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IBC SOLAR AeroFix 15-S Installation Instructions Manual

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Installation instructions
IBC AeroFix
Version 18.01 Date: 1-Mar-2018
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Summary of Contents for IBC SOLAR AeroFix 15-S

  • Page 1 Installation instructions IBC AeroFix Version 18.01 Date: 1-Mar-2018...

  • Page 2: Table Of Contents

    Contents 0. Introduction ............................3 01. Tool list .............................4 02. General information, standards and regulations ..................4 03. System variants ..........................8 04. Technical data...........................9 05. System planning ..........................10 06. System design/dimensioning ......................13 07. System installation .......................... 14 08. System security device ........................42 09.

  • Page 3: Introduction

    Please read these instructions carefully before installation. If you still have questions after reading them, please contact your IBC partner, who will be happy to assist you. We wish you a sunny day! Your team IBC SOLAR AG Version 18.01, 1-Mar-2018...

  • Page 4: Tool List

    01. Tool list  Cordless screwdriver with various bits (Torx 40, SW8 socket, ...)  Bit holder 300 mm  Pencil  Tape measure  Folding rule  Plumb line  Angle grinder with diamond grinding wheel  Torx screwdriver with T-handle, size TX40 ...
  • Page 5  Condition for the 10-year guarantee to be granted: this only applies with the use of IBC components. The guarantee is not valid for components from other suppliers. Complete guarantee conditions are stated in the guarantee document.  We advise the use of gloves to avoid injuries. ...
  • Page 6  TAB (technical closing conditions for connecting to the low-voltage grid of power supply companies)  VDEW guidelines (guidelines for connection and parallel operation of decentralised power generation in the low-voltage grid)  Notes on solar from the German Institute of Civil Engineering (DIBt), in the current edition ...
  • Page 7 Framed solar modules Please note that the guarantee for the solar modules will expire if modifications are made to the module frames (e.g. by drilling additional holes). For warranty reasons, the assembly instructions from the respective solar module manufacturer must be strictly adhered to. Lightning and surge protection Please note that the lightning and surge protection of the PV system is to meet the current requirements ...

  • Page 8: System Variants

    03. System variants Southern orientation Fig. 1: AeroFix 15-S / AeroFix 15-S Kits Fig. 2: AeroFix 10-S East-west orientation Fig. 3: AeroFix 10-EW beginning / ending with wind plates Fig. 4 AeroFix 10-EW beginning / ending with modules Version 18.01, 1-Mar-2018...

  • Page 9: Technical Data

    Product guarantee in accordance with complete guarantee conditions in the version valid at the time of assembly that you received from your IBC SOLAR trade partner. Guarantee assumes assembly is in accordance with applicable assembly instructions. We reserve the right to make modifications which will improve our product.

  • Page 10: System Planning

    This is excluded by restricting the module field sizes (splitting individual module fields). AeroFix 15-S and AeroFix 10-S must be separated at the latest after 15 rows and after 15 modules in the row.
  • Page 11 Fig. 5 thermal separation within the module row Fig. 6 AeroFix South separation between rows Fig. 7 AeroFix EW separation between rows Load-bearing reserve In order to apply the additional loads from the PV system onto the roof, the load-bearing capacity of the roof and the insolation must be assured by a static expert before planning the installation of the photovoltaic system.
  • Page 12 Static friction coefficients In terms of proof of stability, analysis of the position stability must be carried out in addition to the component analysis. For this, the system must be adequately secured against lifting off and shifting. A key factor influencing the proof of position stability is the static friction coefficient µ...

  • Page 13: System Design/Dimensioning

    To determine the static friction coefficient between the building protection mat and roof cladding:  Clean roof cladding  Place test specimen on roof cladding  Draw the test specimen parallel to the roof using measurement device  Record result The testing is based on DIN EN ISO 8295 Plastics –...

