novotegra Green roof East-west User manual

I
Änderungen vorbehalten. Abbildungen sind beispielhaft und können vom Original abweichen.
V4.2.1 –März 2022/TP,
Copyright novotegra GmbH
Mounting instructions
Green roof
East-west

II
Änderungen vorbehalten. Abbildungen sind beispielhaft und können vom Original abweichen.
V4.2.1 –März 2022/TP,
Copyright novotegra GmbH
TABLE OF CONTENTS
1Notes ................................................................................................................................................ 1
2Maintenance of the mounting system........................................................................................... 4
3novotegra for green roof................................................................................................................ 4
4System components, tools and equipment ................................................................................. 5
4.1 What is required for mounting .................................................................................................... 5
4.2 Mounting system components –optional................................................................................... 6
5Installing the mounting system..................................................................................................... 7
5.1 Substrate plate installation and support component mounting .................................................. 7
5.2 Rail mounting and fastening....................................................................................................... 8
5.3 Module installation...................................................................................................................... 9
5.4 Mounting variations (MV).......................................................................................................... 10
6Warranty / product liability (exclusion)....................................................................................... 13

1
Änderungen vorbehalten. Abbildungen sind beispielhaft und können vom Original abweichen.
V4.2.1 –März 2022/TP,
Copyright novotegra GmbH
1 Notes
The following instructions are generally valid for our mounting system novotegra and are to be applied or
interpreted accordingly regardless of the respective roof and mounting system type.
Safety information
Mounting tasks may only be carried out by qualified and competent persons. During the work protective
clothing in accordance with the relevant national regulations and guidelines must be worn.
Mounting must be carried out by at least two persons to ensure help in case of an accident.
All relevant national and locally applicable health and safety regulations, accident prevention regulations,
standards, construction standards and environmental protection regulations as well as all regulations of the
employers’ liability insurance associations must be complied with.
The national regulations for working at height / on the roof must be complied with.
Electrical work must be carried out in compliance with the national and locally applicable standards and
guidelines and the safety rules for electrical work.
Earthing / equipotential bonding of the mounting system must be carried out in accordance with the
national and locally applicable standards and guidelines.
Categorisation into hazard classes
To alert the user of potential danger situations the hazard classes analogous to ANSI Z 535 are used. The
hazard class describes the risk if the safety information is not observed.
Warning symbol with signal word
Hazard class analogous to ANSI Z 535
DANGER! describes an immediate danger. If it is not
avoided, death or serious injury will result.
WARNING! describes a potential danger. If it is not avoided,
death or serious injury might result.
CAUTION! describes a potential danger. If it is not avoided,
light or minor injury might result.
NOTE! describes a potentially harmful situation. If it is not
avoided, the plant or objects in its vicinity might be damaged.
General information
After receipt the goods must be inspected for completeness using the accompanying delivery note.
novotegra GmbH does not accept the costs, nor can we guarantee subsequent express deliveries if
missing material is only noticed during mounting.
Since our mounting systems are subject to continuous development, mounting processes or components
may change. Therefore, please check the current status of the mounting instructions on our website prior to
mounting. We are also happy to send you current versions upon request.
The mounting system is suitable for the attachment of PV modules with standard market dimensions.
Please find more detailed information about this in chapter 3.
The usability of the mounting system for the respective project must be checked for each individual case on
the basis of the roof cover / roof construction / facade present.

