East West System III Long side

Product Information

Specifications:

• Product Name: novotegra Installation System

• Roof Type: Flat roof | East-West-System III Long side

• Mounting System: Modular clamping system with cross elevated
  modules

• Permissible Roof Pitch: 0 to 60 degrees for pitched roof, 0 to
  5 degrees for flat roof

Product Usage Instructions:

Mounting Instructions:

1. Ensure installation is carried out by qualified personnel
familiar with relevant regulations and safety standards.

2. Verify the static requirements of the mounting system and the
load-bearing capacity of the roof before installation.

3. Use SolarPlanit design software for individual static
calculations for each project.

4. Follow installation instructions provided by PV module
manufacturers.

Safety Instructions:

1. Follow all national and locally applicable safety
regulations, construction standards, and environmental protection
guidelines.

2. Ensure proper grounding and potential equalization of the
mounting system.

3. Keep a copy of assembly instructions on-site during
installation.

Additional Notes:

1. Check for any updates or changes to installation procedures
on novotegra’s website before installation.

2. Contact novotegra GmbH for assistance if there are
contradictions in installation instructions.

Frequently Asked Questions (FAQ):

Q: Can the novotegra mounting system be used on different roof

types?

A: Yes, the novotegra mounting system is generally applicable
for various roof types but must be installed according to specific
guidelines.

Q: Are there specific requirements for the PV modules used with

the novotegra system?

A: The mounting system is suitable for standard market
dimensions of PV modules. Installers must adhere to the
installation instructions provided by module manufacturers.

Q: How should the grounding of the mounting system be

done?

A: Grounding/potential equalization should be performed in
accordance with national standards and guidelines to ensure safety
and proper functioning of the system.

Flat roof | East-West-System III Long side
Modular clamping system with cross elevated modules
Mounting instructions
· Safety instructions 2 · General conditions & Notes on mounting 3 · Tools, system components and optional components 4­5 · Mounting the substructure 6­14 · Mounting variations 15­18 · Maintenance of the mounting system 19

Safety instructions

The following instructions are to be understood as generally valid for our novotegra installation system and are to be applied accordingly, regardless of the particular roof type and installation system.
Systems may only be installed and commissioned by persons who are able to ensure that they are carried out in accordance with the regulations on the basis of their professional qualifications (e.g. training or activity) or experience.
All relevant national and locally applicable occupational health and safety regulations, accident prevention regulations, standards, construction regulations and environmental protection regulations as well as all regulations of the employers` liability insurance associations must be observed.
· During the work, safety clothing must be worn in accordance with the relevant national regulations and guidelines.
· The assembly must be carried out by at least two persons in order to be able to guarantee help in case of an accident.
· The national regulations for work at heights and on roofs must be observed.
· The electrical work must be carried out in compliance with the national and locally applicable standards and guidelines in compliance with the safety regulations for electrical work.
The installer is responsible for dimensioning the novotegra mounting system. Before installation, it must be checked whether the mounting system meets the static requirements on site For roof systems, the on-site load-bearing capacity of the roof must also be checked. Please note our instructions on static calculations, which can be viewed at novotegra.com/downloads.
The installer is responsible for connecting the interfaces between the mounting system and the building. This also includes the tightness of the building envelope. The mounting system must always be statically calculated individually for each project using the SolarPlanit design software.
The mounting system is suitable for mounting PV modules with standard market dimensions. The installation instructions of the module manufacturers must be observed and complied with. There is no inspection by novotegra GmbH re-

garding constructability or mounting guidelines.
The specifications of the cable and inverter manufacturers must be observed. If there are any contradictions to these installation instructions, please be sure to consult your novotegra GmbH sales team or – in the case of components not supplied by novotegra GmbH – the manufacturer concerned before installing the novotegra mounting system.
It must be ensured that a copy of the assembly instructions is within reach in the immediate vicinity of the work on the construction site.
Since our assembly systems are constantly being further developed, assembly procedures or components may change. Therefore, please check the current status of the installation instructions on our website novotgera.com/downloads /flat-roof before installation. The assembly sequence of these instructions must be observed. We will also be happy to send you current versions on request.
In the event of improper use and non-compliance with our safety instructions and installation specifications, as well as non-use of associated installation components or use of third-party components that are not part of the installation system, all claims under guarantee, warranty and liability vis-à-vis novotegra GmbH shall lapse. The user is liable for damage and resulting consequential damage to other components such as PV modules or to the building itself, as well as for personal injury.
The permissible roof pitch for the use of the mounting system in accordance with these installation instructions is 0 to 60 degrees for installation parallel to the roof on a pitched roof and 0 to 5 degrees for elevated installation on a flat roof. Facade systems are to be mounted parallel to the facade.
The grounding / potential equalization of the mounting system must be carried out in accordance with the national and locally applicable standards and guidelines.
If all safety instructions are observed and the system is installed properly, there is a product warranty claim of 12 years. Please note our warranty conditions, which can be viewed at novotegra.com/downloads.
The system can be dismantled in reverse order to the steps described below.

