lower rail Horizontal Hanger bolt axis Module support rail Vertical Symmetrically below the module Also ensure that the maximum length of the horizontally and vertically running rails does not exceed 8.5 m. With larger rail lengths an expansion joint of at least 20 mm must be provided. For information on extending the C-rails and providing expansion joints, see chapter 3.5. The permitted overhangs of the rails are given in the Solar-Planit software. 8

13 3.5 Rail extension and expansion joints General information Due to temperature-related length expansions, certain limits regarding the rail lengths must be observed, and expansion joints must be created. The rails are extended using the rail connectors. The expansion joints can be created using two methods Rail extension Components of the rail connector set Units Aluminium profile 1 Saucer head screw M12 2 Locking nuts M 12 2 The rails are extended using the rail connector set. The connection is made using saucer head screws and locking nuts tightened to a torque of 50 Nm (Figure 12 left). If the rail joint is located above a hanger bolt, the saucer head screw can be replaced by the hanger bolt. (Figure 12 right). The rail joint is to be constructed as a contact joint. This type of connection means that the joint area functions like a normal rail segment. Figure 6 Rail extension 9

14 3.5.3 Designing expansion joints using module arrays The mounting system must be separated at specific distances in order to avoid problems with longitudinal expansion. By interrupting the substructure, module fields are created, at the beginning and end of which the modules are clamped using end brackets. The permitted overhangs of the rails are given in the Solar-Planit software and must in all cases be observed Designing expansion joints using movable bearings Components of the movable bearing set Units Aluminium profile 1 Saucer head screw M12 2 Saucer head screw M12, coated 2 Locking nuts M 12 4 Expansion joints can also be implemented using movable bearings. To create the joints, you will require a movable bearing set, which consists of these components. Connect the rails to the rail connector in accordance with Figure 7 and with two bolts for each side. Figure 7 Arrangement of the components for movable bearing mounting The screw connections on the fixed side are to be tightened to a torque of 50 Nm. The screws to be used on the movable side have a red coating on the threads. These screws must also first be tightened to 50 Nm and then loosened by approximately a half-turn. The specified clearances between the rails, or between the edges of the elongated holes, are to be adhered to, so that the screws each have at least 10 mm free play to the edges of the elongated holes. A movable bearing must not be installed below a module. When using movable bearing expansion joints, an additional expansion joint must be created via a new module array after a maximum distance of 40 m. 10

15 3.6 Module fastening Before mounting the module, the slip guards must be fitted. Vertical module mounting: The M6 or M8 module slip guards must be secured in the mounting holes in the module frame (Figure 14). Horizontal module mounting: Secure the slip guard with the saucer head screw and the locking nut in the elongated hole of the vertical C-rail 50 Nm torque (Figure 15). Figure 8 Slip-guard for vertical module mounting Figure 9 Slip guard for horizontal module mounting Mounting system components Middle clamp End bracket Tightening torque 12 Nm 8-10 Nm The solar module must be clamped at min. 4 points (two on every longitudinal side). The module manufacturer s specifications must be observed. The end brackets must first be rotated into the rails at the edge of the module array to fasten the first module. The module is then slid flush onto the end brackets. The end brackets can be aligned flush with the C-rail and must be tightened to the required tightening torque of 8 10 Nm. For this purpose, a overhang of the C-rail over the outer edge of the module of at least 13 mm is required (Figure 10). The middle clamp must now be screwed into the C-rail next to the already fastened module and slid flush into position. Then push the next module to the middle clamp and fasten it with the required tightening torque (Figure 10). This allows the following modules to be mounted with a module gap of 12 mm. The last module is then fastened again with an end bracket. A gap of at least 10 mm must be maintained between the modules along the short side. 11

16 When mounting the end brackets and middle clamps, ensure that the screw axis is vertical to the rail axis, and the width of module clamps matches the rail width, to ensure that the modules are securely fastened. Ensure that the clamps are mounted correctly, especially for steep roofs. Figure 10 Middle clamp and end bracket 12

