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Renusol ConSole Manual

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ConSole
Installation instructions
2 — Renusol ConSole · EN · 04/2011
INSERTION
Product Information
The ConSole assembly system is the ideal solution for installing PV modules
on flat roofs with pitch of up to 5° without roof penetration. Most commercially
available framed standard PV modules fit on the ConSole.
The ConSole is weighed down with ballast (gravel, paving slabs, etc.) in order to
resist the wind loads. The necessary weight of the ballast depends on the height
of the building, its location and condition of the ground and the wind and snow
loads.
Reference values for the necessary ballast are contained in "Preparing the
assembly – point 2." in the table on page 5 above.
The ConSole is made from 100% recycled chlorine-free polyethylene (HDPE).
The material of the ConSole satisfies the fire prevention measures of DIN 4102
class B2. The energy amortization time of the ConSole is shorter than one year.
A ConSole weighs 5 −7.2 kg depending on the type and can be stacked with up
to 40 ConSoles per pallet. The circular assembly edge will facilitate a fast
installation. Generously sized ventilation channels ensure efficient air circulation.
The boreholes on the ground of the ConSole are conducive for drainage.
We wish to point out that work must be carried out according to current safety
regulations (e.g., VBG37) in order to prevent accidents. Please carry out the
respective safety measures.
Warranty
Our warranty only applies if an original ConSole complete system is used.
In order to adjust the system optimally for the local conditions and to fulfil all
applicable regulations, we recommend an expert report be prepared if in any
doubt. The installation should be carried out by skilled and trained personnel.
If you have questions concerning training, please contact Renusol.
Installation instruction
Please read these installation instructions carefully before starting installation.
First, familiarize yourself with the system components. The ConSole can be
stored and used at temperatures of between -30° C and +50° C. We recommend
the ConSoles be assembled at plus temperatures. The roof area must in any case
be free of snow and ice.
During the installation and, in particular, while working on the roof, be sure to
observe the relevant health and safety provisions and please follow the current
rules and regulations.
Please also check the current version of our installation instructions on our
website at www.renusol.com. Here, you can also find instructions in other
languages, if required. The figures and texts in the installation instructions
correspond to current technology at the time of printing. We reserve the right
to make changes.
The installation instructions merely contain recommendations in accordance
with current technology and are based on the experience of how systems made
by Renusol can be installed. If any roof or object-specific characteristics are to be
considered, please, if necessary, involve specialists such as roofers or structural
engineers for the purposes of explanation.
The Renusol team wishes you a successful installation.
Renusol ConSole · EN · 04/2011 — 3
A ConSole
B U profiles of aluminium
C PV module
D Generously sized
Ventilation channels
E Boreholes for draining
the ConSole
F Circular assembly edge
B
B
C
D
D
D
D
E
E
F
F
A
SYSTEM OVERVIEW
SYSTEM OVERVIEW OF COMPONENTS
TOOLS REQUIRED (not included in delivery)
8 hexagonal
screws
M6 x 20 mm,
stainless steel
OPTIONAL EXTENSION RAILS
ConSole set of extension rails
consisting of:
– 2 ConSole extension rails, aluminium
– 4 hexagonal screws M6 x 20 mm, stainless steel
– 4 washers, stainless steel
– 4 self-locking hexagon nuts M6,
stainless steel
8 Self-locking
hexagon nuts M6,
stainless steel
8 washers,
stainless steel
– Cordless screwdriver with hexagonal insert
for 10-mm screw
– 7-mm drill
– 10-mm open end or ring spanner
55
150
A ConSole B 2 U profiles,
aluminium
1.
4 — Renusol ConSole · EN · 04/2011
E
D
B
A
25°
A
min, innen
E
min, innen
E
C
Decide on the correct ConSole for the
module
First measure the distance "d" of the
assembly boreholes on the rear of the
module. Then calculate based on the table
which ConSole fits the width of the
module.
Indicate any extension rails required as a
separate position in the order.
If there are several possibilities, select the
ConSole that best suits the length of the
current module.
Measurement "A" of the ConSole should
correspond roughly to the length of the
module. Overlapping modules require more
ballast due to the larger area exposed to
the wind.
Always select the ConSole on which the
module surface overlaps the assembly edge
of the ConSole as little as possible. The
maximum overlap of length "A" per side
should not be over 12 cm.
ASSEMBLY PREPARATION
Recommended measurement of ConSole/PV module
Table for calculating the
suitable combination ConSole/PV module
Explanatory views
of the ConSole dimensions
PV module bottom view
X
= only with extension rail
d
Hole spacing
d = mm
ConSole
4.1 4.2 5.2 6.2
661− 700
701− 720
721− 780
781− 840
X
841− 850
X
851− 894
895− 910
911−1014
1015−1085
XXX
Measurement
A
mm
B
mm
C
mm
D
mm
E
mm
A
min, interior
x E
min, interior
mm
Installation surface
m²
Building protection mat
mm
ConSole 4.1 1680 840 400 50 740 1300 x 400 0,62 cca. 1400 x 500
ConSole 4.2 1240 1090 530 50 960 890 x 490 0,47 cca. 1000 x 700
ConSole 5.2 1520 1080 500 40 960 1140 x 630 0,76 cca. 1300 x 700
ConSole 6.2 1740 1070 500 50 970 1380 x 630 0,84 cca. 1500 x 700
2.
3.
Renusol ConSole · EN · 04/2011 — 5
A
h
B
ASSEMBLY PREPARATION
Calculating the amount of ballast for the
ConSole
The wind loads acting on the ConSole re-
quire it to be weighed down with ballast.
Gravel, stones, plates and similar materials
are suitable as ballast.
The table opposite can serve as a guide for
the required ballast. These values are calcu-
lated according to DIN 1055-4:2005-03 and
Eurocode. Several years experience confirm
the reliability of the system.