Subjects excepted. Illustrations are exemplary and may vary from the original. V1.0 ­ June 2024/TP, © novotgera GmbH

2

General conditions

Location: Roof inclination: Alignment: Edge distance: Elevation angle: Module mounting: Module size: Distance between rows: Module field size:

Flat roofs with and without parapet 0° ­ 5° East/West
Distance from system to roof edge (without parapet) = 0.50 m Distance from system to parapet (inside edge) = 0.50 m
10° landscape
Module width: 995 mm ­ 1145 mm Module lenght: max. 2600 mm
2230 mm ­ 2483 mm (depending on module width) max. module field length: 40 m (rail length) max. module field width: 21 m

General installation instructions for flat roof system

For flat roofs the roof insulation must be evaluated by the installer on site within his own responsibility regarding the material of the sealing layer, resistance, ageing, compatibility with other materials, overall condition of the roof insulation, need for a separating layer between the roof insulation and the mounting system. The required and necessary measures or precautions for the protection of the roof insulation for the mounting of the substructure of a PV system must be initiated by the installer with the aid of a specialist tradesman where necessary.
Depending on the roof seal material, separation and/ or protection membranes may need to be added between the roof seal and the substructure. This must be agreed upon directly between the company installing the PV system, the building owner and the specialist roof sealing company. The substructure is installed without penetrating the roof. The PV system is secured against wind suction by

providing ballast (e.g. suitable stones), based on the results of the wind tunnel tests for the system. The required ballast is determined by BayWa r.e. Solar Energy Systems GmbH based on the project data provided by the installation company. The ballast applies to the planned system; on-site deviations from planning may lead to different results.
The installer must review the friction coefficient used in the calculation for the verification of the slip safety of PV systems on flat roofs on site. Friction coefficients determined on site can be taken into account by entering them in the Solar-Planit planning tool.
The system must be secured on site to prevent it from ,,creeping” due to expansion caused by temperature. This can be achieved by installing suitable stop points on the roof surface or by anchoring to the parapet, for example. The connection points on the building and building parts must be able to bear the forces exerted.

Subjects excepted. Illustrations are exemplary and may vary from the original. V1.0 ­ June 2024/TP, © novotgera GmbH

3

Tool and Equipment

Cordless screwdriver

Mounting & removal tool

Assembling jig 1300-1700 mm without C-Shape

special nut socket
8 mm

special nut socket
18 mm

Mounting system components*

Base element e/w
690/840 mm

Connector-set Edge closure set Module support

e/w

970 mm

10° long side

1940 mm

Flat Roof End Clamp 30-42

Flat roof mounting screw chip-
less 5.5

Support Brace 20x20x1,5 2000 mm

*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

Subjects excepted. Illustrations are exemplary and may vary from the original. V1.0 ­ June 2024/TP, © novotgera GmbH

4

Mounting system components ­ optional**

Cable channel base element
1250 mm

Cover cable channel
1250 mm

Cable channel Cable-tie clip for module support profile flange
2000/2400 mm

Cable clip d = 10 mm

Mounting-Set Optimizer FR

Surface extension Ballast trough Ballast cantilever Grounding

180×150 mm

530 mm

650/1150 mm connector C-rail

**Optionally available installation system components, e.g. for improving the aesthetics of the system, cable management o grounding of the installation system.

Subjects excepted. Illustrations are exemplary and may vary from the original. V1.0 ­ June 2024/TP, © novotgera GmbH

5

Mounting the substructure
1 Laying out components

c

b

a

A Arrangement of components as

delivered.

a Connector set e/w

b Base element e/w

c Edge closure set

Subjects excepted. Illustrations are exemplary and may vary from the original. V1.0 ­ June 2024/TP, © novotgera GmbH

6

2 Rail mounting

A Push back surface extension.
novo-tip: To make it easier to click in the components later, push the surface extension all the way back.

B Observe module widh.

Module width

Base element

995 mm ­ 1020 mm

690 mm

A

1020 mm ­ 1045 mm 690 mm

B

1045 mm ­ 1070 mm

690 mm

C

1070 mm ­ 1095 mm

840 mm

A

1095 mm ­ 1120 mm

840 mm

B

1120 mm ­ 1145 mm

840 mm C

A CB A BC

Subjects excepted. Illustrations are exemplary and may vary from the original. V1.0 ­ June 2024/TP, © novotgera GmbH

7

C Connecting the base element with the edge closure set.

D Remove the connecting safeguarding from the support and install it.

novo-tip: An audible click indicates that the system securing device has been installed correctly.

Subjects excepted. Illustrations are exemplary and may vary from the original. V1.0 ­ June 2024/TP, © novotgera GmbH

8

3 Installing module supports

A Use the mounting and removal tool to click in the module supports.

novo-tip: The position of the supports can be found in the planning documents. Do not observe the markings on the base element.

