IBC SOLAR TopFix 200 Installation Manual Download

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Version: 23.01

As of: 01/2023

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Summary of Contents for TopFix 200

Page 1: ...Instalation manual TopFix 200 IBC SOLAR AG Version 23 01 As of 01 2023...

Page 2: ...3 7 Schiefer S roof hook 26 5 3 8 Plain tile S roof hook 27 5 3 9 Alu Vario Eco S roof hooks 28 5 3 10 Alu Mammut S roof hooks 29 5 3 11 Alu Mammut SV roof hooks 30 5 4 ASD screws Mounting on rafter...

Page 3: ...ting support rails 71 7 Fitting PV modules 73 8 Fitting cable clips 76 9 Fitting the two layer carrier system 77 9 1 General information 77 9 2 Roof hook connecting support profiles e g type TF50 77 1...

Page 4: ...S slate tile roof hook 26 Figure 24 Parameters roof hook Schiefer S 26 Figure 25 Biber S plain tile roof hook 27 Figure 26 Depression for Biber S 27 Figure 27 parameters roof hook Biber S 27 Figure 28...

Page 5: ...gure 72 Trapezoidal clamp screwed 49 Figure 73 Insert transverse securing clamps 49 Figure 74 Drilling transverse securing clamps 49 Figure 75 Rivet transverse securing clamps 50 Figure 76 Screwed tra...

Page 6: ...ide blue and leaf spring for potential equalization red 72 Figure 125 Join the second support profile together 72 Figure 126 Assembled clamps sectional view 73 Figure 127 Inserting middle clamps G3 74...

Page 7: ...nsertion rail 89 Figure 159 Possible module frame heights 90 Figure 160 Insertion system adapter rail 90 Figure 161 Insert module 91 Figure 162 Put down module 91 Figure 163 Slide module into position...

Page 8: ...l 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 br...

Page 9: ...lumb line Angle grinder with diamond cutting disc Torx screwdriver with T grip size TX40 TX30 TX25 socket SW8 SW10 Torque wrench Assembly gloves Assembling jig Section 5 9 2 Required tools auxiliary a...

Page 10: ...f the current installation manual is available on the construction site Other important information and dimensioning standards The entire PV system must be mounted according to the generally recognize...

Page 11: ...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 DIBt building regulation list in the curre...

Page 12: ...urrent requirements for DIN VDE 0185 part 1 to 4 DIN VDE 0100 part 712 and VdS 2010 For more detailed information please refer to the local regulations and the aforementioned standards and guidelines...

Page 13: ...r 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 Th...

Page 14: ...ent of the mounting system and the modules on the roof The most common option is to horizontally assemble type e g TF50 support rails and arrange solar modules vertically For this reason any further m...

Page 15: ...transparency Description A Solar moduel B Roof hooks C Rafters D Module clamp E TF50 TF50 m TF60 support rail F M10x25 A2 T head screw and M10 A4 hexagon nut with locking teeth Figure 2 Fastenings for...

Page 16: ...m MB Module width MH Module hight n Number of modules A TF50 TF50 m TF60 support rail B Roof hook C Middle clamp D Outside clamp E max 400 mm X X selected fixing interval dimensioned using PV Manager...

Page 17: ...ure of the building must be checked for sufficient stability The wooden substructure must have a service life of more than 20 years In case of doubt consult a roofer or joiner and a civil engineer As...

Page 18: ...the roof hook in the depression in the pantile and align it centrally Screw the roof hook to the rafter using two offset flat head screws There is no need to drill holes beforehand Observe edge dista...

Page 19: ...e installation site is in a high snow load zone the use of sheet metal supports or tin tiles is recommended The guidelines of the roofing manufacturer must be observed The securing screws in the rafte...

Page 20: ...mm Dimensions base plate length width height 135 70 4 mm Dimensions hook width height 30 6 mm Drilling holes baseplate 10 x 9 mm Drilling holes hook Slot 11 mm L 30 mm Hook distance from the base plat...

Page 21: ...es hook Slot 11 mm L 30 mm Hook distance from the base plate 35 mm weight 0 820 kg General construction approval Z 14 4 661 Maximum ch load roof hook kN Calculation via PV Manager Accessories flat hea...

Page 22: ...ss steel 1 4307 S275 S460 yield strength Stirrup fy k 460 N mm Ground plate 275 N mm Dimensions base plate length width height 135 70 4 mm Dimensions hook width height 35 6 mm Drilling holes baseplate...

Page 23: ...nless steel 1 4307 S275 S355 yield strength Stirrup fy k 350 N mm Ground plate 275 N mm Dimensions base plate length width height 135 70 5 mm Dimensions hook width height 35 8 mm Drilling holes basepl...

Page 24: ...ook width height 35 6 mm Drilling holes baseplate 10 x 9 mm Drilling holes hook Slot 11 mm L 30 mm Hook distance from the base plate 45 mm weight 1 02 kg General construction approval Z 14 4 661 Maxim...