The exterior module series and column re-
quire more ballast according to the table.
The values indicated prevent the ConSoles
from tipping over, sliding or being lifted-
ConSoles.
In order to ensure safety against sliding, the
coefficient of friction between the roofing
and the ConSole must be greater than 0.6 .
This can be established using a spring
scale. A ConSole filled with 100 kg of ballast
should only move from the spring scale
under a horizontal tensile force of over
60 kg.
Additional ballast
In a higher wind load zone: 30% more bal-
last per level.
When using extension rails: 10% more bal-
last.
In case of excess length of the modules on
the side:
additional ballast in proportion to the excess
length.
Calculation basis
The ballast values are calculated for wind
load zone 1 for Germany according to DIN
1055-4:2005-03 and for terrain category III:
Suburbs, industrial or commercial zones and
forests.
*The system weight is not included in the
recommended ballast values.
Recommended ballast values for ConSoles in kg in terrace systems*
A = minimum distance of the ConSolen series:
ConSole 4.1 >1.2 m
ConSole 4.2/5.2/6.2 >1.5 m
B = minimum
roof edge > 1/5 h
h = Building height
Schematic diagram of a ConSole terrace system
Distances between rows on the ConSole system
Positioning the ConSoles
Check whether the installation surface
(e.g., the roof) is enough for the additional
roof load.
The surface must be level, clean and not
too slippery. With slippery surfaces, e.g.,
with PVC roof membranes, an anti-slip mat
should be used, e.g., a building protection
mat.
Place the ConSole with the opening facing
south. A minimum distance of a fifth of the
building height "h" should be maintained
from the side of the roof. Building height 10
metres => minimum distance 2 metres.
The minimum distance between
the ConsSoles is clear from the schematic
diagram.
Filling ballast
Now fill in the correct ballast. Reference
values here are contained in the table
"Recommended ballast values" at the top
of this page.
Ballast diagrams for all ConSole types are
available on our website
www.renusol.com/download as a PDF le.
inner ConSoles
in the slipstream
circular,
non-binding
roof area
outer,
wind-exposed
ConSoles
Roof edge
Building height
Up to 8 meters Up to 12 meters Up to 16 meters
interior exterior interior exterior interior exterior
ConSole 4.1 62 99 73 115 82 128
ConSole 4.2 58 94 68 110 77 122
ConSole 5.2 63 106 75 123 84 137
ConSole 6.2 83 134 98 156 110 173
4.
5.
6 — Renusol ConSole · EN · 04/2011
A
A
A
B
BBB
C
C
D
E
H
G
F
ASSEMBLY
Assembling optional extension rails
end clamps
The optional extension rail should be
assembled on the slotted hole of the U
profile on the upper side of the ConSole.
Only use the screws, washers and nuts
supplied for fastening the installation.
Note:
The extension rail is only for
optimal assembly of the PV module on the
corresponding ConSoles.
Assembly step 1:
Now fasten the U profiles to the module.
Ensure that the slotted hole is on the
higher side of the ConSole and the smaller
round holes are on lower side.
Only ever use the fastening material sup-
plied.
Tighten the M6 screws with a maximum
torque of 10 Nm.
Assembly step 2:
The cabling of the PV modules should be
carried out by trained specialists.
Assembly step 3:
Lay the PV module symmetrically onto the
ConSole. When seated correctly, the clips
on the U profiles prevent from module
from slipping.
Important!
Regarding lightening, advice from specialist
companies is generally recommended. It
should be explained in the planning phase
of the PV installation on a building as
to what requirements are stipulated here
by the property insurer on the subject
of lightening and overvoltage protection.
The notes and regulations from the manu-
facturer of the modules and inverers should
be observed when carrying out (functional)
earthing.
Assembling the U profiles onto the PV module
OPTIONAL EXTENSION RAILS
Section A-A E PV module
F Hexagon screw M6 x 20 mm
G Washer
H Self locking nut M6
A ConSole
B U prole
C Extension rail
D Module frame
Self locking nut M6
Washer
U-Prol
Hexagon screw
M6 x 20 mm
Elongated hole
Round hole
Module frame
6.
Renusol ConSole · EN · 04/2011 — 7
7.
Fasten the PV module with U profile on the
ConSole mounting rails
Drill a hole 7 mm wide in the edge of the
ConSole through the holes on the clips of
the U profiles (fig. A).
Now fasten the profiles using the supplied
fastening material to the ConSole mounting
rails. Ensure that the washer is between the
nut and the ConSole.
Note:
Start by fastening the U profiles to the
lower side of the ConSole.
Important!
Tighten the 4 M6 screws with a maximum
torque of 10 Nm.
Congratulations,
You have assembled ConSole, the ideal
solution for an installation of PV modules
on flat roofs as the perfect aesthetic
solution, ready to use.
We are pleased that you have completed
a beautiful reference object. If you have
any photographs of the assembly and the
result, please send us the digital reference
photographs, the object data and the
address of the property by e-mail to:
info@renusol.com.
We regularly award prizes for the most
beautiful reference photos and present
them together with the company logo of
the respective specialized company on
our website.
Thank you very much for your trust in
Renusol.
Assembly completed
Installation result: PV module ready
assembled on the ConSole.
ASSEMBLY
A
Hexagon screw M6 x 20 mm
Module frame
U-Prol
ConSole
Washer
Self locking nut M6
A
Screwdriver 7 mm
Screwdriver 7 mm
Renusol GmbH
Piccoloministraße 2, 51063 Köln, Germany
T +49 221 788707-0, F +49 221 788707-99
info@renusol.com, www.renusol.com
ConSole IM A03 EN
Technical changes, mistakes and printing errors excepted.
6


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