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IBC SOLAR TopFix 200 Installation Manual

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Instalation manual
TopFix 200
IBC SOLAR AG
Version:23.01
As of: 01/2023

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Summary of Contents for IBC SOLAR TopFix 200

  • Page 1 Instalation manual TopFix 200 IBC SOLAR AG Version:23.01 As of: 01/2023...

  • Page 2: Table Of Contents

    Table of contents 1. Introduction ........................... 8 2. Tool list ............................9 3. General information, standards and regulations ............10 4. Mounting diagram ........................14 5. Fitting the various mounting systems ................17 5.1 General dimensioning information .................................. 17 5.2 Fitting the roof hooks ......................................18 5.3 Roof hook types .........................................
  • Page 3 11.2 System installation ........................................84 12. Bill of materials ......................... 95 13 Appendix ............................ 109 13.1 Notes on IBC TopFix 200 ....................................109 13.2 Weights/installation times for pitched roof installations ........................ 111 13.3 Notes on maintenance ......................................111 13.4 Documents ..........................................112 Version: 23.01...
  • Page 4 Figure 2 Fastenings for the IBC TopFix 200 pitched roof mounting system ......................15 Figure 3 Module fastening of the IBC TopFix 200 pitched roof mounting system ....................15 Figure 4 Layout of the IBC TopFix 200 pitched roof mounting system ........................16 Figure 5 Roof hook ..............................................
  • Page 5 Figure 48 Fix the mounting plate ........................................38 Figure 49 Cover cap and roof hook ......................................... 39 Figure 50 Roof hook fixing ........................................... 39 Figure 51 Hanger bolt ............................................. 40 Figure 52 Pre-drilling diameters for plate and substructure; screwing depths for substructure ..............40 Figure 53 Correctly fitted hanger bolt with universal connector .............................
  • Page 6 Figure 99 "Trapezoidal system Eco 340mm & 420mm" distributed as specified ....................63 Figure 100 Drilling clamps ............................................. 64 Figure 101 Inserting blind rivets.......................................... 64 Figure 102 Riveting using a standard rivet head ..................................64 Figure 103 Apply the screw ..........................................64 Figure 104 Trapezoidal System Eco screwed .....................................
  • Page 7 Figure 151 Adjusting the assembly jig ......................................86 Figure 152 Positioned assembly jig ........................................87 Figure 153 Detail position assembly jig bottom, analog top ..............................87 Figure 154 Position two-layer connector ...................................... 88 Figure 155 Two-layer connector ........................................88 Figure 156 Side view two-layer connector ....................................88 Figure 157 Butt connector insertion rail ......................................

  • Page 8: Introduction

    To ensure that you can install and start up your IBC TopFix 200 module mounting system quickly and simply we have enclosed detailed assembly instructions. They should help you to quickly become familiar with the assembly of the bracket and the modules.

  • Page 9: Tool List

    2. Tool list • Power drill or cordless screwdriver with wrench socket, a variety of bits (TX 25, TX 30, TX 40, socket SW8, SW10.) and torque control • Drill bits (up to Ø 15 mm) • Pencil • Tape measure •...

  • Page 10: General Information, Standards And Regulations

    3. General information, standards and regulations The IBC TopFix 200 mounting system is is used for installing your solar modules. The number of components varies according to the size of the system. Important information • Your IBC TopFix 200 mounting system will be delivered complete with all accessories! •...
  • Page 11 Please note in particular (this is not an exhaustive list): • DIN / VDE 0100, particularly part 712 (erection of power installations with nominal voltage up to 1000 V) • DIN / VDE 0298 (electric cables) • VDI 6012 Blatt 1.4 (Integration of distributed and renewables-based energy systems in buildings - Fundamentals - Fixing of solar modules and solar collectors on buildings) •...
  • Page 12 • DGUV Information 203-080 - Installation and maintenance of PV systems • DGUV Information 201-056 - Planning principles of anchor devices on roofs • Model Building Regulation (MBO) / state building regulations Solar modules Framed solar modules may only be used if they fulfill the following criteria: •...
  • Page 13 Dimensioning Our TopFix 200 mounting system is dimensioned using our very own PV Manager software, used to determine the degree of utilisation and hence the suitability of the components to be mounted on your roof. The software is designed as a planning tool. It does not substitute official, static calculations.

  • Page 14: Mounting Diagram

    TF50+ support rails and arrange solar modules vertically. For this reason, any further mounting procedures describe such an arrangement. Figure 1 View of the IBC TopFix 200 pitched roof mounting system Version: 23.01...

  • Page 15: Figure 2 Fastenings For The Ibc Topfix 200 Pitched Roof Mounting System

    We have illustrated the layout of the IBC TopFix 200 mounting system to improve transparency: Figure 2 Fastenings for the IBC TopFix 200 pitched roof mounting system Figure 3 Module fastening of the IBC TopFix 200 pitched roof mounting system...

  • Page 16: Figure 4 Layout Of The Ibc Topfix 200 Pitched Roof Mounting System

    Figure 4 Layout of the IBC TopFix 200 pitched roof mounting system Description L = (MB + 20 mm) × n + 48 mm Support rail= (MB + 20 mm) × number of modules per row + 48 mm Module width...

