Icosun Console - Installation manual by Jad Solucions informàtiques

DEVEB n° 67 | 01/11 | Révision N° 0

Design & installation manual

Icosun Console

Contents 1. General description

2. Installation

2.1 Waterproofing

2.2 Electrical connection

3. Use and application field

3.1 General

3.2 Layout of the photovoltaic modules

4. Instructions relating to the deck substrate

4.1 General

4.2 Masonry supports

4.3 Supports for wood and fibre board panels

4.4 Supports for reinforced autoclaved cellular concrete slabs

4.5 Non-bearing insulation supports

4.6 Supports for existing waterproofing covering

5. Instructions concerning the system in the main areas

5.1 Composition of the system fixed to the waterproofing covering

5.2 Installing the system

5.2.1 Installing the waterproof membranes

5.2.2 Installing the consoles

6. Servicing

7. Repairing and replacements

8. Materials

8.1 Icosun FIX consoles

8.2 Icosun DIF consoles

8.3 Aluclic sections

8.4 Fixing elements of Icosun modules

9. Manufacture and quality assurance operations

10. Experimental results

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1. General description The Icosun Console system incorporates a waterproof membrane with a series of consoles and rails to support glass photovoltaic modules. It consists of the Icosun FIX consoles, mechanically fixed to the roof deck and waterproofed by a synthetic or bituminous weatherproof collar according to the type of membrane used. The Icosun DIF consoles are bonded directly to the waterproof membrane and are also used to support the modules.

The Icosun FIX consoles are designed to support snow loads and resist wind uplift forces without applying stress on the existing membrane and the Icosun DIF consoles distribute the load of the system more evenly over the roof deck. The waterproofing consists of either a single layer or two-layer membrane of styrene-butadiene-styrene (SBS) bitumen fully bonded, partially bonded, or mechanically fixed. Alternatively TPO or PVC synthetic membrane can be used.

2. Installation 2.1 Waterproofing

2.2 Electrical connection

The installation is exclusively carried out by qualified Siplast approved installers.

The electrical connection of the modules to the inverter (including supply and installation of the inverters) is carried out by an approved electrical installer qualified for photovoltaic installations (QualiPV Elec Certification in France for example). The electrical connection of the installation to the grid is carried out by the electricity utility (ERDF for France).

3. Use and application field 3.1 General The Icosun Console system is suited to roofs without pedestrian or vehicular traffic (inaccessible roofs), for temperate climates (altitude  900 m): In the new build and refurbishment sector. On the following types of roof deck: concrete, complying with local building regulations with the exception of sloped grids of concrete of ordinary aggregates (except in renovation and after validation by testing in situ), or of lightweight aggregates, of pre-stressed shell walls, of thin precast shell walls, of hollow bodies with or without distribution screeds, of floors with in-floor heating and of floors containing embedded electricity distribution. The substrates are prepared in conformity with the local building regulations. wood or wood fibre panels, in conformity with local building regulations. profiled metal decks in compliance with local

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building regulations (example: Arval Hacierco 34 SR). Also allowable are decks of profiled steel sheets, having a corrugated top opening  70 mm. The direct substrate of the waterproofing may be: the above bearing elements with the exception of the corrugated steel sheets; thermal insulation boards, minimal compressibility Class C, according to UEAtc standards; an existing waterproofing covering.

The Icosun Console system is suitable for all types of buildings for slopes equal to or less than 20%, with the exception of those with very high humidity. Its minimal slope will be the same that is allowed for the load-bearing structures; nevertheless, it is recommended that the minimum roof pitch should not be less than 3%, to allow self cleaning of the modules by rainfall and to prevent the incidence of standing water lying on the surface of the modules.

3.2 Layout of the photovoltaic modules The photovoltaic modules should not to be installed on areas that might be shaded (by equipment, neighbouring walls or buildings, foliage etc.). They should not be installed across a change in level or slope or across an expansion joint. They

should not be installed less than a metre from the roof edge or 0.5m from a plant room. They should be installed no less than 0.5m from the base of any internal upstands. The rails and photovoltaic modules should not be installed astride a slope break area or on an expansion joint.

4. Instructions relating to the deck substrate 4.1 General The deck substrate intended to receive the waterproofing must be stable and dry, have a clean surface, free of hydrocarbons and oils and any loose debris. Before the works begin, the client should confirm the suitability of the system on the roof deck in relation to the additional structural loading created by the Icosun Console system. The permanent load added by the system is around 20kg/m2. This load varies depending upon the weight of the module but also upon its dimensions and orientation. The reason for this is that they have an influence on the distance between the aluminium sections. Therefore the final loading cannot be determined precisely until after the module and its configuration have been decided upon. If using a profiled metal deck, the roof design should allow for the additional load to determine the required span between sheets according to local building regulations.