2
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V4.2.1 –März 2022/TP,
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The roof cover / roof construction / facade must meet the requirements of the mounting system with regard
to load bearing capacity, support structure and condition.
Requirements for the material of the roof construction / roof cover / facade:
Wooden components (rafters/ purlins) at least strength class C24: no fungal decay or rottenness. OSB with
material grade OSB 3.
Steel purlins for stock screw installation exclusively material grade S235.
Tensile strength Rm, min Trapezoidal sheets: steel 360 N/mm²; aluminium 195 N/mm².
Wall construction material: concrete, brick or sand-lime brick in solid or hollow block design.
The load bearing capacity of the roof / roof construction (rafters, purlins, trapezoidal metal, concrete floors,
number of adhesive points, folded seams, etc.) or the facade (wall construction materials) must be checked
by the user or a check be commissioned.
Physical building aspects concerning insulation penetrations (e.g. condensation) must be taken into
account by the user.
Notes on mounting
The components of the novotegra mounting system are intended exclusively for the attachment of PV
modules. Dependent on the roof type of the building the designated mounting system components must be
used.
A condition for the intended use of the novotegra mounting system is the mandatory compliance with the
specifications in these instructions regarding safety information and mounting.
In case of unintended use and non-compliance with the safety information and mounting instructions and
non-utilisation of the corresponding mounting components or use of third party components not belonging
to the mounting system any warranty and liability claims against the manufacturer are voided. The user is
liable for damage and resulting consequential damage to other components, such as PV modules, or the
building as well as personal injury.
The user must read the mounting instructions prior to mounting. Unresolved issues must be clarified with
the manufacturer prior to mounting. The mounting sequence in these instructions must be adhered to.
It must be ensured that a copy of the mounting instructions is accessible in the immediate vicinity of the
work on site.
The mounting specifications (module load, attachment, clamping areas etc.) of the module manufacturer
must be observed and complied with.
Prior to mounting the mounting system must be statically calculated with the loads to be assumed for the
building project in accordance with the national standards. Information relevant to mounting (e.g. roof hook
distance, lengths of bolts, overhang and protrusions or distance of base trough and required ballast) must
be determined by the static calculation using the design software www.solar-planit.
The permissible roof inclination for using the mounting system according to these installation instructions is
0 to 60 degrees for roof-parallel installation on a pitched roof and 0 to 5 degrees for elevated installation on
a flat roof. Facade systems must be mounted parallel to the facade.
For roof-parallel installation with the clamping system, two module support rails per module must be
mounted symmetrically under the modules for equal load transfer into the substructure. Alternatively, the
roof-parallel installation can also be installed with insertion rails.
The specified tightening torques must be adhered to and checked randomly on site.

3
Änderungen vorbehalten. Abbildungen sind beispielhaft und können vom Original abweichen.
V4.2.1 –März 2022/TP,
Copyright novotegra GmbH
Notes on static calculations
The mounting system must generally be statically calculated for each individual project using the design
software Solar-Planit. Excluding façade systems, the calculation for this will be carried out by the company
novotegra GmbH.
The static calculation only determines the load bearing capacity of the novotegra mounting system and also
takes account of the attachment to the building (rafters, purlins, trapezoidal metal, facade etc.). The load
transfer within the building is not considered (customer static calculations).
The load bearing capacity of the mounting system components is determined on basis of the planned
module layout and the underlying building information (project data recording). Deviations from the
planning on site may lead to different results.
The load assumptions (load and roof division) are country-specific in accordance with the specifications of
the Eurocode load standards. The determination of the loads to be assumed for Switzerland is in
accordance with SIA 261.
At pitched roof, the modules may not be fitted above the gable end, ridge and eaves or the facade
(increased wind load). At the ridge the modules may be fitted up to max. a theoretical horizontal line with
the ridge tile and perfectly flush with the gable end. In the eaves area the modules may reach to max. the
end of the roof cover due to loads.
In case of an exposed building position (with wind load e.g. at the edge of a slope) or snow accumulation
(e.g. dormer or catchment grill or roof structures like domelights etc) the specifications of the Eurocode load
standards or SIA 261 (Switzerland) must be taken into account by the user within his own responsibility.
The design software does not consider these cases.
The static calculation of the mounting system is based on the symmetrical placement of the modules on the
mounting rails at the longitudinal side of the modules (roof-parallel clamping systems) or on the support
components (elevation) for equal load transfer into the substructure. For the insertion system a cross rail
arrangement is expected for equal load transfer.
The results calculated with the design software, such as distances of the fasteners (e.g. roof hooks, stock
screws, saddle clamps etc.), rail lengths and number of fasteners (e.g. direct attachment on the trapezoidal
metal), overhang (e.g. rail and roof hook protrusions) or distances between the base troughs and number
of fixing materials (e.g. rail joint) and the other calculation notes must be considered and complied with.
novotegra has been tested and certified by TÜV Rheinland:

4
Änderungen vorbehalten. Abbildungen sind beispielhaft und können vom Original abweichen.
V4.2.1 –März 2022/TP,
Copyright novotegra GmbH
2 Maintenance of the mounting system
The mounting system must be checked for stability and operation at regular intervals during the system
maintenance.
Besides the visual inspection of the components, we recommend random connection checks.
The installation should be checked regularly for shady areas due to vegetation growth.
Removal is possible in reverse order in the work steps mentioned below. The maintenance work must be
carried out by a specialist company with proven experience in electrical systems and work on mounting
systems.
3 novotegra for green roof
The contents of this installation manual describe the installation of the substructure on roofs with sheet or
bitumen waterproofing, with or without gravel respectively substratum.
On flat roofs without parapets, the modules must be mounted at a distance of at least 1.50 m to the edge of
the roof. On flat roofs with parapets, a minimum distance of at least 0.50 m must be maintained between
the module edge and the inner edge of the parapet, or rather, the distance to the edge must be taken into
account after the individual calculation in the planning software to ensure that the general conditions of the
wind tunnel tests can be maintained.
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 puncturing the roof. The photovoltaic system is secured against wind
suction with ballasting (substrate or suitable stones) on the basis of the results of the wind tunnel tests for
the system. The required substrate or ballast height must determined specifically for each project with the
planning software. The ballasting applies to the planned installation; deviations from the plan by the
installer may lead to different results.
General conditions to be observed in accordance with the wind tunnel test results:
- Roof incline 0 –5 degrees
- Flat roofs with and without parapet
- Distance from system to roof edge (without parapet) = 1.50 m
- Distance from system to parapet (inside edge) = min. 0.50 m
- Module width = max. 1,34 m
- Module length = max. 1,85 m
- Angle of installation (fixed) = 10°
- Distance between rows = see planning software Solar-Planit
The mounting system is designed for loads up to 2.4 kN/m² (2,400 Pa). The module is clamped (clamping
area 11 x 52mm) along the long side. Any potentially existing drainage openings on the module frames
must not be obstructed; the same applies to the formations on the supporting components designed for this
purpose.

5
Änderungen vorbehalten. Abbildungen sind beispielhaft und können vom Original abweichen.
V4.2.1 –März 2022/TP,
Copyright novotegra GmbH
4 System components, tools and equipment
4.1 What is required for mounting
Figure
Tool
Component*
Product group
Green roof substrate plate
Material: Recycled HDPE
Substrate layer /
protection layer
Half green roof substrate plate
Material: Recycled HDPE
Substrate layer /
protection layer
Green roof high module support:
Recycled plastic
module elevation
Green roof low module support:
Recycled plastic
module elevation
Green roof module support
6 x 80 mm mounting screw
material: Stainless steel
Tool: TX25
fastening equipment
Green roof module support rail
Material: Aluminium
profile rails
6.5 x 51 mm mounting screw for
green roof module support rail
Material: Stainless steel
Tool: Socket bit AF 8 mm
fastening equipment
Rail connector set C47 S
Material: Aluminium
Tool: Socket bit AF 8 mm
rail connector
Middle clamp set C
Material: Aluminium, cast aluminium
and stainless steel
Tool: Socket bit AF 8 mm
Module elevation
End clamp set C
Material: Aluminium, cast aluminium
and stainless steel
Tool: Socket bit AF 8 mm
Module elevation
* 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.

6
Änderungen vorbehalten. Abbildungen sind beispielhaft und können vom Original abweichen.
V4.2.1 –März 2022/TP,
Copyright novotegra GmbH
Figure
Equipment
Use for tool
Application
Cordless
screwdriver
Bit-Torx TX25
Socket bit AF 8mm
Component
connections, clamp
assembly
Torque key up
to at least 8 Nm
Socket bit AF 8 mm
Socket bit AF 18 mm
Clamp assembly
Ground connector
Chopsaw
---
Cutting rails
4.2 Mounting system components –optional
Figure
Tool
Component***
Product group
Cable-tie clip for profile flange
Cable fixing
Cable-Clip d = 10 mm
Cable fixing
Grounding connector set AF 18 mm
Material: stainless steel
Tool: Special lock nut AF 18 mm
deep
Accessories and
optional components
Perforated Alu-tape 10,000 x 20 x 1
Material: Aluminium
Tool: Socket bit AF 8 mm
Accessories and
optional components
Mounting screw SL 5,5
fastening equipment
Contact latch module clamp
Accessories and
optional components
*** Optionally available installation system components, e.g. for improving the aesthetics of the system,
cable management or grounding of the installation system.