  • Page 17: Fitting The Various Mounting Systems

    5. Fitting the various mounting systems 5.1 General dimensioning information The PV system on your roof is subject to considerable forces caused by snow and, most of all, wind. Improper fastening of the PV system, particularly the modules, may cause significant damage to objects as well as personal injury. For this purpose, it is crucial you observe the following section.

  • Page 18: Fitting The Roof Hooks

    5.2 Fitting the roof hooks In order to comply with warranty conditions (rain-proofing etc.) we recommend having the roof hooks fitted by a professionally trained personal e.g. roofing firm. Please also take into account the manufacturer's regulations and specifications for the corresponding roofing, in particular with regard to the use of manufacturer accessories for roofing as well as the overview in section 11 containing data on the rafter dimensions required as per EN 1995-1-1.

  • Page 19: Figure 10 Roof Hook Load Distribution

    If the roof hook cannot be fitted as shown above due to the form of the tile or the position of the depression, it is imperative that a roofer is engaged. Changes to roof covering materials (roof tiles, clay tiles, roof panels, cast stone, etc.) may only be made in accordance with the applicable roofing trade regulations and the manufacturer’s guidelines.

  • Page 20: Roof Hook Types

    5.3 Roof hook types Attention! The specifications of the general building approval Z-14.4.-661 for steel roof hooks and Z-14.4.-515 for aluminum roof hooks have to be considered. 5.3.1 Standard S+ roof hook Generally the "Standard" S+" roof hook is used. It is suitable for the most commonly used types of pantiles.

  • Page 21: Standard S+ 35 Mm" Roof Hooks

    5.3.2 Standard S+ 35 mm" roof hooks Figure 13 Standard S+ 35 mm roof hook Parameters Value Material Stainless steel 1.4307 S275 + S460 Stirrup: fy,k = 460 N/mm² yield strength Ground plate: 275 N/mm² Dimensions base plate (length / width / height) 135/ 70/ 4 mm Dimensions hook (width / height) 30/ 6 mm...

  • Page 22: Mammut S+ Roof Hooks

    5.3.3 Mammut S+ roof hooks Mammut S+ roof hooks are used to ensure the safety of the structure under high snow loads. This roof hook provides improved static characteristics compared with the "Standard S+" roof hook. In certain conditions (e.g. low snow load zone), it may be possible to install "Mammut S+" roof hooks only on every second rafter and consequently reduce the number of roof hooks.

  • Page 23: Mammut Xl S+ Roof Hooks

    5.3.4 Mammut XL S+ roof hooks Mammut XL S+" roof hooks are used to ensure the safety of the structure under very high snow loads. This roof hook provides improved static characteristics compared with the "Mammut S+" roof hook. In certain conditions (e.g.

  • Page 24: Mammut Sv+ Roof Hooks

    5.3.5 Mammut SV+ roof hooks Suitable for vertical installation of the support profile in the 1st layer, e.g. insertion system or module portrait at two-layer systems. Figure 19 Mammut SV+ roof hook Parameters Value Material Stainless steel 1.4307 S275 + S460 Stirrup: fy,k = 460 N/mm²...

  • Page 25: Vario S+ Roof Hooks

    5.3.6 Vario S+ roof hooks For horizontal and vertical adjustability at the base plate. Figure 21 Vario S+ roof hook Parameters Value Material Stainless steel 1.4307 S460 yield strength fy,k = 460 N/mm² Dimensions base plate (length / width / height) 155/ 75/ 5 mm Dimensions hook (width / height) 35/ 6 mm...

  • Page 26: Schiefer S+ Roof Hook

    5.3.7 Schiefer S+ roof hook Special roof hooks designed for the particular roofing tile shape are used for slate tiles. Figure 23 Schiefer S+ slate tile roof hook Parameters Value Material Stainless steel 1.4307 S460 yield strength fy,k = 460 N/mm² Dimensions base plate (length / width / height) 280/ 30/ 6 mm Dimensions hook (width / height)

  • Page 27: Plain Tile S+ Roof Hook

    5.3.8 Plain tile S+ roof hook Plain tiles have a different shape from normal roofing tiles. For this reason, a different roof hook type is used. Figure 25 Biber S+ Figure 26 Depression for Biber S plain tile roof hook Parameters Value Material...

  • Page 28: Alu-Vario Eco S+ Roof Hooks

    5.3.9 Alu-Vario Eco S+ roof hooks 4-way adjustable aluminum roof hooks Figure 28 Alu-Vario Eco S+ roof hook Parameters Value Material EN AW 6005-T6 Stirrup: fy,k = 225 N/mm² yield strength Ground plate: 225 N/mm² Dimensions base plate (length / width / height) 135/ 70/ 4 mm Dimensions hook (width / height) 30/ 6 mm...

  • Page 29: Alu-Mammut S+ Roof Hooks

    5.3.10 Alu-Mammut S+ roof hooks Figure 30 Alu-Mammut S+ roof hook Parameters Value Material Alumnium EN AC-42100-K-T6 (DIN EN 1706) yield strength Hook: fy,k = 210 N/mm² Dimensions base plate (length / width / height) 150/ 63,5/ (12) mm Dimensions hook (width / height) 35/ 6 - 8 mm Drilling holes baseplate 10 x ∅...