4.2 Masonry supports Such supports are allowable when they conform to local building regulations as are the non-conventional supports, holding a Technical Assessment for an application as a roof bearing element with the exception of slope screeds of ordinary aggregates (except in renovation and after validation by on-site testing) as well as lightweight granulate concrete, pre-stressed shell walls, precast shell walls, hollow bodies with and without distribution screeds, floors with in-floor heating and floors containing embedded electricity distribution. The supports are to be prepared in compliance with the specifications of local building regulations.

4.3 Supports for wood and fibre board panels Supports for wood and fibre board panels are acceptable, when they conform to local building regulations as are non-conventional supports in the form of ligno-cellulose panels and composite sandwich panels, holding Technical Assessments for use in direct support of a mechanically fixed waterproofing covering.

4.4 Supports for reinforced autoclaved cellular concrete slabs The bearing elements and substrates of reinforced concrete slabs complying with local technical standards are accepted

4.5 Non-bearing insulation supports The thermal insulation boards that can be used with the Icosun Console system are: Mineral wool, bare or bitumen faced; Polyisocyanurate (PIR) or polyurethane (PUR); Fibrous perlite, bare or bitumen faced; Cellular glass with a minimal compressibility class of C (according to UEAtc standards); E xpanded polystyrene with a compressibility class of B at 80°C.

4.6 Supports for existing waterproofing covering The work shall be done on bearing elements and supports of the same type as those specified for new works. The existing waterproofing membrane must first be cleaned by efficient brushing of the existing covering to remove any loose debris (flakes, mud, dust, etc.). The Icosun Console structure cannot be directly placed on an existing waterproofing covering. A new waterproof membrane needs to be laid with interposition of a Class C support decking at 80°C (according to UEAtc standards), capable of receiving a waterproofing covering if the existing insulation is not one of those allowed (mentioned above). Every project needs to be looked at on an individual basis, and the contracting company needs to assess the quality of the existing waterproof membrane (surface condition, eveness etc.). The existing thermal insulation also needs to be assessed by Icopal and deemed to be sufficiently rigid for the application of the system.

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5. Instructions concerning the system in the main areas 5.1 Composition of the system fixed to the waterproofing covering Type of covering

Fully Bonded

Partially Bonded

Mechanically fixed

Deck Type

In conformity with § 4.1 to 4.4

Non-bearing thermal insulation board

In conformity with § 4.5

Waterproofing covering

Bituminous two-layer or single layer: - Parafor Solo GS - Paradiene SR4+Paradiene 30.1

Bituminous two-layer or single layer: - Adesolo G - Adepar JS+Parafor 30

Bituminous two-layer PVC synthetic or single layer: membrane: * Parafor Solo GFM FM Monarplan * Parafor Solo GFX * Paradiene FM R4 + Paracier

Console Icosun Fix

Console Icosun FIX-B Console Icosun with bitumen FIX-B with bitumen weathering collar

Thermo- plastic polyolefin (TPO) synthetic membrane: TPO Monarplan

Console Icosun FIX-B with bitumen weathering collar

Console Icosun FIX-P Console Icosun FIX-T with PVC weathering with TPO weathering collar collar

Console Icosun DIF Console Icosun DIF polypropylene

Console Icosun DIF polypropylene

Console Icosun DIF polypropyene

Adhesive

Dynol

5.2 Installing the system 5.2.1 Installing the waterproof membranes The waterproof membranes are to be installed in accordance with the Technical Assessments, Application Technical Rules (DTAs) or Icopal Installation Specifications as follows: Reference

Waterproofing membrane

European Technical Approval (ATE) no. 08/0379 // CCP DEVEB No. 52 | 02-09 | revision 2