7
Änderungen vorbehalten. Abbildungen sind beispielhaft und können vom Original abweichen.
V4.2.1 –März 2022/TP,
Copyright novotegra GmbH
5 Installing the mounting system
Prior to installation, the module array must be measured out on the roof and the position of the modules
determined, taking into account any obstacles such as light domes or strips, fans or drains.
The individual mounting steps for the east/west system variation are explained below with reference to the
mounting variations (MV) for the different installation options or the system variations "south" and
"butterfly". This is then followed by the respective work sequence.
5.1 Substrate plate installation and support component mounting
Arrange substrate plates
Define starting point and measure up first whole
substrate plate. Lay the following substrate plates
(whole/half) according to planning documents
The substrate plate overlaps must always been
taken into account. The substrate plates must be
laid on top of an existing and suitable protection
fleece.
Position and fasten module supports
Position module supports (high/low) on the
substrate plates according to planning documents.
Fasten each support at the positions specified with
four 6 x 80 mm support mounting screws. The
supports must be placed in the corners of the
(whole) substrate plates. On these corners, the
substrate plates (half) may overlap.
The horizontal and vertical substrate plate line grid
pattern must be adhered to. Always refer to the
planning documents.

8
Änderungen vorbehalten. Abbildungen sind beispielhaft und können vom Original abweichen.
V4.2.1 –März 2022/TP,
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5.2 Rail mounting and fastening
Position green roof C-rail
Place rail on module supports.
Fasten a 6.5 x 51 mm module support rail mounting
screw as close to the middle of each module
support as possible.
Do not over tighten the screws. Maximum rail
overhang on the last module support 65 cm. Always
heed the planning documents. Each rail part must
lie on and be fastened to at least two module
supports.
After the module support and rail installation, the
substrate is placed on top. The ballasting is
achieved with the substrate; refer to the planning
documents for the substrate weight per m². If
necessary, additional stones must be put on top of
the substrate plates as ballast. The mounting
system will only stand securely once the required
amount of ballast/substrate has been put in place.
Observe the accident prevention regulations when
sawing the rails.
Connect green roof C-rail
Push the rail connector set (1) halfway into one of
the rails to be connected (2) and fasten it there with
one self-drilling screw on either side, at a distance
of approx. 20 mm to the end of the rail. After that,
push the other rail fully onto the rail connector set
until both rail ends meet (3), then fasten as
described above.
Do not over tighten the screws.
Observe the accident prevention regulations when
sawing the rails.
1
2
3

9
Änderungen vorbehalten. Abbildungen sind beispielhaft und können vom Original abweichen.
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C-rail green roof expansion joint
Push the rail connector set (1) halfway into one of
the rails to be connected (2) and fasten it there with
one self-drilling screw on either side, at a distance
of approx. 20 mm to the end of the rail. Then push
the other rail on top at a distance of 40mm - 50mm
(3) and fasten it only to the following supports.
Do not over tighten the screws.
Do not install the expansion joint underneath a
module. Maximum rail length without expansion
joint 17m. Always heed the planning documents.
Observe the accident prevention regulations when
sawing the rails.
5.3 Module installation
Module positioning and clamping
Position the photovoltaic modules upright onto the
mounting rails, ensuring that they are straight. End
clamps are used at the start and the end of a
module row; middle clamps are used between the
modules.
Panel gap at the ridge must be at least 50 mm.
Middle and end clamp installation
At the clamping point, guide the middle and end
clamps into the rail chamber from the top. Then
turn the rail nut inside the rail and push the module
clamps onto the module frame.
Contact latch installation see MV 3.2
Middle clamp fastening torque 10 Nm
End clamp fastening torque 8 Nm
1
2
3