17 3.7 Elevated mounting for north and south-facing roofs General information The following chapter explains how to mount the Novotegra mounting system for corrugated fibre cement, sandwich and trapezoidal sheet roof coverings, with elevated mounting for south and north-facing roofs. The substructure is designed as a cross rail assembly (CRA) with a lower rail (C-rail) and a module support rail (base profile) on top of this. The modules must be horizontally mounted. In principle, the mounting system can be used for roof coverings on purlin roofs on which direct attachment of the mounting system on the roof cladding is either not possible (e.g. corrugated fibre cement), not permitted (e.g. sandwich profiles, aluminium trapezoidal sheets) or not desired. When mounting photovoltaic systems on asbestos cement roofs (e.g. old corrugated fibre cement coverings), the appropriate regulations must be observed. The mounting system is connected to the roof structure via hanger bolts. The hanger bolts must be screwed into the purlins through the raised beading or crest of the roof covering. The structural calculations in the Solar-Planit software include the attachment to the roof supporting structure Roof division The roof is divided into two areas (Figure 11) according to the various wind loads on the roof. The exposed edge modules at the verge, ridge and eaves (red surface) are considered separately to the middle modules (yellow surface). Figure 11 Schematic diagram, roof division 13

18 3.7.3 Module arrangement In general, the modules should be arranged in a row in blocks. The length of the base profile should be selected in such a way that four modules with a length of up to approx m and an approximate distance of the frame drill holes in ¼-point (connections points of the module fasteners) can be placed on it (Figure 12). If it is not possible to form a block of four due to the number of modules in a row, the following instructions should be followed analogously for blocks with three or two modules. Individual modules should be mounted as described below. Figure 12 Module block with four modules Cross rail assembly components, module block - Lower rail (C-rails): Number according to statical calculations from the Solar-Planit Lengths, including expansion joints - Module support rail (base profile): Two base profiles, length 6.18 m with block of four; with less than four modules, the length depends on the module and corresponds to the distance between the outer edges of the front module fasteners of the first and the last module in the block. 14

19 Cross rail assembly components, individual module - Lower rail (C-rails): The number and length of the rails depend on the result of the statical calculations in the Solar-Planit for the module block. This results in the number of rails for the individual module with reference to the module block: For module blocks For individual modules Number of rails 3 2 Number of rails = 4 2 Number of rails = 5 3 Number of rails = Module support rail (base profile): Two base profiles are required: The length depends on the module and corresponds at least to the distance between the outer edges of the front module fastener. The maximum base profile length is the length of the module Arrangement of the C-rails Before mounting the rail sections, the module block or individual module length layout must be specified. This length is required to mark the axes of the rails. This length also allows you to check the roof division. The correct alignment of the C-rails automatically ensures compliance with the permitted overhangs of the base profiles. Depending on block or individual mounting, the following conditions apply: Module block: The C-rails must be aligned symmetrically under the base profiles (Figure 12). For the axial clearance between the C-rails, please refer to the structural analysis of the Solar- Planit. The rails are arranged on the roof at right-angles to the ridge or to the eaves, and therefore at right-angles to the purlins. Individual module: The C-rails should be symmetrically arranged below the base profiles and centrally below the module fastener set. The axis distance therefore depends on the module. The rails are arranged on the roof at right-angles to the ridge or to the eaves, and therefore at right-angles to the purlins. 15

20 3.7.5 Fastening the C-rails The lower rail is fastened on hanger bolts. A description of how to mount the hanger bolts is given in chapter 3.2. Mounting the rails on hanger bolts for wooden purlins: Figure 13 C-rail as lower level of the cross rail assembly Before mounting the lower rail, screw the lower locking nut (corrugations facing upwards) onto the hanger bolt. Then place the rails vertically onto the hanger bolts (elongated holes below). The upper locking nut is lightly tightened (corrugations facing downwards) in order to lightly hold the rails in position. Finally, affix the C-rail 50 Nm torque after adjusting the height (Figure 13). Mounting the rails on hanger bolts for steel purlins: Before mounting the lower rail, screw out the lower nut onto the hanger bolt and thread it into the lower washer. Then place the rails vertically onto the hanger bolts (elongated holes below). To secure the position, first attach the upper washer, and then loosely screw out the self-locking nut. Finally, affix the C-rail 50 Nm torque after adjusting the height. The permitted overhang of the lower rail is given in the Solar-Planit software. The length of the overhang relates to the distance from the load application axis of the base profile through to the hanger bolt axis. In order to be able to make optimum use of the overhang, the lower rail must therefore be longer than the length of the overhang by half of the base profile width (approx. 65 mm) (Figure 14). The lower rails of the cross rail assembly can be installed without expansion joints with a length of up to 8.50 m. In order to avoid length expansions which are too great, the C-rails should be interrupted. This can be done by arranging module fields (chapter 3.5.3) or installing movable bearings (chapter 3.5.4). Figure 14 Permitted overhang, lower rail 16