  • Page 30: Alu-Mammut Sv+ Roof Hooks

    5.3.11 Alu-Mammut SV+ roof hooks Suitable for vertical installation of the support profile in the 1st layer, e.g. insertion system. Figure 32 Alu-Mammut SV+ roof hook Parameters Value Material Alumnium EN AC-42100-K-T6 (DIN EN 1706) yield strength Hook: fy,k = 210 N/mm² Dimensions base plate (length / width / height) 181/ 71/ (12) mm Dimensions hook (width / height)

  • Page 31: Asd Screws- Mounting On Rafter-Mounted Insulation Systems

    Observe the minimum edge distances and dimensions according Figure 175. Select the required screw length according to Figure 34 or using the IBC SOLAR AG PV Manager dimensioning software. It is not required to drill bores before inserting the screws.

  • Page 32: Figure 36 Inserting Flat Head Screws

    Proceed as follows when assembling: • Two ASD flat head screws are required to fasten one roof hook. Figure 36 Inserting flat head screws Figure 37 Inserted flat head screws • Each roof hook connection must additionally be secured by a ASD countersunk screw to absorb sliding / transverse forces at an angle of 60°.

  • Page 33: Mammut Form S+ Roof Hook

    For available types and colours of tiles, please refer to the IBC Premium Partner portal. Your personal IBC SOLAR AG contact person will of course also be happy to help.

  • Page 34: Figure 40 Fastening The Reinforcing Runner In The Rafter With Drilling Screw 5.0×120 Mm

    Step 2: Figure 40 Fastening the reinforcing runner in the rafter with drilling screw 5.0×120 mm Figure 41 Fastening the reinforcing runner in the counter battens with drilling screw 5.0×70 mm • Remove roof tile from the specified area • Horizontally move the reinforcing runner (2) horizontally until the slot on the support member (3) covers the hole of the reinforcing rail.

  • Page 35: Figure 42 Connecting Sheet Metal Roof Tiles With Batten Rail

    Step 3: Figure 42 Connecting sheet metal roof tiles with batten rail • Fit roof hooks using screws (6) and (4) and additionally secure the reinforcing runner to the batten using screw (4) (may alternatively be fastened from the top). Information If the existing screw connection of the counter battens cannot adequately dissipate the forces that occur during the on-site structural check, it is possible to reinforce them with the ASD screws from "Figure 34 Overview of screw lengths".

  • Page 36: Fitting Mammut Form S+ Roof Hooks On Bitumen Roofs

    5.5.2 Fitting Mammut Form S+ roof hooks on bitumen roofs Legend: Roof hook 4.8×32 mm drilling screw (3) 4.8×60 mm drilling screw Figure 44 Mammut Form S+ Bitumen • Specify the roof hook position so that the roof hook (1) can be attached to the rafter using screws (3). •...

  • Page 37: Fitting "Mammut Form S+" Roof Hooks On Plain Tile Roofing

    5.5.3 Fitting "Mammut Form S+" roof hooks on plain tile roofing Figure 45 Mammut Form S+ plain tile dual roofing Figure 46 Mammut Form S+ plain tile crown roofing • Installation is as described in chapter 5.5.1 Fitting "Mammut Form S+" roof hooks. The beaver bricks lying above must be processed.

  • Page 38: Fitting „Mammut Form S+" Roof Hook For Slate And Metal Shingle Roofs

    5.5.4 Fitting „Mammut Form S+“ roof hook for slate and metal shingle roofs Step 1: Legend: (1) Metal plate (2) Mounting plate (3) Woodscrew 8x140 mm (4) cover cap (5) roof hook (6) Screw nut M6 Figure 47 Insert the metal plate (slte roof only) •...

  • Page 39: Figure 49 Cover Cap And Roof Hook

    Step 3: Figure 49 Cover cap and roof hook Step 4: Figure 50 Roof hook fixing • Fix the cover cap (4) and the roof hook (5) at the mountig plate with the M6 nuts (6). (torque 10 Nm) Version: 23.01 As of: 01/2023 Page 39 from 119...

  • Page 40: Installation Using M12×300, M12X250 And M10X200 Hanger Bolts On The Timber Substructure

    5.6 Installation using M12×300, M12×250 and M10×200 hanger bolts on the timber substructure Hanger bolts are used on corrugated eternit, trapezoidal sheet metal- and sandwich element roofs as well as bitumen roofs to attach the support rails. The load bearing roof construction to which the hanger bolt is secured consists of timber purlins or timber rafters.

  • Page 41: Figure 53 Correctly Fitted Hanger Bolt With Universal Connector

    • For stress reasons, the universal connector must always be mounted in the direction of the roof ridge. Figure 53 Correctly fitted hanger bolt with universal connector Attention! The stress values for the M12x300 hanger bolt relate to a fixing distance l = 100mm for a use of corrugated eternit panels.

  • Page 42: Assembly With Solar Fasteners On A Steel Substructure

    For stress reasons, the universal connector must always be mounted in the direction of the roof ridge. • Adapt the required length of the solar fastener to the height of the roof structure. Use IBC SOLAR AG's very own "PV Manager" planning software to ensure you select the right solar fastener.
  • Page 43 Information Comply with the following requirements regarding the roof profile type: • The steel purlins must be made of steel types S235 according to DIN EN 10025-2 or S280GD or S320GD according to DIN EN 10346. The solar fastener cannot be screwed into higher quality steel grades. On request, it may be possible to order suitable solar fasteners from the manufacturer EJOT for higher-quality steel grades.