Monarplan FM

DTA 5/09-2093

Parafor Solo

DTA 5/07-1931

Adepar

Technical Assessment 5/02-1581 and Mod 01, 02, 03, 04, 05

Paracier FM

Technical Assessment 5/02-1629 and Mod 01, 02, 03, 04, 05, 06

Parafor Solo FM

Technical Assessment 5/02-1668

Paradiene S

Special Specification Book (CCP) DEVEB No. 11 | 04-09 | revision 3

Adesolo

Certification on-going

Monarplan TPO

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5.2.2 Installing the consoles Preliminary remark: for each photovoltaic installation, Icopal will provide the solar installation company with a detailed layout drawing, defining the area and the layout of the consoles as well as the alignment of the rails and photovoltaic modules. a) Installing the Icosun FIX consoles The Icosun FIX console is a flat mounting making it possible to mechanically fix it to the roof deck through the insulation board. This type of mount provides a good distribution of both the systems weight and any wind uplift loads due to its secure fixing to the deck. The console flange is covered by a weathering collar made from the same type of waterproofing membrane as the main capsheet and is factory made to create a watertight seal between the various components. The first step is to identify the locations of the Icosun FIX consoles (defined on the layout drawing) using a marking line. The space between the consoles is calculated by Siplast depending on the weight of the modules and wind exposure of the site. Minimum density of the Icosun FIX consoles is one console for every 4m2 of roof area. First of all, the Icosun FIX consoles are installed at the various locations identified on the marking line. In order to correctly align the consoles, the Aluclic 80 primary rail is simply positioned in the fork of

each console. The waterproofing operative lifts the weathering collar of the console to mechanically fix the metal flange using screws with or without polyamide cold bridge counter sleeves (eg: Etancoplast diameter 50). The sleeves are used in combination with VMS screws from the LR Étanco Company; diameter 4.8mm and Pksr = 154daN. The metal flange has 4 punched holes per side. Preferably, they are fixed through the holes located in the four corners of the flange. However, in case of profile metal decks, the profile may make it impossible to fix through the two holes located in the direction of the rib with a screw of the same length. In order to know the position of the trough, the waterproofing contractor should use a metal Tee. During pre-puncturing the insulation boards, the position of the trough can easily be determined, and one hole besides the corner one can be used. Since the trough will generally follow the pitch of the roof, the next line of consoles can equally be fixed (a chalk line could be used to mark the line of trough). The last step is to fully bond the weathering collar to the main capsheet, using conventional methods, e.g welding with hot air, torch, solvent glue, etc. To obtain a homogeneous weld, the operation is carried out in two phases: the weathering collar is first of all fully bonded onto the metal flange then it

Aluclic 80

Icosun Dif Console

Icosun Fix Console

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Dynol glue

is welded to the main capsheet. In case of a torch weld on bituminous covering, the waterproofing operative shall first of all embed the self-protection of the covering with the aid of the torch and of a spatula and intensify the heating of the covering. Comment: no weathering collar or flange should bridge an overlap in the capsheet. If this situation is likely to occur, then the console should be slightly moved away from the overlap, according to the direction of the rail. b) Installing the Icosun DIF consoles In order to best distribute the weight of the system the Icosun DIF consoles are positioned between the Icosun FIX consoles. These consoles are placed in a low position and aligned in advance, using the Aluclic 80 section. They are then bonded to the waterproofing covering with WM18 Dynol glue.

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The density and position of these consoles should conform to the layout drawings supplied by Icopal. The minimum density of Icosun DIF consoles, between two Icosun FIX consoles, is one console every 1 linear metres of rail. c) Installing the primary rails and adjusting the Icosun DIF Consoles Once the Icosun FIX consoles and the Icosun DIF consoles are installed, the primary Aluclic 80 rails are positioned in the fork of the Icosun FIX consoles without mechanically fixing them, making sure that the groove is directed upwards. The waterproofing operative can, in this way, realign, if necessary, the Icosun DIF consoles. Then adjust the height of those same consoles, line by line, so as to compensate for any variation in levels of the roof. To do this, a spirit level is positioned on the Aluclic 80

Aluclic 80

Aluclic Angle Brace

Icosun Fix TH 5,5 x 19

section. Then these consoles are adjusted in height manually, using an adjustment nut. The waterproofing operative shall make sure that each Icosun DIF console is in contact with the Aluclic 80 section. After having levelled the consoles of a single line, the primary rails are mechanically fixed in the forks of the Icosun FIX consoles using 4 Icosun Fix TH drive-in screws 5.5x19mm. The waterproofing operative will need to make sure that the forks are centred in advance. d) Mechanical fixing of the rails The secondary Aluclic 40 rails are then screwed in perpendicular to the Aluclic 80 rails using Aluclic Angle Braces. The Aluclic Angle Brace is screwed onto the two Aluclic sections using two Aluclic Nuts, clipped into the grooves of each section. These nuts then make it possible to position the DIN912 M8-16

screws, fitted with M8 washers. The spacing of the Aluclic 40 sections depends on the dimensions of the modules decided upon. They shall be positioned so as to support the module at one quarter up and at three quarters up its height. e) Installing the photovoltaic modules The Icosun Console system makes it possible to incorporate the photovoltaic modules, whether framed or not. The direction of installation of the modules (portrait or landscape) depends on the installation direction of the rails. The module’s height is arranged perpendicular to the rails. The modules are positioned on the rails, making sure that the modules are spaced 1.5cm from each other in each direction. The modules are then held in place by 4 Icosun module fixing elements:

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2 500

1 500

Aluclic 40 Section 1/4

1 000

Icosun DIF

Icosun FIX

1/2

1/4

Aluclic 80 Section

The Alu MC-I or EPDM MNC-I fixing elements between two modules, framed or not; The Alu MC-E or EPDM MNC-E fixing elements at the edges of the field (modules framed or not).

The MNC-E and MNC-I fixing elements are screwed to the Aluclic 40 section, using Aluclic Nuts and DIN912 M8-35 screws, fitted with M8 locking washers. As for the MC-E and MC-I fixing elements, they are directly clipped to the Aluclic 40 section then locked by screwing. For ease of servicing and general access on the roof, it is strongly recommended that walkways be provided across the photovoltaic area. Hence it is recommended to divide the PV area in groups with maximum dimensions of 18m long and 6m on slope. If the waterproofing contractor installs the modules, it is mandatory for them to work with an electrical installer company holding a certificate to carry out PV installation. Their task is to supply, install and connect the inverters and to connect the modules according to the input characteristics of those inverters. It is forbidden for the waterproofing operative to connect the modules.

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f) Routing the cables The cable trays are specified, sized and validated by the electrical contractor then installed by the waterproofing operative by adhering or fixing using, flashing strips of capsheet, to the waterproof membrane. This can be done using a PVC cable tray WM18 duct, length 5.6m, which rests on the PVC Base support plates for WM18. In this case, the support plates are bonded to the waterproof capsheet using Dynol Glue WM18. Figure 3 - Example of galvanised steel omega section Sheet steel drilled to facilitate sufficient adhesion 5cm

5cm 5cm 5cm

Figure 4 - Fixing the omega sections by flashing strip

Strip of the same material as the existing roofing membrane

Figure 5 -

Swivel

Upper surface of protection

Cable

Plate 0,15m 0,12m

10cm

Sleeve

Trays made from other weather resistant materials (for example galvanised steel, wire mesh trays, UV resistant plastics, etc.) can also be used. In this case, the cable tray supports are, for example, galvanised steel omega sections, fixed to the waterproofing by flashing strips (see Figures 3 and 4) before the bonding of the photovoltaic modules. The electrical contracting company then determines their spacing (which should remain less than 1.5m), as well as their earthing. The cable-ducts fixed through the waterproofing and insulation to facilitate the electric wiring are to

be installed by the waterproofing operative and this is done by means of swivel elbows in conformity with the local standards (see Figure 5). Another solution is to mechanically fix the cable trays using small concrete slabs, dimensions 30x30x3cm minimum. A loose laid sacrificial m embrane (the same type as the capsheet) should be placed underneath the slabs to protect the waterproof membrane. This system is not mandatorily installed by the waterproofing operative but is only applicable for roof slopes less than 5%.

6. Servicing Roofs are to be maintained in conformity with local building regulations. For those roofs equipped with an electricity generating system, the owner shall mandatorily, for a servicing contract, require: at least one half yearly inspection visit and carry out maintenance as necessary, checking the waterproofing, the electricity installation and to clean the modules. The contracting company in charge of maintenance will need to be aware of objects which might create shade and thus reduce the efficiency of the modules. They should also check the installation yield to detect any possible anomalies The frequency of cleaning of the modules is deter-

mined according to their pitch (soiling more readily occurs on modules installed on shallow pitches) and also relating to the environment in which they are located (foliage, dust, pollution, bird droppings, etc.)., The cleaning will need to be done with water without added chemicals, at a pressure of less than 3 bars. Use non-scratching brushes, sponges or rubber squeegees. It is forbidden to: Walk on the photovoltaic modules; U se aggressive compounds, chemicals or solvents on the photovoltaic cells.