21 3.7.6 Arranging the base profiles The base profiles form the module support rail. They lie on the C-rails and run parallel to the ridge and eaves. They must be aligned symmetrically on the C-rails. The permitted overhangs of the base profiles are specified by the Solar-Planit software, and must be observed while complying with the prescribed rail clearances (Figure 12). One front and one rear base profile run under the module; the rails must be mounted such that the mounting spiral faces south (the platform of the mounting spiral faces north (Figure 15). The distance between the base profile axes is calculated by the planning software on the basis of the data entered, as is the distance between the module rows (Figure 12). Figure 15 Platform (left) and mounting Fastening the base profiles The base profile is fastened using the indirect fastening set for base profiles (Figure 16) on the C- rails below it. The base profiles should be trimmed on site for module blocks with fewer than four modules, or with individual modules. The base profiles cannot be extended in length. Figure 16 Indirect fastening set for base profile The base profiles are fastened on both sides through the platforms of the base profiles without drilling the C-rail into the flange of the C-rails (Figure 17). Do not tighten the fastening set excessively, as the self-drilling screw then no longer has a structural effect. Screw the base profile to the C-rail at each cross point using four self-drilling screws each time. Figure 17 Fastening the base profile to the C-rails 17

22 3.7.8 Module fastening and position securing Mounting system components Units / module Module fastening set, front 2 Rear module fastener set 2 Module support set 2 For each module, two front module fastener sets and rear module fastener sets must be screwed through the mounting holes in the module so that they cannot be moved to a tightening torque of Nm (Figure 18). Figure 18 Mounting the module fastener set at the rear (left) and at the front (right) Figure 19 Inserted module support set At the same time, the module support sets can be inserted into the rear base profiles (Figure 19). The module is then inserted into the base profiles with the front module fastener set, and lowered at the back onto the module support sets. Every module is mounted consecutively in this way. There must be a clearance of at least 10 mm between the modules in a row. The module can be attached seamlessly to the required elevation angle using the thread of the module support (Figure 20). The module supports are not secured via the screw at the rear module fastener set until after they have been aligned. Figure 20 Height-adjustable module supports 18

23 To secure the position of the modules, secure them to the front module fastener set using a self-drilling screw (Figure 21). The following regulation per module applies: Roof orientation Modules Position securing Number of screws South-facing Only verge Module fastener front, 1 front outer edge North-facing All Module fastener front 2 front To secure the modules in position, the self-drilling screws from the indirect fastening set for base profile are used. To secure the modules, place the self-drilling screw into the guide groove of the mounting spiral and screw it into the module fastener through the base profile. The module cables are attached to the module frames using self-locking cable ties. Per module, 2 3 cable ties are required depending on the cable length. If the module cables are too short, they must be extended accordingly using extension cable and affixed to the module frame. Figure 21 Module securing on the front module fastener set 19

24 3.8 Elevated mounting for east and west-facing roofs General information The following chapter explains how to mount the Novotegra mounting system for corrugated fibre cement, sandwich and trapezoidal sheet roof coverings, with elevated mounting for east and west-facing roofs. The substructure is designed as a cross rail assembly (CRA) with a lower rail (C-rail) and a module support rail (base profile) on top of this. The modules must be horizontally mounted. In principle, the mounting system can be used for roof coverings on purlin roofs on which direct attachment of the mounting system on the roof cladding is either not possible (e.g. corrugated fibre cement), not permitted (e.g. sandwich profiles, aluminium trapezoidal sheets) or not desired. When mounting photovoltaic systems on asbestos cement roofs (e.g. old corrugated fibre cement coverings), the appropriate regulations must be observed. The Novotegra mounting system is connected to the roof structure via hanger bolts. The hanger bolts must be screwed into the purlins through the raised beading of the roof covering. The structural calculations in the Solar-Planit include the attachment to the roof substructure. In order to mount the Novotegra mounting system for corrugated fibre cement/sandwich roof elevation, the following tools are required: Tool Mounting system component Electric screwdriver Torque wrench External hexagon, size 8 Self-drilling screws The tools required for mounting the hanger bolts for wooden or steel purlins are listed in chapter Roof division The roof is divided into two areas (Figure 22) according to the various wind loads on the roof. The exposed edge modules at the verge, ridge and eaves (red surface) are considered separately to the middle modules (yellow surface). Figure 22 Schematic diagram, roof division 20