  • Page 14: System Installation

    07. System installation Before constructing the PV system the roof must be cleared of dirt, snow and ice. 7.1 Base rails Measure roof and mark out edge and corner areas Fig. 10 Roof preperation Install base rails with integrated building protection mat Fig.
  • Page 15 Fig. 12 Installation base rails Fig. 13 Installation base rails Version 18.01, 1-Mar-2018...
  • Page 16 Extend base rails Fig. 14: Insert base rail connectors up to half-way into the base rail Fig. 15 Secure each base rail connector with a sheet-metal screw Version 18.01, 1-Mar-2018...
  • Page 17 Fig. 16 Join the base rails together and screw in 2 more sheet-metal screws Base rail alignment Fig. 17 Align the base rails so that they are parallel and vertical. Version 18.01, 1-Mar-2018...
  • Page 18 Fig. 18 Distance between base rails: module length + 20 mm or module length - 160 mm Important information: On very uneven roofs, it can happen that the base rail rests on the roof covering. In this case additional protection mats must be placed. Building protection mats can be ordered separately. Version 18.01, 1-Mar-2018...
  • Page 19 7.2 Third Base rail In order not to exceed the permissible surface pressure of the roof insulation, a third base rail may be necessary. The additional baserail with supports is placed cetrally under the modules. Module clamps are not reqired here. Fig.
  • Page 20 7.3 Supports AeroFix Southern orientation - AeroFix 15-S / AeroFix 10-S Fig. 21 AeroFix 15-S Dimensions Fig. 22 AeroFix 15-S „Support top“ and „support bottom“ Version 18.01, 1-Mar-2018...
  • Page 21 AeroFix 10-S / 15-S: “Support bottom” must be laid out completely on the base rail. Fig. 24 Standard grid spacing, or mark out individual spacing AeroFix 15-S: 1,8m (1,62m – 1,98m) AeroFix 10-S: 1,6m (1,44m – 1,76m) Version 18.01, 1-Mar-2018...
  • Page 22 Fig. 25 Screw the „support bottom“ onto the base rail on the marking with screw M8x16 Fig. 26 Mounted „support bottom“ Version 18.01, 1-Mar-2018...
  • Page 23 Fig. 27 AeroFix 15-S, Screw „support bottom“ onto the base rail at „x“ distance with 2 M8x16 screws Distance between supports AeroFix 15-S Module width Distance x 950 mm 715 mm 960 mm 725 mm 970 mm 736 mm 980 mm...
  • Page 24 Fig. 28 AeroFix 10-S, Screw „support bottom“ onto the base rail at „x“ distance with 2 M8x16 screws Distance between supports AeroFix 10-S Module width Distance x 950 mm 763 mm 960 mm 773 mm 970 mm 783 mm 980 mm 793 mm 990 mm 803 mm...
  • Page 25 Attaching the ballast rail Fig. 29 The ballast rail is attached directly in front of the „support top“ and secured onto the base rail with 2 M8x16 screws The number and position of the ballast rail is determined by the static calculations for the project. See more at chapter “7.4”...
  • Page 26 AeroFix East-west orientation - AeroFix 10-EW Fig. 30 AeroFix 10-EW with module finish Fig. 31 AeroFix 10-EW with wind plate finish Determining the position of the supports Define the position of the „lower support“. The distance from the leading edge of the base rail to the „support bottom“...
  • Page 27 Fig. 34 Standard grid spacing 2.3 m Fig. 35 Screw the “support bottom” into the base rail on the marking with screw M8x16 Version 18.01, 1-Mar-2018...
  • Page 28 Fig. 36 Screw “supports top” onto the base rail at “x” distance with 2 M8x16 screws Distance between supports Module width Distance x 950 mm 763 mm 960 mm 773 mm 970 mm 783 mm 980 mm 793 mm 990 mm 803 mm 1000 mm 813 mm...