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7. Repairing and replacements a) Photovoltaic modules A damaged photovoltaic module will need to be replaced by a fully functioning one. A damaged module can easily be located when the installation is equipped with a string by string measurement system or by using a thermographic camera. As stated, modules must be dismounted to access the defective one, without walking on the panels. b) Aluclic rails The photovoltaic modules should be dismounted in the zone concerned. The support rails should then to be replaced by those in good condition. The modules can then simply be remounted. c) FIX Console The photovoltaic modules and rails should be dismounted in the zone concerned. The FIX Console weathering collar will need to be pulled out and the fixing screws removed. The waterproofing should

then to be reconstructed according to the specifications described in this document. d) DIF Console The photovoltaic modules and the rails should be dismounted in the zone concerned. The DIF Console will need to be pulled out. If the waterproof membrane is damaged, a new patch will need to be welded or bonded over the affected area. The waterproofing will then be reconstructed according to the specifications described in this document. e) Wa terproof membrane under the Icosun Console system The photovoltaic modules, rails and consoles should be dismounted in the zone concerned. A new capsheet should then be welded or bonded on the existing membrane. The system is then to be remounted according to the specifications described in this document.

8. Materials 8.1 Icosun FIX Console

8.2 Icosun DIF Console

The Icosun FIX console consists of a stainless steel flange 40x40cm, specially designed to provide it with considerable mechanical strength with minimal thickness. It contains large perforations, regularly distributed to enable the mechanical fixing to the roof deck through the waterproof membrane using cold bridge counter sleeves. This flange is covered with a weathering collar of waterproof membrane 60x60cm, fabricated in the factory with a stainless steel mount. The weathering collar is designed to be welded, around its edges, to the waterproof capsheet. It is supplied in bituminous or synthetic versions according to the nature of the waterproof membrane upon which the system is to be installed. The console comes assembled, ready-to-use.

The Icosun DIF console manufactured from polypropylene comprises of the following separate elements: Base with distribution plate; Control nut for height adjustment; Support head.

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The height adjustment ranges from 40 to 65mm. Characteristics Distribution plate: surface area approximately 330 cm2. Mechanical strength under centred load at 20°C: 2,000kg.

8.3 Aluclic sections Aluclic 80 primary section

Aluclic 40 secondary section

Directed upward

Aluclic Nut Part to slide first in the channel

Dimensions

Weight

Span

Aluclic 80

Section

6,100x80x40mm

8.79kg

Aluclic 40

6,100x40x40mm

5.62kg

1,5m

The Icosun Rail primary and secondary sections consist of extruded aluminium sections. Their shape has been specially designed to facilitate fixing, using a clamping nut system. These sections can be delivered up to 6.1m long. Given this considerable length and in order to avoid having to slide each nut inside the sections’ grooves, Aluclic T-ball nuts are used. These nuts can easily be clicked into the profile channels anywhere along the section. They can then be slid into place and are self-aligned. When working with rail lengths exceeding 6.1m, the sections can be connected using an Aluclic connector. This aluminium component slides within the sections of the two connected Aluclic profiles. It is recommended to leave a gap of 2cm between the two connected sections to allow for any heat

expansion. To connect two Aluclic 40s, a single connector is required. Two are required to connect two Aluclic 80s.

Aluclic connector

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8.4 Fixing elements of Icosun modules Modules with frames Fixing element MC-I

Modules without frames

Fixing element MC-E

Fixing element MNC-E

The fixing elements of the Icosun modules are available in two versions designed to be used for modules with or without frames. They are manufactured from aluminium and, in the case of non-framed modules that are more fragile, an EPDM lining sits between the laminate and the aluminium. The MNC-E and MNC-I fixing elements fit every non-framed module, thicknesses from 6 to 9mm.

They are held on the Aluclic 40 rail by a screw DIN912 M8-35, fitted with self locking M8 washers. The MC-E and MC-I fixing elements fit the framed modules but their given height is adapted to the thicknesses of the frames. These fixing elements are delivered pre-assembled and include an aluminium angle brace or U-clamp, a screw, a nut and a clip. In this way, they are directly clipped to the Aluclic 40 section, then fixed in place by screwing.

9. Manufacture and quality assurance operations

10. Experimental results

The self-inspection of the production is part of the quality system as a whole, in conformity with the specifications of Standard ISO 9001.

Normal pull out tests of the Icosun FIX consoles;

Fixing element MNC-I

Watertightness tests of the consoles under one metre water level in vertical pressure gauge tube; Wind tunnel test of the zone of photovoltaic modules.

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C1-72 - 01/11 - Illustrations : Icopal - These drawings are not contractually binding - R.C.S. Nanterre B 552 100 984

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12, rue de la Renaissance F-92184 Antony Cedex - France Tél: +33 1 40 96 35 00 Fax: +33 1 46 66 24 85 www.siplast-international.com