B Check the alignment of the module support.
The head of the module support must tilt towards the base foot.

Subjects excepted. Illustrations are exemplary and may vary from the original. V1.0 ­ June 2024/TP, © novotgera GmbH

9

4 Laying out rails

A The distance between the rails can be found in the planning documents.
Use assembling jig.

Subjects excepted. Illustrations are exemplary and may vary from the original. V1.0 ­ June 2024/TP, © novotgera GmbH

10

5 Ballast

A Place the required ballast in accordance to the ballast planning inside or on top of the base element, connector- and edge closure set.

novo-tip: For ballast installations using large amounts of ballast, ballast troughs (MV 10) or additional base cantilevers (MV 10.1) are recommended.

Warning: The selection of the ballast stone is up to the customer.
The dimensions are to be adapted to the weight of the ballast indicated at each point.

Subjects excepted. Illustrations are exemplary and may vary from the original. V1.0 ­ June 2024/TP, © novotgera GmbH

11

6 Installing the support brace between the module rows
A Mount the support brace. Fit the support brace to the base foot set as shown and screw it to each east-west connector. Mount the support brace overlapping in the centre.
Warning: The screw must not be overtightened! Do not use an impact function when tightening the screws.

Subjects excepted. Illustrations are exemplary and may vary from the original. V1.0 ­ June 2024/TP, © novotgera GmbH

12

7 Module clamping

a

b

A Insert module clamps.
a Centre screw of the clamp in the screw channel of the base foot or module support.
b Insert the module and tighten the clamps. Using the cordless screwdriver to max. 6 Nm.

Warning: The screw must not be overtightened! Do not use an impact function when tightening the screws.

Subjects excepted. Illustrations are exemplary and may vary from the original. V1.0 ­ June 2024/TP, © novotgera GmbH

13

8 Installing support brace at the edges
B Mount the support brace flush at the edge and overlapping in the middle. The support brace must be screwed to each edge closure set. Warning: The screw must not be overtightened! Do not use an impact function when tightening the screws.

novo-tip: If ballast cantilever are used, see mounting variation 2, we recommend mounting them before the support brace.

Subjects excepted. Illustrations are exemplary and may vary from the original. V1.0 ­ June 2024/TP, © novotgera GmbH

14

Mounting variations
1 Cabel channel

A Hang up cable channel.

B Put on cover cable channel.

Subjects excepted. Illustrations are exemplary and may vary from the original. V1.0 ­ June 2024/TP, © novotgera GmbH

15

2 Optional ballasting

A Hang up ballast troughs. max. 120 mm

novo-tip: Using ballast troughs allows small and large ballast which can be securely inserted or laid on if required. The ballast troughs must be mounted sideways to the base elements.
B Slide on ballast cantilever and screw tight on both sides.

novo-tip: Ballast cantilever allows to redistribute ballast at installation edges.

Warning: The screw must not be overtightened! Do not use an impact function when tightening the screws.

Subjects excepted. Illustrations are exemplary and may vary from the original. V1.0 ­ June 2024/TP, © novotgera GmbH

16

3 Lightning protection and potential equalization
A Install grounding connector set. One grounding connector must be installed per module field. Earthing wire: 20 Nm Earthing cable: 10Nm
Warning: The applicable standards and guidelines, e.g. lightning protection standard, must be observed.

Subjects excepted. Illustrations are exemplary and may vary from the original. V1.0 ­ June 2024/TP, © novotgera GmbH

17

4 Increase surface pressure

A Insert surface extension.
The surface extension must be inserted into the edge clousure set or connector set before clicking it into the base element.
novo-tip: The surface extension can be used when the surface pressure of the insulation is overloaded. Up to two surface extension can be used per edge closure set or connector set.

Subjects excepted. Illustrations are exemplary and may vary from the original. V1.0 ­ June 2024/TP, © novotgera GmbH

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Maintance mountin system

The mounting system must be checked for stability and function at regular intervals during plant maintenance. We recommend an annual visual inspection.
In addition to the visual inspection of the components, we recommend a random check of the connections and the safe and correct position of the ballasting on the base rails and ballast trays. The screw connections should also be checked and, if necessary, retightened in accordance with the tightening torques specified in the assembly instructions.

All system components should be checked for damage caused by, for example, weathering, animals, dirt, deposits, adhesions, fouling (especially on green roofs), roof penetration, sealing, stability and corrosion. The inspection of the system and maintenance work must be carried out by a specialist company that has experience with electrical systems and work with mounting systems, or by an expert. After unusually strong impacts (e.g. from earthquakes, heavy snowfall, storm events, etc.), an inspection of the system must always be carried out.

novotegra GmbH Eisenbahnstraße 150 | 72072 Tübingen | Germany
Tel. +49 7071 98987-0, info@novotegra.com www.novotegra.com
Errors and omissions excepted. Status: 06/2024

References

• Solar Mounting Systems ☀️ | novotegra
• Solar Mounting Systems ☀️ | novotegra

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