Page 25: ...m Drilling holes hook Slot 11 mm L 30 mm Hook distance from the base plate 42 mm 55 mm weight 1 355 kg General construction approval Z 14 4 661 Maximum ch load roof hook kN Calculation via PV Manager...

Page 26: ...gth width height 280 30 6 mm Dimensions hook width height 30 6 mm Drilling holes baseplate 3 x 8 5 mm Drilling holes hook Slot 11 mm L 30 mm Hook distance from the base plate Not specified weight 0 55...

Page 27: ...ng holes baseplate 10 x 9 mm Drilling holes hook Slot 11 mm L 30 mm Hook distance from the base plate 45 mm weight 0 97 kg General construction approval Z 14 4 661 Maximum ch load roof hook kN Calcula...

Page 28: ...height 30 6 mm Drilling holes baseplate 10 x 9 mm Drilling holes hook Slot 11 mm L 30 mm Hook distance from the base plate 45 mm weight 0 97 kg General construction approval Z 14 4 661 Maximum ch loa...

Page 29: ...ok width height 35 6 8 mm Drilling holes baseplate 10 x 7 mm Drilling holes hook Slot 9 mm L 25 mm Hook distance from the base plate 46 mm weight 0 367 kg General construction approval Z 14 4 515 Maxi...

Page 30: ...9 mm 3 x 9 x 14 mm 2 x 9 x 19 mm Drilling holes hook Slot 8 5 mm L 26 5 mm Hook distance from the base plate 46 mm weight 0 455 kg General construction approval Z 14 4 515 Maximum ch load roof hook kN...

Page 31: ...r battens By the customer it must be proofed that the corresponding counter battens are fastend to the substructure so that the additional loads can be absorbed and the function of the insulation is n...

Page 32: ...e required to fasten one roof hook Each roof hook connection must additionally be secured by a ASD countersunk screw to absorb sliding transverse forces at an angle of 60 Figure 36 Inserting flat head...

Page 33: ...0 Information Superficial damage to the surfaces scratches that affect neither static nor anti corrosion properties of the roof hook shall not be accepted as a valid reason for complaints IBC SOLAR AG...

Page 34: ...rail Secure the reinforcing runner using one screw 4 screw may alternatively be fastened from the top Remove the roof hook once again and fasten the reinforcing runner to the rafter using screws 5 5...

Page 35: ...crew 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 Overvie...

Page 36: ...Secure roof hooks to the roofing substructure using screws 2 3 In accordance with the valid specialist professional code and directives governing flat roofs set out by the association of German roofe...

Page 37: ...Form S roof hooks on plain tile roofing Installation is as described in chapter 5 5 1 Fitting Mammut Form S roof hooks The beaver bricks lying above must be processed Figure 45 Mammut Form S plain ti...

Page 38: ...that this can be fastened with the screws in the rafter Observe the edge distances according Figure 175 Replace the slate plate with an individual manufactured metal plate 1 Not necessary for metal s...

Page 39: ...n 23 01 As of 01 2023 Page 39 from 119 Step 3 Step 4 Fix the cover cap 4 and the roof hook 5 at the mountig plate with the M6 nuts 6 torque 10 Nm Figure 49 Cover cap and roof hook Figure 50 Roof hook...

Page 40: ...tted by a roofing company Please also observe the guidelines and regulations of the manufacturer of the respective roofing Proceed as follows during mounting Do not drill into the water bearing depres...

Page 41: ...for a use of corrugated eternit panels Exceeding the fixing distance has a detrimental effect on static values The calculation in the PV Manager software is based on a fixing distance of l 100 mm Att...

Page 42: ...Drill 11 mm bores into the outer roofing sheet metal Depending on the thickness of the steel drill into the metal substructure accordingly to fasten the solar fasteners For this purpose take into acc...

Page 43: ...ess around the fasteners is 0 4 mm for steel and 0 5 mm for aluminum The nominal width of the outer layer of the sandwich element around the fasteners is 0 4 mm The nominal width of the steel substruc...

Page 44: ...ofiles TF50 and TF50 m on the other hand a universal connector and additional screws for fixing the universal connector are required in accordance with Figure 58 For fixing a TF60 profile only a RH pr...

Page 45: ...itional loads are created by the PV system in connection with the IBC mounting system and fixing points fixed points and wind suction the installer contractor has to check the statics of the load capa...

Page 46: ...he clamp 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...

Page 47: ...ratures do not normally create any problems Prevent the formation of condensation to safeguard appropriate adhesive properties Condensate can form if for example the materials to be connected have hig...

Page 48: ...of 5 0 mm per TRAPEZOIDAL CLAMP In this process make sure you drill carefully to maintain static properties Now insert the 4 8x15mm blind rivets into the bores and rivet The enclosed 4 8x15 mm blind...

Page 49: ...Pre drilling of the trapezoidal sheet is not permitted Step 8A Insert and affix the transverse securing clamp with blind rivets The transverse securing clamps are affixed next to the trapezoidal clam...