25 3.8.3 Module arrangement In general, the modules should be arranged in a row in blocks. The length of the base profile should be selected in such a way that four modules with a length of up to approx m and an approximate distance of the frame drill holes in ¼-point (connections points of the module fasteners) can be placed on it (Figure 23). If it is not possible to form a block of four due to the number of modules in a row, the following instructions should be followed analogously for blocks with three or two modules. Individual modules should be mounted as described below. The module blocks should be placed as symmetrically as possible on the substructure. The system must be placed on the roof accordingly, depending on the purlin distance, and maintaining the permitted overhang of the base profiles. For individual modules and purlin distances greater than the distance of the outer edges of the module fasteners, the base profiles must be extended so that they reach the C-rail. This may mean that a complete covering of the roof area is not possible. Figure 23 Block of four modules Cross rail assembly components, module block - Lower rail (C-rails): Laid on each purlin; the number depends on the purlin grid. Lengths, including expansion joints. - Module support rail (base profile): Two base profiles are required. The length with the block of four is 6.18 m; with fewer than four modules, the length depends on the purlin grid and the permitted overhang of the base profile. Taking these considerations into account, the base profile must be at least as long as the distance of the outer edges of the front module fasteners of the first and last module of the block. In some circumstances, the base profiles must be extended so that they reach the C-rails. 21

26 3.8.4 Arrangement of the C-rails For east and west-facing roofs, the lower rails can only be laid and fastened directly above the purlins. As a result, this grid determines the way in which the rails are laid. In order to avoid a load concentration, lay the rails on each purlin Fastening the C-rails The lower rail is fastened on hanger bolts. A description of how to mount the hanger bolts is given in chapter 3.2. Mounting the rails on hanger bolts for wooden purlins: Before mounting the lower rail, screw the lower locking nut (corrugations facing upwards) onto the hanger bolt. Then place the rails vertically onto the hanger bolts (elongated holes below). The upper locking nut is lightly tightened (corrugations facing downwards) in order to lightly hold the rails in position. Finally, affix the C-rail 50 Nm torque after adjusting the height. Mounting the rails on hanger bolts for steel purlins: Before mounting the lower rail, screw out the lower nut onto the hanger bolt and thread it into the lower washer. Then place the rails vertically onto the hanger bolts (elongated holes below). To secure the position, first attach the upper washer, and then loosely screw out the self-locking nut. Finally, affix the C-rail 50 Nm torque after adjusting the height. Figure 24 Permitted overhang, lower rail The permitted overhang of the lower rail is given in the Solar-Planit software. The length of the overhang relates to the distance from the load application axis of the base profile through to the hanger bolt axis. In order to be able to make optimum use of the overhang, the lower rail must therefore be longer than the length of the overhang by half of the base profile width (approx. 65 mm) (Figure 24). The lower rails of the cross rail assembly can be installed without expansion joints with a length of up to 8.50 m. In order to avoid length expansions which are too great, the C- rails should be interrupted. This can be done by arranging module fields (chapter 3.5.3) or installing movable bearings (chapter 3.5.4). 22

27 3.8.6 Arranging the base profiles The base profiles form the module support rail. They lie on the C-rails and run at rightangles to the ridge and eaves. They should be arranged symmetrically on the C-rails (Figure 23). The permitted overhang of the base profiles is given in the Solar-Poanit software. For better positioning of the system on the roof, an increased overhang of the base profiles is permitted through the additional installation of hanger bolts below the C-rails (Figure 25). The length of the permitted overhang is given in the Solar-Planit software. Figure 25 Increased permitted overhang One front and one rear base profile run under the module; the rails must be mounted such that the mounting spiral faces south (the platform of the mounting spiral faces north (Figure 26). The distance between the base profile axes is calculated by the Solar-Planit software on the basis of the data entered, as is the distance between the module rows (Figure 23). Figure 26 Platform (left) and mounting spiral (right) 23

