Transcript
Installation manual novotegra for folded seam roof
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TABLE OF CONTENTS
1 Information .......................................................................................................... 1 2 Installation system maintenance ....................................................................... 3 3 novotegra for folded seam roof ......................................................................... 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 Clamp assembly .............................................................................................. 6 5.2 Installing the rails ............................................................................................. 6 5.3 Installing the module ........................................................................................ 7 5.4 Installation variants .......................................................................................... 8 6 Warranty / product liability and disclaimer ..................................................... 11
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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. Solar Energy Systems 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 loadbearing 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
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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.
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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 TÜV Rheinland:
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 folded seam roof The contents of this installation manual describe the construction of the substructure on folded seam roof (standing and round seam roofs) or profile sheet roofs (Zambelli RibRoof 465 and 500 or Domico GBS). The seam and profile sheet clamps must be attached to every seam in the area of the module array and are suitable for roof coverings made from steel and copper sheet, titanium zinc, aluminium and stainless steel. Depending on the thickness of the sheet and the roofing material, A2SS saddles may need to be installed beneath the clamps, depending on the clamp.
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4 System components, tools and work equipment 4.1 Required for installation Image
Tool
Component* Seam/profile sheet clamp set Material: V2A and aluminium Tool: Bit setscrew Open-end wrench 13 mm
Product group Roof fasteners and fastening equipment
C-rail Material: Aluminium Tool: Special lock nut AF 18 deep
Module support rail
Rail connector set Material: Aluminium and V2A Tool: Special lock nut AF 18 deep
Module support rail
Middle clamp set Material: Aluminium, cast aluminium and V2A Tool: Socket bit AF 8 mm
Module fasteners
End clamp set Material: Aluminium, cast aluminium and V2A Tool: Socket bit AF 8 mm
Module fasteners
Module slip guard 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 40 Socket 8 mm
Component connections, clamp assembly
Special lock nut AF 18 deep
Installing the rails
Socket 8 mm
Clamp assembly
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Cutting rails
Torque key up to at least 50 Nm Torque key up to at least 12 Nm Chopsaw
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4.2 Installation system components – installation variants Image
Tool
Component**
Product group
Cross rail connector set Material: Cast aluminium and V2A Tool: Special lock nut AF 18 deep
Roof fasteners and fastening equipment
Expansion joint* Material: Aluminium and V2A Tool: Special lock nut AF 18 deep
Module support rail
Slip guard for landscape modules installation Material: Aluminium and V2A Tool: Special lock nut AF 18 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
C-rail end cap Material: Aluminium and V2A Tool: Special lock nut AF 18 deep
Optional items
Top cover C-rail 2,000 mm Material: Aluminium
Optional items
Grounding connector set AF 18 Material: V2A Tool: Special lock nut AF 18 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.
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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 Clamp assembly Marking out the clamp axis The clamps must be installed centred under the C rails. To do this, first mark out the axis on the roof covering or mark it with the cord. Two rail axes must be provided for each row of modules.
Upper Rail axis Lower
Scaffolding must be constructed in accordance with the relevant regulations.
Place the clamp on the seam and fasten using the setscrew. The clamps must not be installed on or near the metal retainers. The image shows the clamp for standing seam roofs. Clamps as per IV 1 and IV 2 are available depending on the roof covering.
Attaching the clamps
Tightening torque for setscrew 15 - 17 Nm
5.2 Installing the rails Installing the rail
Place the C-rail on the clamp and tighten the rail using the locking bolt. If installing in a cross rail configuration, the upper rail is fastened using cross rail connectors (IV 3).
Tightening torque for locking bolts: 50 Nm.
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Push the ends of the rails tightly together, place the rail connectors centrally and screw together using the bolts contained in the set. Maximum uninterrupted rail length 3.06 m, after this expansion joints or installation of expansion jonits for the C-rail (IV 4).
Connecting the rails
2 bolts
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 module slip guard must be mounted on the holes in the frame above the upper or lower rail side (IV 5a/b).
Clamping the module
Following this, fasten the modules to the rails using end and middle clamps.
Installing the end and middle clamps Insert the end or middle 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.
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Space requirement for end and middle clamps
The end clamp can also be installed flush with the rail end. Push the modules fully to the rail nuts of the middle clamps.
End clamp: 13 mm to rail end
Middle clamp: 12 mm clearance to module
Tightening torque for middle 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. round seam clamps or cross rail configuration). IV 1 – Clamp set for copper roof covering A2SS saddle
Standing seam clamp set for copper: - For copper standing seam roofs - Install the A2SS saddle (image left) - Place the clamp in position - Fasten the clamp with the setscrew - Tightening torque 20 Nm - The clamps must not be installed on or near the metal retainers.
IV 2 – Clamp set variants Round seam clamp set: - For Kalzip roof coverings - Place the clamp in position - Push in the clamp insert - Fasten the clamp with the setscrew - Tightening torque 15 - 17 Nm - The clamps must not be installed on or near the metal retainers. Profile sheet clamp set ZD: - For Zambelli RibRoof 465 and Domico GBS roof coverings - Material thickness = 0.7 mm requires installation of an A2SS saddle (image right) - Place the clamp in position - Fasten the clamp with the setscrew on both sides - Tightening torque for material thickness > 0.7 mm = 15 Nm - Tightening torque for material thickness = 0.7 mm = 17 Nm - The clamps must not be installed on or near the metal retainers.
A2SS saddle
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Profile sheet clamp set Z: - For Zambelli RibRoof 500 roof coverings - Place the clamp in position and click into place - Fasten the clamp with both screws (open-end wrench 13 mm) - Tightening torque 25 Nm - The clamps must not be installed on or near the metal retainers. IV 3 – Installing the cross rail connectors 1
Cross rail installation: Insert cross rail connector from top into the rail nut (1) and make a 90° turn (2). 2 Tightening torque for cross rail connectors: 40 Nm.
IV 4 – Installing expansion joints 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 9.20 m, plan for proper expansion joint after this.
Gap between C rails Fixed side
Tightening torque for locking bolt on fixed side: 50 Nm. Distance between adjacent rail ends = 20 mm.
Moving side
IV 5a – Installing anti-slide protector on module frame Thin sheet screw
Nut M6
Push the nut over the screw and screw the thin sheet screw into the module frame without predrilling.
Do not overtighten the thin sheet screw.
Rear side Module frame
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IV 5b – 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.
5 mm gap
Tightening torque for locking bolt: 50 Nm.
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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. Solar Energy Systems 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. Solar Energy Systems GmbH for the calculation. BayWa r.e. Solar Energy Systems 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. Solar Energy Systems GmbH sales team prior to installation or else the relevant manufacturer for components not supplied by BayWa r.e. Solar Energy Systems 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. Solar Energy Systems 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.
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BayWa r.e. Solar Energy Systems GmbH Eisenbahnstraße 150 D-72072 Tübingen Phone +49 7071 98987-0 Fax +49 7071 98987-10
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Subject to errors and amendments. Date: Juni 2015/ASC, version 3.0 Copyright BayWa r.e. Solar Energy Systtems GmbH
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