10
Änderungen vorbehalten. Abbildungen sind beispielhaft und können vom Original abweichen.
V4.2.1 –März 2022/TP,
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Middle and end clamp space requirement
End clamps may be installed flush with the rail end.
Push module completely onto the rail nut of the
middle clamps.
Middle clamp fastening torque 10Nm
End clamp fastening torque 8Nm
5.4 Mounting variations (MV)
MV1
Module position south-facing
Heed the planning documents and position and
fasten the components accordingly. Further
installation steps the same as variation
east/west.
MV2
Module position "butterfly" (east/west)
Heed the planning documents and position and
fasten the components accordingly. Further
installation steps the same as variation
east/west.
13 mm
12 mm

11
Änderungen vorbehalten. Abbildungen sind beispielhaft und können vom Original abweichen.
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MV 3 Grounding
MV 3.1 Grounding connector installation
Grounding wire ( as per national
specifications): Disassemble grounding
connector, remove clamp washer (1). Push the
component through the green roof module
support rail from below. Push the grounding wire
(2) through the opening (suitable for  6-10mm)
and fasten the component to the rail floor with
the self-locking flange nut. Grounding cable
( as per national specifications): Strip the
grounding cable (e.g. stranded wire) and push it
through the opening. Leave clamp washer in
place (1). Clamp to rail floor with the self-locking
flange nut.
Grounding wire fastening torque 20 Nm,
grounding cable 10 Nm.
The grounding connector is used to connect the
mounting system to the potential equalisation.
The applicable standards and guidelines, e.g.
lightning protection standard, must be observed.
MV 3.2 Contact latch installation
Use the sliding clip to push the contact latch over
the vertical bridges of the middle clamps up to
the screw.
The middle clamp with the contact latch in place
is installed as previously described in Chapter
5.3.
1
2

12
Änderungen vorbehalten. Abbildungen sind beispielhaft und können vom Original abweichen.
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MV 3.3 Strapping installation
Cut aluminium strapping to size. Position the
strapping over the groove at the side of the
module support rail. Position the mounting screw
at the groove and fasten.
The aluminium strapping is used to connect the
individual module rows with each other for the
potential equalisation.
The applicable standards and guidelines, e.g.
lightning protection standard, must be observed.

13
Änderungen vorbehalten. Abbildungen sind beispielhaft und können vom Original abweichen.
V4.2.1 –März 2022/TP,
Copyright novotegra GmbH
6 Warranty / product liability (exclusion)
In addition to the above-mentioned regulations and safety notices the applicable regulations and rules of
technology must be observed by the installing specialist company.
The installer is responsible for the dimensioning of the mounting system.
The installer is responsible for the connection of the interfaces between the mounting system and the
building. This also includes the tightness of the building envelope.
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. novotegra GmbH does not accept liability for faulty or inadequate measures
and precautions for the protection of the roof insulation!
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. novotegra GmbH does not guarantee the correctness of the
assumed values and is not liable for damage due to the use of incorrect values.
The specifications of the module, cable and inverter manufacturers must be observed. If these contradict
the mounting instructions, always consult the novotegra GmbH sales team before mounting the novotegra
mounting system or –in the case of components not supplied by novotegra GmbH –the manufacturer
concerned.
During the preparation of the offers for novotegra by our sales staff the local conditions are not always
sufficiently known, which is why changes to the offered quantities may result during installation. These
changes relate mainly to the number of fasteners for the building envelope (for example roof hooks). In this
case the additionally required components must always be installed in accordance with the dimensioning.
novotegra GmbH is not liable for incorrect or incomplete data collection sheets. Error-free and fully
completed data collection sheets are essential for correct dimensioning.
The information in the mounting instructions, the warranty terms and the information about the liability
exclusion must be noted.

novotegra GmbH
Eisenbahnstraße 150
72072 Tübingen | Deutschland
Tel. [phone]
Fax [phone]
[e-mail]
www.novotegra.com