  • Page 44: Mounting Plate Duo

    5.8 Mounting plate duo The mounting plate duo is used for fixing with two hanger bolts or two solar fasteners. The two screws are connected through the mounting plate duo. The rooftop connector profile is then fixed on the mounting plate duo. There are two different variants for connecting the profiles.

  • Page 45: Mounting With Trapezoidal Sheet Metal Clamps

    5.9 Mounting with trapezoidal sheet metal clamps 5.9.1 Introduction IBC SOLAR AG trapezoidal sheet metal mounting systems in combination with the IBC TopFix 200 mounting system is a fast, universal and structurally tested solution for attaching solar modules onto trapezoidal sheet metal roofs. The trapezoidal sheet clamp and the Trapezoidal System Eco 340mm &...

  • Page 46: Dimensioning

    5.9.3 Dimensioning The mounting system is dimensioned in our very own PV Manager software, taking into account local conditions. Attention! Do not exceed a maximum support profile length of approximately 11.90 m (5 beams 2.38 m) for continuous support rails due to thermal expansion. 5.9.4 Mounting trapezoidal sheet metal panels Step 1: Dimensioning using "PV Manager"...

  • Page 47: Figure 61 Removing The Protective Foil

    Step 4: Affix the TRAPEZOIDAL CLAMP Information The heavy-duty adhesive tape can be used from an object and working temperature of 0° C; final adhesion occurs after approx. 72 h at an ambient temperature of 20° C. The higher the temperatures, the faster this process is complete. We do not recommend to bond surfaces below these temperatures as the adhesive agent may become too hard and prevent adequate adhesion.

  • Page 48: Figure 64 Insert The Support Rail

    Step 6: Insert and align the TF27-T support rail Figure 64 Insert the support rail Figure 65 Align the support rail Figure 66 Close the clamp Figure 67 Mount support rail Step 7A: Affix the TRAPEZOIDAL CLAMP to the outer roofing with blind rivets Attention! A drill with a diameter of 5.0 mm is mandatory to maintain static properties!

  • Page 49: Figure 71 Apply The Screw

    Step 7B: Affix the TRAPEZOIDAL CLAMP to the outer roofing with self drilling screws • When using the self drilling screws, two screws are placed per TRAPEZOIDAL CLAMP. In this process, make sure you screw carefully to maintain static properties. The self drilling screws are tightened until the seal swells out a little. •...

  • Page 50: Figure 75 Rivet Transverse Securing Clamps

    • Now insert the 4.8x15mm blind rivets into the bores and rivet. Figure 75 Rivet transverse securing clamps Step 8B: Insert and affix the transverse securing clamp with self drilling screws • The transverse securing clamps are affixed next to the trapezoidal clamp on the left and right with a clearance of approximately 20 mm.

  • Page 51: Trapezoidal Support

    Step 9: If required: Insert butt connector • Butt connectors are inserted via the TF27 support rail and fixed. • The butt connector is either attached using two 4.8x15 mm blind rivets (pre-drilling) or two 5.5x25 mm self drilling screws. Figure 77 Insert butt connectors Figure 78 Joining together the support rails 5.9.5 Trapezoidal support...

  • Page 52: Figure 80 Mark The Position Of The Bottom Support In The Grid Spacing

    Step 2: Position of the Bottom Support It is recommended to maintain the AeroFix standard grid spacing from the front edge Bottom Support to the front edge next Bottom Support. These are as follows. • AeroFix 15-S 1,8 m (variable 1,62 m – 1,98 m) •...

  • Page 53: Figure 83 Distance Aerofix 15-S Supports

    Setp 4: Distance Bottom Support / Top Support Figure 83 Distance AeroFix 15-S supports Distance between supports AeroFix 15-S Module width Distance x 950 mm 715 mm 960 mm 725 mm 970 mm 736 mm 980 mm 746 mm 990 mm 756 mm 1000 mm 767 mm...

  • Page 54: Figure 84 Distance Aerofix 10-S Supports

    Figure 84 Distance AeroFix 10-S supports 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 1000 mm 813 mm 1010 mm 823 mm 1020 mm 833 mm...

  • Page 55: Figure 85 Distance Aerofix 10-Ew Supports

    Figure 85 Distance AeroFix 10-EW supports Distance between supports AeroFix 10-EW 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 1010 mm 823 mm 1020 mm 833 mm...

  • Page 56: Figure 86 Fasten Top Support With Two Screws And Rhombus Nuts

    Step 5: Mounting Top Support For easier installation, the screws with the rhombus nuts shoud be mounted on the support before. Figure 86 Fasten Top Support with two screws and rhombus nuts Figure 87 Mounted Top Support Version: 23.01 As of: 01/2023 Page 56 from 119...

  • Page 57: Figure 88 Insert The Module In The Bottom Support And Top Support

    Step 6: Module assembly The procedere for the module assembly is identical for all supports. Figure 88 Insert the module in the Bottom Support and Top Support Figure 89 The module must rest against the Top Support (with wind plate-end) Version: 23.01 As of: 01/2023 Page 57 from 119...