28 3.8.7 Fastening the base profiles Figure 27 Indirect fastening set for the base profile The base profile is fastened using the indirect fastening set for base profile (Figure 27) on the C- rails below it. The base profiles should be trimmed on site for module blocks with fewer than four modules, or with individual modules. The base profiles cannot be extended in length. Fasten the base profiles without pre-drilling the C-rail on both sides through the platforms on the base profiles into the flange of the C-rails (Figure 28). Do not tighten the fastening set excessively, as the self-drilling screw then no longer has a structural effect. The base profile must be screwed to the C-rail with four self-drilling screws at every intersection. Figure 28 Fastening the base profile to the C-rails 24

29 3.8.8 Module fastening and position securing Mounting system components Items per module Front module fastener set 2 Rear module fastener set 2 Module support set 2 For each module, two front module fastener sets and rear module fastener sets must be screwed through the mounting holes in the module so that they cannot be moved to a tightening torque of 12-14Nm (Figure 29). Figure 29 Mounting the module fastener set rear (left) and front (right) At the same time, the module support sets can be inserted into the rear base profiles (Figure 30). Figure 30 Inserted module support set (here with south-facing roof with hanger bolt mounting as an example) The module is then inserted into the base profiles with the front module fastener set, and lowered at the back onto the module support sets. Every module is mounted consecutively in this way. There must be a clearance of at least 10 mm between the modules in a row. 25

30 The threads of the module supports allow the module to be adjusted steplessly to the elevation angle (Figure 31). The module supports are not secured via the screw at the rear module fastener set until after they have been aligned. Figure 31 Height-adjustable module supports To secure the position of the modules, they should be secured using a self-drilling screw on the front module fastener set respectively on the module support set depending on the roof pitch and the load (Figure 33). The following regulation per module applies: Roof orientation Diagonal Modules Position securing Number of screws East and westfacing roof fastener No All Front module 2 front East and westfacing roof front and rear 1 Yes All Module fastener 2 front and rear Figure 32 Securing the position on the front module fastener set To secure the modules in position, the selfdrilling screws from the indirect fastening set for base profile are used. Depending on the roof pitch and the load arising, it may be necessary to additionally secure the modules with diagonal reinforcers and a slip guard on the module support. The Solar-Planit software will indicate this when the system is being planned. In such cases, you should contact the sales division at BayWa r.e. Solarsysteme. To secure the modules at the front, place the self-drilling screw in the guide groove of the mounting spiral and screw it into the module fasteners through the base profile. Rear slip guard is implemented by screwing the self-drilling screw into the base profile under the module support (Figure 40). The self-drilling screw can either be screwed in through the mounting spiral or the platform (Figure 33). 26

31 The module cables are attached to the module frames using self-locking cable ties. Per module, 2 3 cable ties are required depending on the cable length. If the module cables are too short, they must be extended accordingly using extension cable and affixed to the module frame. Figure 33 Securing the module on the front module fastener set (left) and on the module support set (right) 27

32 4 Earthing the mounting system/ electrical installation 4.1 Earthing the mounting system The EN lightning protection standard requires increased vigilance and caution when installing photovoltaic systems on buildings. Before planning and erecting the system, please first obtain exact information on the lightning protection measures required. General procedure: At least one of the two module support rails under each module row must always be connected to one of the two rails of all other rows. The system is earthed from one of these rails connected to one another. If the mounting system is fastened directly to the roof cladding (e.g. Novotegra for trapezoidal sheet roofs), it is earthed via the self-drilling screws. Sufficient earthing of the roof cladding must be ensured. If a mounting system has multiple earthing points, any incoming lightning current is distributed to the various earths, so that the current per earth cable is reduced. The earthing connector can be used to earth the mounting system. It can be mounted through the elongated holes in the C-rail. When using an earthing connector combined with the base profiles or other rails from the system family, 11 mm diameter holes at the end of these profiles must be drilled for fastening the earthing connector. The earthing connector is also suitable for connecting two earthing round wires (smoothly sawed) or two earthing lines. We distinguish the following cases for earthing the mounting system or integration in the lightning protection system: Building without external lightning protection: If there is no external lightning protection, the PV system must be earthed on the equipotential bonding rail or deep earth rods (dissipation must be repeated every 15 m). Care must be taken to ensure that the earthing cable is laid outside the building to prevent lighting current from passing through the building. The earthing cable (on-site) can be designed as: Round earthing wire with a diameter of 8-10 mm (or 6-10 mm diameter in Switzerland). Connection to the C-rail requires a tightening torque of 20 Nm (Figure 41 above). OR Connected earthing cables with at least 16 mm² (suitable for lightning currents, copper, no fine wine), (Figure 35 below). Torque 10 Nm Building with external lightning protection: If external lightning protection is present, we recommend installing the solar generator in the protection area of the existing lightning conductors, complying with the separation clearance s (guideline figure x = 0.5 m). The separation clearance "s" must be calculated precisely per DIN VDE Alternatively, the conductors must be expanded such that the PV system remains in the protection area. The lightning conductor rods should not cast shadows on the photovoltaic system. The entire mounting system must be connected to the equipotential bonding system or equipotential bonding rail with at least 6 mm² diameter earthing cables (16 mm² is recommended). In this case, all DC lines and the mounting system arrangement must be laid with a separation distance s from the lightning capture and dissipation devices (meshes). The fastening of the earthing connector to the C-rail is described below. 28