  • Page 29 Attaching the ballast rail Fig. 37 The ballast rail is attached directly in front of the „support top“ and secured onto the base rail with 2 M8x16 screws The number and position of the ballast rail is determined by the static calculations for the project. For more information on ballast please refer to chapter „7.4“.
  • Page 30 7.4 Ballast Fig. 38 AeroFix 10-EW ballast with ballast rail and base rail Fig. 39 AeroFix 15-S, AeroFix 10-S ballast with ballast rail and base rail Important information: When adding ballast to the base rail it is not permitted to completely seal the space between the base rail and the module with ballast stones! Version 18.01, 1-Mar-2018...
  • Page 31 Stone 40 x 40 x 4 cm The ballast should always be placed under the module. The max. ballasting potential on the base rail is and corresponds, in the above-mentioned blocks, the Aerofix 15-S (Aerofix 10-S / AeroFix 10-EW): Fig. 40: Ballasting oft he base rail If the system has to be loaded with more than 42 kg (28 kg) per module a ballast rail is necessary.
  • Page 32 7.5 Snow load rail The snow load rail for all mounting support is required, if the allowed snow load on the modules is exceed in corner clamping. The snow load rail is inserted in the mountuing supports and is fixed with clips on the module.
  • Page 33 Fig. 44 Short and long snow load rail Fig. 45 Snow load rail long with 2 clips and G4 middle clamp Important information: The snow load rail can only be installed with the middle clamp G4 and at the end of the row with the EC adapter.
  • Page 34 7.6 Module assembly The procedure for installing “AeroFix10-S / AeroFix 10-EW” is identical to that of „AeroFix 15“. Fig. 46 Insert the module into the “support top” and “support bottom“ Fig. 47 The module must lie flat against the end stop on the “support top“ (with wind plate mounting) Version 18.01, 1-Mar-2018...
  • Page 35 Fig. 48 Module on the end stop and clamped Fig. 49 Lay out the modules and attach using module clamps (in front “support top” without wind plate mounting) Ensure that a distance of 65 mm is maintained between the module frame and the rear panel of the upper support.
  • Page 36 The middle and outer clamp are delivered pre- assembled. The middle clamp G3 covers a clamping area of 30-50 mm. However the outer clamp G3 must be ordered for G3 Middle and outside clamp each module height. The middle clamp G4 covers a clamping area of 33-46 mm.
  • Page 37 The middle clamp G4 is pivoted from above into the support or introduced laterally, where it is needed. Fig. 51 Pivoting the middle clamp G4 The adaptor EC is clamped by the given frame height with the middle clamp G4 and substitutes thus the end clamp.
  • Page 38 7.7 Wind plate assembly Fig. 54 Mounted wind plate Beginning with the rear side of the left module row, mount the wind plate on the supports. Screw the left side of the wind plate to the base rail with screw M8x16. Slide the wind deflector for the next module sideways on the previously mounted plate and mount onto the next support.
  • Page 39 Fig. 56 Wind plate assembly starting from the left Fig. 57 Insert wind plate Version 18.01, 1-Mar-2018...
  • Page 40 Fig. 58 Wind plate assembly Fig. 59 Fixation wind plate Version 18.01, 1-Mar-2018...
  • Page 41 7.8 Cable clip assembly Fig. 60 assembly cable clip 0° Fig. 61 assembly cable clip 90° Version 18.01, 1-Mar-2018...