  • Page 58: Figure 90 Module At The Stop Of The Top Support And Clamped

    Figure 90 Module at the stop of the Top Support and clamped Figure 91 Mounted modules Version: 23.01 As of: 01/2023 Page 58 from 119...

  • Page 59: Figure 92 Wind Plate Assembly Starting From The Left

    Step 7: Wind plate assembly The system is not wind tunnel tested. The wind plate is therefore not mandatory. However, it is still recommended to use it. The suction loads can thus be reduced. 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 TF27 rail with screw M8x16.

  • Page 60: Figure 93 Insert Wind Plate

    Figure 93 Insert wind plate Figure 94 Fixed wind plates within the row Version: 23.01 As of: 01/2023 Page 60 from 119...

  • Page 61: Figure 95 Fixed Wind Plate On The Top Support At The Beginning / Ending Of The Row

    Figure 95 Fixed wind plate on the Top Support at the beginning / ending of the row Version: 23.01 As of: 01/2023 Page 61 from 119...

  • Page 62: Trapezoidal System Eco 340Mm & 430Mm

    5.9.6 Trapezoidal System Eco 340mm & 430mm The Trapezoidal System Eco 340mm & 430mm is a pre-assembled, short-rail system to which trapezoidal profiles are riveted or scrwed together. • Trapezoidal System Eco 340 mm: raised bead distance 207 - 250 mm •...

  • Page 63: Figure 97 Removing The Protective Foil

    Step 4: Affixing the "Trapezoidal System Eco 340mm & 420mm" Information The heavy-duty adhesive tape can be used from an object and working temperature of 0° C; final adhesion occurs after approx. 72 h at an ambient temperature of 20° C. The higher the temperatures, the faster this process is complete. We do not recommend to bond surfaces below these temperatures as the adhesive agent may become too hard and prevent adequate adhesion.

  • Page 64: Figure 100 Drilling Clamps

    Step 6A: Affix " Trapezoidal System Eco 340mm & 420mm" to the outer roofing with blind rivets Attention! A drill with a diameter of 5.0 mm is mandatory to maintain static properties! • When using the rivets drill two bores with a diameter of 5.0 mm per "clamp base". In this process, make sure you drill carefully to maintain static properties.

  • Page 65: Figure 105 Aligning Pv Modules

    Information Positive-Locking-Clamps do not have to be used because the carrier profile is plastically deformed at the end. Figure 105 Crimping trapezoidal system Eco 350 or 420 Step 7: Alignment of PV modules Figure 106 Aligning PV modules Version: 23.01 As of: 01/2023 Page 65 from 119...

  • Page 66: Trapezoidal System Eco 120 Mm

    5.9.7 Trapezoidal System Eco 120 mm Step 1: Dimensioning using "PV Manager" Step 2: Mark the fixing points of the Trapezoidal System Eco 120mm Figure 107 Marking fixing points Step 3: Clean the roofing Exclusively clean the roofing in areas where you intend to affix trapezoidal clamps at a later point. The surfaces must be dry and free from grease, oil or silicone as well as dirt particles to safeguard optimum integrity.

  • Page 67: Figure 109 "Trapezoidal System Eco 120Mm " Distributed As Specified

    Step 5: Distributing the " Trapezoidal System Eco 120mm" as specified Figure 110 "Trapezoidal System Eco 120mm " distributed as specified Step 6: Affix " Trapezoidal System Eco 120mm" to the outer roofing with self drilling screws • When using the self drilling screws, two screws are placed per “clamp base”. In this process, make sure you screw carefully to maintain static properties.

  • Page 68: Figure 112 Place The Clamps On The Center Of The Trapezoidal Tystem Eco 120Mm

    Step 7: Alignment of PV Modules Figure 113 Place the clamps on the center of the Trapezoidal System Eco 120mm Figure 114 Aligning PV modules Version: 23.01 As of: 01/2023 Page 68 from 119...

  • Page 69: Installation Of Sheet Seam Clamps

    5.10 Installation of sheet seam clamps Special fastening elements are used to fasten PV modules on standing seam roofs, which are then attached to the support rails or module clamps. The roofing must not be damaged by the load on the installed clamps. For this reason, we recommend having sheet seam clamps fitted by a roofing company.The tightening torque of the sheet seam clamp must be limited in such a way that the sheet metal is not deformed and the thermal expansion of the sheets is not hindered.

  • Page 70: Installation Of Kalzip® Clamps

    5.11 Installation of Kalzip® clamps Use "Kalzip® clamps" to fasten the system on so-called Kalzip® roofs. The clamps are distributed vertically according to the number of cross girders. As a rule, fit one standing seam to each clamp. On each side the support rail must protrude by a maximum of 0.4 m. Figure 119 Kalzip®...

  • Page 71: Fitting Support Rails

    6. Fitting support rails • Insert the pre-assembled securing screw (M10 connection piece for roof hook profile) through the roof hook slot. Rotate by 90° and insert into the mounting groove of the e.g. TF50+ support rail. Connect TF50+ support rail to the roof hooks at the required height and tighten the screw.