33 If this separation distance "s" to the lightning conductor and protection systems (loops) cannot be maintained, the PV generator must be connected to the external lightning protection system using earthing connectors via the shortest route possible. It is sufficient to connect one of the two rails of every individual module row. This is done with a round earthing wire and a diameter of 8-10 mm (in Switzerland, 6-10 mm diameter applies), and with the matching branch terminals for the lightning protection system (this must be realised on site). The earthing connector is attached to the C-rail as described in (Figure 40 above) with a torque of 20 Nm. Important note: The function of the lightning protection system may not be impaired by this. Per DIN VDE , additional protective measures must be taken, such as internal lightning protection. Please take this into consideration in the planning process. Figure 34 Connection of the mounting system to the earthing using Novotegra earthing connectors 29

34 4.2 Laying the main DC line To prevent contact with dangerous DC voltage on subsequent electrical connection of the modules, lay the main DC wire from the roof to the DC isolator and DC load circuit breaker or other approved load separators first. When passing the cables through the roof, ensure that the cable insulation is not damaged and the cable does not rub or kink in the penetration. 30

35 5 Safety instructions and warnings When performing any work, please observe the following safety instructions and updates to these instructions, the specifications of the module, inverter and cable manufacturers and the regulations of the local energy suppliers: Safety rules Standard BGV C22 BGV A1 BGV A3 BGI 663 BGI 807 BGI 757 BGI 5074 BGI 8683 TRBS TRBS TRBS DIN 4102 DIN DIN DIN DIN DIN DIN VDE DIN VDE VDEW guideline VDEW Guideline leaflet VDN Guideline VDI 6012 sheet 2 DIN EN DIN VDE 0185 Parts 1-4 DIN VDE 0100 part 410 TAB 2000 Content BG regulation (German Employer's Liability Insurance Association); Accident prevention regulation construction work General regulations Electrical systems and equipment Handling instructions for working scaffolding and safety scaffolding Securing of sides, edge securing and roof protection walls as fall prevention during construction work Protection against falling during the construction and operation of overhead line systems Workplaces and traffic routes on roofs Protection against falling when working on electrical systems on roofs Provision and use of scaffolding Provision and use of ladders Provision and use of access and positioning systems using ropes Fire behaviour of building materials and building components Working scaffolding and safety scaffolding, Part 1: Safety scaffolding Performance requirements, design, construction and dimensioning General rules applying to all types of construction work Roofing and roof sealing work Scaffolding work Metal construction Erection of low voltage systems Selection and installation Earthing, protective conductors and equipotential bonding conductors Independent generation systems on the low voltage grid Independent generation systems on the low voltage grid Independent generation systems on the low voltage grid Decentralised energy systems in buildings photovoltaics Lightning protection Lightning protection Earthing Technical conditions for connection to the low voltage grid 31