  • Page 42: System Security Device

    08. System security device For a roof inclination >3° it is an additional system security device necessary. With the anti-slip safety device, the module arrays are connected to each other via the ridge. Alternatively, the anti-slip syftey device can be attached at the building. The fastening to the building must be planned and statically tested by the customer.
  • Page 43 Placement of the anti-slip device over the ridge. The roof cladding must be protected from any damage. Fig. 64: Ridge placement The perforated tape is connected to the base rail with a M8x16 socket head screw. Fig. 65: Base rail anti-slip security device cross connection The perforated tape is connected to the base rail with at least two M8x16 socket head screws.

  • Page 44: Final Inspection

    09. Final inspection After completing the PV system inspect the screw and clamp connections. Check the entire structure for strength and stability and check the roof cladding for damage. It is advisable to document the completed system. Version 18.01, 1-Mar-2018...

  • Page 45: Parts List

    10. Parts list Image Product no. Description AeroFix 10 / 15 Base rail with integrated building protection mat 6101100029 Base Rail G2, 800mm 6101100030 Base Rail G2, 1500mm 6101100031 Base Rail G2, 2200mm 6101100032 Base Rail G2, 3100mm 6101100033 Base Rail G2, 4200mm 6101100034 Base Rail G2, 5400mm Base rail with integrated building protection mat foil-...
  • Page 46 Image Product no. Description 6101100041 Base rail connector 6101100022 Ballast rail Middle clamp G3 6700400125 Middle clamp G3 30-50 mm End clamp G3 6700400127 End clamp G3 31 mm 6700400164 End clamp G3 32 mm 6700400129 End clamp G3 33 mm 6700400130 End clamp G3 35 mm 6700400132...
  • Page 47 Image Product no. Description 6700400144 Middle clamp G4 33-46mm 6700400161 EC adapter 33-46mm Self-drilling-screw 4.8x19 – SW8 6900600010 6900100012 Socket Cap Screw M8x16 A2 TX40 AeroFix 10 –S 6101100042 Support top Also used in AeroFix 10-EW with wind plate beginning and ending.
  • Page 48 Image Product no. Description AeroFix 10-EW 6101100044 Support top Without windplate mounting 6101100045 Support bottom SeroFix 15-S 6101100046 Support top 6101100047 Support bottom 6101100019 Wind plate Version 18.01, 1-Mar-2018...
  • Page 49 Image Product no. Descriptionv Optional 6101100020 Building protection mat 500x172x15 mm 6101100021 Building protection mat (ak), foil-laminated 500x172x15 mm 6101100025 Slide protection Coil 10 m - 25 mm width - Ø 9 mm 6101100027 Cable clip 0° 6101100028 Cable clip 90° 6700200039 Clamp for equipotential bonding Version 18.01, 1-Mar-2018...
  • Page 50 Image Product no. Description Optional 6101100023 Assembling jig - ground rail distance - support distance 6101100024 Static friction measuring device to determine the static friction coefficients incl.: - case - dynamometer 6101100048 Snow load rail long G2 incl.: – 2 clip 6101100049 Snow load rail short G2 incl.:...

  • Page 51: Appendix

    11. Appendix 11.1 Information about IBC AeroFix Tightening torques of screw connections The tightening torques of the screw connections used in the IBC AeroFix flat roof system should be dimensioned in accordance with DIN ISO 3506. Due to the difficulty in determining the friction coefficients in the external area, dimensioning in accordance with DIN ISO 3506 can prove difficult.
  • Page 52 Version 18.01, 1-Mar-2018...
  • Page 53 11.3 IBC Aerofix Stiction Log IBC AeroFix flat-roof system Test record Determination of stiction coefficients CUSTOMER INFORMATION Name Phone Company Mobile Street / No. Post code/city E-mail CONSTRUCTION PROJECT Customer name Phone Street / No. Mobile Post code/city Com.: E-mail TEST PROCEDURE The tests are to be performed in accordance with the October 2004 edition of DIN EN ISO 8295, Plastics - Films and sheeting - Determining coefficients of friction.
  • Page 54 Sketch of roof structure (from top to bottom) Date: Time: Temperature: Test Test Measured Measured Test No. specimen µ specimen µ force force weight weight G (kg) F (kg) F / G G (kg) F (kg) F / G µ = Evaluation (based on lowest measured value) Roof layout plan with measuring point locations / test Appendix:...
  • Page 55 11.4 Checklist IBC AeroFix Version 18.01, 1-Mar-2018...
  • Page 56 Version 18.01, 1-Mar-2018...

  • Page 57: Notes

    12. Notes Version 18.01, 1-Mar-2018...

  • Page 58: Version 18.01, 1-Mar

    IBC SOLAR AG Am Hochgericht 10 96231 Bad Staffelstein Phone +49 (0) 9573-92 24 0 Fax +49 (0) 9573-92 24 111 info @ ibc-solar.de www.ibc-solar.com Version 18.01, 1-Mar-2018...

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