  • Page 72: Figure 122 Butt Connector Tf50+ / Tf50+M Inside

    The ends of the rows must be aligned at an exact right angle (90°) to the bottom rail, as otherwise it will not be possible to align the joints between the modules. • Once the carrier rails have been aligned, re-tighten IBC SOLAR AG screws to the corresponding tightening torque and re-check. Version: 23.01...

  • Page 73: Fitting Pv Modules

    7. Fitting PV modules The middle and outer clamp are delivered pre-assembled. The middle clamp G3 covers a clamping area of 30-50 mm. The outer clamp G3 must be ordered for each module height. G3 Middle and outside clamp The middle clamp G5 covers a clamping area of 30-40 mm. The EC adapter 30-40 mm is installed with the middle clamp G5 and Secure clip for EC adapter / cable guide and replaces the traditional outer clamp.

  • Page 74: Figure 127 Inserting Middle Clamps G3

    • The middle and outside clamps can be inserted into the carrier rail directly from the top, into the position where they are required. Figure 128 Inserting middle clamps G3 • The middle clamps G5 can be inserted into the supports directly from above where required. Figure 129 Inserting the middle clamp G5 Version: 23.01 As of: 01/2023...

  • Page 75: Figure 129 Ec Adapter 30-40 Mm With Middle Clamp G5 And Secure Clip

    • The adaptor EC 30-40 mm is clamped by the given frame height with the middle clamp G5 and substitutes thus the end clamp. Secure clip for EC adapter / cable guide fixes the AK adapter to the middle clamp G5.. Figure 131 EC adapter 30-40 mm frame hights Figure 130 EC adapter 30-40 mm with middle clamp G5 and secure clip...

  • Page 76: Fitting Cable Clips

    The cable clips are used to fix the module connector cables and prevent sagging of the cable. The clips can be clamped to the carrier rails of the mounting system TopFix 200 or to the photovoltaic module frames without any tools. Figure 132shows the attachment of the cable clips 0°...

  • Page 77: Fitting The Two-Layer Carrier System

    9. Fitting the two-layer carrier system 9.1 General information In contrast to single-layer carrier rails, this method additionally employs carrier rails as so-called roof hook connecting rails before the actual carrier rail is fitted. 9.2 Roof hook connecting support profiles e.g. type TF50+ Figure 136 Roof hook connecting support profiles and support profiles as a unit Description Support rail length =...

  • Page 78: Figure 136 Cross Section Of A Two-Layer System Structure

    Two-layer systems are dimensioned in the same way as single-layer systems. However, the following special features must be taken into account: • A two-layer connector must be plannes for each intersection of roof hook connection rail and support profile.. • Please also take into account the static values of roof hook connecting rails in addition to the roof hooks and carrier profiles.

  • Page 79: Delta Support

    10. Delta support 10.1 General information Delta supports enable to use the IBC TopFix 200 mounting system as an elevated mounting system and achieve optimum module inclination. Delta supports are available with single as well as continuous base rails. Inclination angles between 10° and 45° can be adjusted in 5°...

  • Page 80: Assembly

    10.2 Assembly Assembling Delta supports Figure 140 Assembling Delta supports at the base rails Delta supports is supplied dissasembled, including three M8×50 hex screws with self-locking nut and tube sleeves. When assembling, all screw connections must be tightened to 15 Nm. Only by the Delta support with continuous base rail, the 12.5mm holes in the base rail must be drilled on site in the centering groove.

  • Page 81: Connection To The Roof

    10.3 Connection to the roof We offer the following connection types to connect Delta supports, depending on the available roof seal and roof substructure: • Fixation by hanger bolt • Fixation by universal connector • Fixation by additional weight (e.g. positioning walkways, etc.) •...

  • Page 82: Figure 142 Fixation By Universal Connector

    Figure 143 Fixation by universal connector Figure 144 Two--layer fixation (two-layer connector) Version: 23.01 As of: 01/2023 Page 82 from 119...

  • Page 83: Mounting Modules

    10.4 Mounting modules Modules can be mounted either horizontally or vertically using Delta supports. Modules up to a module size of 1.7 m can are suitable for vertical mounting. • Vertical module – clamps on the long sides In this case, Delta supports are connected using two support rails (TF50+/TF50+m/TF60).

  • Page 84: Insertion System

    11 Insertion system 11.1 General The same conditions and prerequisites apply as described in section 5.1 General dimensioning information. The insertion rail is always mounted horizontally. On tiled roofs the insertion system is built as a 2 layer system. Therefore, only roof hooks can be used where the roof connector rail can be mounted from ridge to eaves. For a better water drainage ≤Ø5 mm holes may be drilled in the insertion rails.

  • Page 85: Figure 148 Roof Connector Rail Assembly

    Step 3: Roof connector rail • Mount and extend the profiles as shown in chapter 6. Fitting carrier rails • Align the other rails with each other by means of a cord. Figure 149 Roof connector rail assembly Figure 150 Butt connector for carrier rail TF50+ Version: 23.01 As of: 01/2023 Page 85 from 119...