36 ZVDH Regulations Regulations for working on roofs The structural design of the mounting system takes the following standards into account: Design loads Content DIN Actions on structures - Basis of design, safety concept and design rules DIN Densities and weights of building materials, structural elements and stored materials DIN Wind loads DIN Snow and ice loads EN Snow loads (Eurocode 1) EN Wind loads (Eurocode 1) SIA 261:2003 Actions on structures (for Switzerland) D 0188 SIA Wind Comments on chapter 6 of the SIA 261 and 261/1 (2003) standards Actions on structures (for Switzerland) ÖNORM B Eurocode 1 Actions on structures; Part 1-3: General actions Snow loads; National decisions on Austrian Standard ÖNORM EN , national explanations and national enhancements (for Austria) ÖNORM B Eurocode 1 Actions on structures; Part 1-4: General actions Wind loads; National decisions on Austrian Standard ÖNORM EN , national explanations and national enhancements (for Austria) Aluminium DIN 4113 Aluminium structures subjected to primarily static loads DIN EN 755 Extruded rod/bar, tube and profiles DIN V ENV EC 9: Dimensioning and design of aluminium structures, Part General dimensioning rules; dimensioning rules for building construction Steel DIN Steel structures. Dimensioning and design DIN V ENV EC 3: Dimensioning and design of steel structures; Part 1-1: General dimensioning rules; dimensioning rules for building construction EN Stainless steels Wood DIN 1052 Design, calculation and dimensioning of wooden structures Guarantee / product liability (exclusion) In addition to the abovementioned regulations and safety instructions, the valid technical regulations and rules must be observed by the specialist installers. The installer is responsible for dimensioning the Novotegra mounting system The installer is responsible for connecting the interfaces between the mounting system and the building. That also includes ensuring that the building envelope is sealed. For flat roofs, the roof seal must be evaluated with regard to the material of the seal strip, resistance, aging, compatibility with other materials, overall condition of the roof seal, requirement of a separating system between the roof seal and mounting system on-site by the installer under their own responsibility. The required and necessary measures or precautions to protect the roof seal for mounting the substructure of a PV system must be performed by the installer with the assistance of a technical specialist if necessary. BayWa r.e. Solarsysteme shall not accept liability for incorrect or insufficient measures and 32

37 precautions for protecting the roof seal! The installer must verify the coefficients of friction applied in the calculation for proving the anti-slip properties of PV systems on flat roofs on-site. Coefficients of friction calculated onsite can be incorporated and must be provided to BayWa r.e. Solarsysteme for calculation. BayWa r.e. Solarsysteme shall not accept liability for the correctness of the assumed values or for damage due to the use of incorrect values. The tightening torques specified must be observed. No components may be omitted or own components added. All specifications and statistics refer to installation of the mounting system in Germany unless explicitly stated otherwise. Other regulations may apply in other countries. As a result, no liability can be accepted for installation of the mounting system outside Germany without the approval of BayWa r.e. Solarsysteme. The specifications of the module, cable and inverter manufacturers must be adhered to. If they contradict these installation instructions, please consult your BayWa r.e. Solarsysteme sales team, or the manufacturer in question for components not delivered by BayWa r.e. Solarsysteme, before installing the Novotegra mounting system. When our sales staff draw up quotations for Novotegra systems, they are not always sufficiently aware of the local conditions, and as a result, the quoted quantities may change during installation. These changes largely concern the number of fastening material to the building envelope (e.g. roof hooks). If this is the case, the additional components required per the dimensioning absolutely must be installed. BayWa r.e. Solarsysteme GmbH accepts no liability for damage resulting from incorrect handling of the installed components. BayWa r.e. Solarsysteme is not liable for incorrectly or incompletely filled in data entry forms. Accurate and completely filled-in data entry forms are essential for correct dimensioning. The mounting system may not be installed close to the sea (risk of corrosion). The mounting instructions, guarantee conditions and liability exclusion information must be observed. The listed standards and guidelines are specified for Germany. The latest versions must be observed. Outside Germany, the relevant national standards and guidelines must be applied. The corresponding accident prevention guidelines must be observed. Internal tests were also carried out to guarantee load-bearing capacities. Please note that the technical approvals and Z and Z must be complied with for screw fastening of roof hooks to rafters. Local construction and safety regulations must also be adhered to. 33

38 Notes: 34

39 Notes: 35

40 BayWa r.e. Solarsysteme GmbH Eisenbahnstraße 150 D Tübingen Phone Fax Sales office Munich Sales office Nuremberg Plinganserstraße 8 Rilkestraße 20 D München D Nürnberg Phone Phone Fax Fax mue.solarsysteme@baywa-re.com nue.solarsysteme@baywa-re.com Sales office Duisburg Sales office Brunswick Philosophenweg 21 Packhofpassage 3 D Duisburg D Braunschweig Phone Phone Fax Fax dui.solarsysteme@baywa-re.com bsg.solarsysteme@baywa-re.com Copyright BayWa r.e. Solarsysteme GmbH Subject to modifications and errors. Status June 2013/GH, Version 2.8 Copyright BayWa r.e. Solarsysteme GmbH. 36