  • Page 86: Figure 150 Insertion Rails Distance: Module Length / -Width + 10 Mm, Or Module Length / Width - 64 Mm

    Step 4: Insertion rail distances and assembly jig Attention! Position the legs of the insertion rails as shown in Figure 151 in relation to the roof pitch. Figure 151 Insertion rails distance: Module length / -width + 10 mm, or module length / width - 64 mm Figure 152 Adjusting the assembly jig Attention! The dimension set on the assembly jig does not correspond to the real length.
  • Page 87 Figure 153 Positioned assembly jig Figure 154 Detail position assembly jig bottom, analog top Version: 23.01 As of: 01/2023 Page 87 from 119...
  • Page 88 Step 5: Two-layer connector • The two-layer connector is mounted on the top and bottom insertion profile only on the inside. All other insertion profiles are fitted with a two-layer connector on both sides. Figure 155 Position two-layer connector Figure 156 Two-layer connector Figure 157 Side view two-layer connector Version: 23.01 As of: 01/2023...
  • Page 89 Step 6: Butt connector • The butt connector is screwed from below with 4 t-head screws to the insertion rail. • A small gap between the insertion rails can be left for a better water drainage. Attention! Ensure that all t-head screws have turned in the rail and are therefore completely engaged. The insertion rail pieces must be fastened to at least two support points before a butt connector may be installed.
  • Page 90 Step 7: Module frame height and adapter rail • At 40 mm module frame height, no adapter rail is required • The adapter rail is inserted into the insertion rail only at module frame heights of 38, 35, 33, 32, 31 and 30 mm at the corresponding position.
  • Page 91 Step 8: Insert module • The modules are inserted diagonally into the upper insertion rail, placed on the lower insertion rail and pushed down to the stop. Figure 162 Insert module Figure 163 Put down module Figure 164 Slide module into position Version: 23.01 As of: 01/2023 Page 91 from 119...
  • Page 92 Step 9: Spacer / protection against theft • The spacer is inserted at the top between the module and the insertion rail • A ratting of the modules by wind is prevented, bacaus the modules are easily clamped. • An illegal removal of the modules is prevented. •...
  • Page 93 Step 10: Side plate • The side plate is fixed to the insertion rail with 2 sheet metal svrews 4.8x19. • Holes in the side plate allow a drainage of water Figure 168 Side plate Figure 169 Mounted side plate Version: 23.01 As of: 01/2023 Page 93 from 119...
  • Page 94 Step 11: End cover • The end cover is clicked into the top and bottom insertion rail. If modules are missing within the module field, end covers are also installed here. Figure 170 Attach the end cover and click in Figure 171 Mounted end cover at the bottom Figure 172 Mounted end cover at the top Version: 23.01...

  • Page 95: Bill Of Materials

    12. Bill of materials Illustration Item no.: Item 6800100043 Support Rail TF50+, 5500mm 6800100044 Support Rail TF50+, 5500mm black 6800100045 Support Rail TF50+, 3300mm 6800100046 Support Rail TF50+, 2250mm 6800100047 Support Rail TF50+, 2250mm black 6800100062 Support Rail TF50+, 5850mm 6800100063 Support Rail TF50+, 5850mm black 6800100064...
  • Page 96 Illustration Item no.: Item 6800100053 Support Rail TF27-T, 5500mm 6800100054 Support Rail TF27-T, 3300mm 6800100055 Support Rail TF27-T, 2250mm 6800100072 Support Rail TF27-T, 5850mm 6800100073 Support Rail TF27-T, 3550mm 6800100074 Support Rail TF27-T, 2380mm 6800100034 Insertion Rail, 5010mm black 6800100038 Insertion Rail, 2010mm black 6800100058 Insertion Rail, 5715mm black...
  • Page 97 Tapping Screw 4.8x19 black Middle Clamp G3 6700400125 Middle Clamp G3 30-50mm 6700400126 Middle Clamp G3 30-50mm black End Clamp G3 IBC TopFix 200 6700400170 End Clamp G3 30mm 6700400171 End Clamp G3 30 mm black 6700400127 End Clamp G3 31 mm...
  • Page 98 Illustration Item no.: Item 6700400134 End Clamp G3 40 mm 6700400135 End Clamp G3 40 mm black 6700400136 End Clamp G3 42 mm 6700400137 End Clamp G3 42 mm black 6700400138 End Clamp G3 45 mm 6700400139 End Clamp G3 45 mm black 6700400140 End Clamp G3 46 mm 6700400141...
  • Page 99 Illustration Item no.: Item 6700100032 Roof Hook Standard S+ 35mm 6700100027 Roof Hook Mammut S+ 6700100028 Roof Hook Mammut SV+ 6700100029 Roof Hook Vario S+ 6700100030 Roof Hook Plain Tile S+ Version: 23.01 As of: 01/2023 Page 99 from 119...
  • Page 100 Illustration Item no.: Item 6700100031 Roof Hook Slate S+ 6700100041 Roof Hook Mammut XL S+ 6700700037- Mammut Form S+ roof hook 6700700040 & Includes: 6700700042- 1x roof hook with sheet metal tile 6700700050 1x reinforcing runner & 3x 4.2x32 mm drilling screw 6700700052- (tallow-drop screw, galvanised, AW 20) 6700700099...
  • Page 101 Illustration Item no.: Item 6700700100 Form S+ exchange screw for rafter-mounted insulati 6700100045 Roof Hook Alu-Vario Eco S+ 6700100038 Roof Hook Alu-Mammut S+ 6700100039 Roof Hook Alu-Mammut SV+ Trapezoidal sheet clamp 6700200036 Without accessories Trapezoidal System Eco, 340 mm 6700200037 Without accessories Trapezoidal System Eco, 420 mm 6700200038...
  • Page 102 Illustration Item no.: Item Hanger bolt M12x300 A2 SW9 Including 6700200041 1x EPDM seal 3x M12 A2 self-locking nuts → completely pre-assembled Hanger bolt M12x250 A2 SW9 Including 6700200045 1x EPDM seal 3x M12 A2 self-locking nuts → completely pre-assembled Hanger bolt M10x200 A2 SW7 Including 6700200026...

  • Page 103: Figure 133 Cable Clip Mc4-Plug

    Illustration Item no.: Item Mounting plate duo TopFix 200 6700300050 Including screws + universal connector Mounting plate duo TopFix 200 6700300051 Including Connecting Connection Piece M10 6700200049 Universal Metal Seam Clamp G2 Original Kalzip® clamp 6700200027 Including universal connector 6101100027 Cable clip 0°...
  • Page 104 Illustration Item no.: Item Delta-Stütze, single 6100300024 Delta support, 10°, single 6100300025 Delta support, 15°, single 6100300026 Delta support, 20°, single 6100300027 Delta support, 25°, single 6100300028 Delta support, 30°, single 6100300029 Delta support, 35°, single 6100300030 Delta support, 40°, single 6100300031 Delta support, 45°, single Delta support, continuous...
  • Page 105 Illustration Item no.: Item 6800900014 Base Rail D-S, 4900mm Butt connector TF50+ / TF50+m inside 6700300066 Including 1x leaf spring for potential equalization Butt connector TF60 6700300044 Including 2x M10x25 A2 T-head screws 2x DIN 6923 M10 A4 locking nuts Butt connector TF27-T 6700300058 Without accessories...
  • Page 106 Illustration Item no.: Item Two-layer connector 6700300037 → completely pre-assembled Rail end cap 6700300041 for TF50+ and TF50+m Rail end cap black 6700300061 for TF50+ and TF50+m Rail end cap 6700300045 for TF60 6900300022 Flange Head Screw 6x100 A2 6900300008 Flange Head Screw 8 x 100 A2 6900300010 Flange Head Screw 8 x 140 A2...
  • Page 107 Illustration Item no.: Item 6908300003 Blind Rivet 4.8x15 6900600011 Self-Drilling-Screw 5.5x25 6700300032 Connection Piece M10 6700300053 Connection Piece M8 Universal Connection Piece 6700300033 TX40 or SW 13 6700200013 Clamp for equipotential bonding Top Support 6101100042 Also used in AeroFix 10-EW with wind plate beginning and ending.
  • Page 108 Illustration Item no.: Item 6101100046 Top Support 6101100047 Bottom Support Wind plate 6101100016 Also used in AeroFix 10-EW with wind plate beginning and ending. 6101100019 Wind plate Assembly jig 6000300021 AeroFix G3 & insertion system TopFix200 Figure 173 Bill of materials Version: 23.01 As of: 01/2023 Page 108 from 119...

  • Page 109: Appendix

    13 Appendix 13.1 Notes on IBC TopFix 200 The tightening torques for the screw connections used in the IBC TopFix200 mounting system must be dimensioned in accordance with DIN ISO 3506, to document and archive for 10 years. Due to the difficulty in determining the outdoor friction coefficients, dimensioning in accordance with DIN ISO 3506 can prove difficult.
  • Page 110 Required rafter and purlin dimensions Comply with the following minimum dimensions for rafters and purlins as per EN 1995-1-1. Figure 175 Minimum distance and required timber component dimensions The minimum rafter/purlin height must be 100 mm. The minimum distance between fastened flat head screws and the edges of rafters and purlins must be three times the flat head screw diameter.

  • Page 111: Weights/Installation Times For Pitched Roof Installations

    13.2 Weights/installation times for pitched roof installations Weight per m² of module surface Weight per kWp Thin-film solar modules 10 … 17 kg/m² 130 … 300 kg/kWp Crystalline solar modules 11 … 21 kg/m² 70 … 175 kg/kWp Single-layer mounting system *2,4 …...

  • Page 112: Documents

    13.4 Documents ☐ AeroFix ☐ AeroFlat Wartungsprotokoll ☒ TopFix 200 Maintenance log TopFix 200 AeroFix AeroFlat Kommission: …………..……..…………………………… Commission: Standort: …………..……..…………………………… Place: i.O. n.i.O. not Ok Anlage befindet sich in einem optisch einwandfreien Zustand und laut Montageplan auf korrekter Position ☐...
  • Page 113 Wartung wurde durchgeführt von Maintenance was carried out by Firma: Person: Company: …………..……..………………………………………..…….. Person: …………..……..………………………………………..…….. Die Wartungsarbeiten sind durch eine Fachfirma, die Erfahrung mit elektrischen Anlagen und Arbeiten mit dem Montagesystem vorweisen kann, auszuführen. The maintenance work must be carried out by a technical company that has experience with electrical systems and works with the mounting systems.
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