Page 50: ...rse 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 There must be a mini...

Page 51: ...listed in 5 9 4 and the AeroFix supports The modules can only be installed landscape Attention The system is not wind tunnel tested and must be verified on site by a structual engineer A static calcul...

Page 52: ...t These are as follows AeroFix 15 S 1 8 m variable 1 62 m 1 98 m AeroFix 10 S 1 6 m variable 1 44 m 1 76 m AeroFix 10 EW 2 3 m not variable Step 3 Fasten Bottom Support For easier installation the scr...

Page 53: ...Top Support 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 1010 mm 777 mm 1020 mm 787 mm 1030 mm 79...

Page 54: ...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 1030 mm 843 mm 1040 mm 854 mm 1...

Page 55: ...etween 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 1030 mm 843 mm 1040 mm 854 mm 1...

Page 56: ...ge 56 from 119 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...

Page 57: ...om 119 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 again...

Page 58: ...Version 23 01 As of 01 2023 Page 58 from 119 Figure 90 Module at the stop of the Top Support and clamped Figure 91 Mounted modules...

Page 59: ...iously mounted plate and mount onto the next support Ensure that the lateral tabs clasp the wind plate Screw both plates onto the TF27 rail The gap between screw and end of the TF27 rail should be at...

Page 60: ...Version 23 01 As of 01 2023 Page 60 from 119 Figure 93 Insert wind plate Figure 94 Fixed wind plates within the row...

Page 61: ...Version 23 01 As of 01 2023 Page 61 from 119 Figure 95 Fixed wind plate on the Top Support at the beginning ending of the row...

Page 62: ...p 2 Mark the fixing points of the clamp 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...

Page 63: ...ese temperatures as the adhesive agent may become too hard and prevent adequate adhesion After adhesion has taken place low temperatures do not normally create any problems Prevent the formation of co...

Page 64: ...uminum thickness of between 0 5 mm and 1 5 mm Step 6B Affix Trapezoidal System Eco 340mm 420mm to the outer roofing with self drilling screws When using the self drilling screws two screws are placed...

Page 65: ...119 Information Positive Locking Clamps do not have to be used because the carrier profile is plastically deformed at the end Step 7 Alignment of PV modules Figure 106 Aligning PV modules Figure 105 C...

Page 66: ...g Attention Please observe the safety regulations when handling solvents and chemicals Step 4 Affix the Trapezoidal System Eco 120mm Information The heavy duty adhesive tape can be used from an object...

Page 67: ...carefully to maintain static properties The self drilling screws are tightened until the seal swells out a little The enclosed self drilling screws 5 5x25 are approved for a sheet metal or aluminum t...

Page 68: ...Version 23 01 As of 01 2023 Page 68 from 119 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...

Page 69: ...m or the spezifications of the respective sheet seam manufactures Attention Clarify on site whether the roof and the substructure are able to withstand the additional forces caused by installing the P...

Page 70: ...ble PV plants on Kalzip roofs the roof must not only carry the additional loads it must also withstand the additional wind dynamics A structural engineer must check the number of fixing points Kalzip...

Page 71: ...the recess Start with the top or the bottom support rail Align the screws with the fixing points e g roof hooks and secure them See Figure 122 Align the other support rails with each other by means of...

Page 72: ...roofs Any carrier rails installed above each other must be in parallel For this purpose align the top or the bottom carrier rail horizontally first The ends of the rows must be aligned at an exact rig...

Page 73: ...p and EC adapter 30 40 mm Information Depending on the height of the module frame a different version of the outer clamp G3 will be required The EC adapter 30 40 mm for G5 middle clamp covers only the...

Page 74: ...s can be inserted into the carrier rail directly from the top into the position where they are required The middle clamps G5 can be inserted into the supports directly from above where required Figure...

Page 75: ...align the module You may also use a piece of string to facilitate alignment Then tighten the clamps to the tightening torque specified in Figure 175 in the Appendix For this purpose we recommend using...

Page 76: ...d 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 at the PV module frame In Figure 133...

Page 77: ...e TF50 Description L MB 20 mm n 48 mm Support rail length MB 24 mm number of modules per row 32 mm L2 MH 20 mm n2 20 mm Roof hook support rail length MH 20 mm number of module rows 20 mm MB Module wid...

Page 78: ...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 Use...

Page 79: ...ix 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...

Page 80: ...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 The hole spacing within the Delta support is 1290mm The row spacin...

Page 81: ...pports 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 Fixation by trapezo...

Page 82: ...Version 23 01 As of 01 2023 Page 82 from 119 Figure 143 Fixation by universal connector Figure 144 Two layer fixation two layer connector...

Page 83: ...sides In this case Delta supports are connected using two support rails TF50 TF50 m TF60 Modules are then mounted on said support rails Please ensure that the modules have been approved for clamping o...

Page 84: ...nly roof hooks can be used where the roof connector rail can be mounted from ridge to eaves For a better water drainage 5 mm holes may be drilled in the insertion rails The load capacity of the insert...

Page 85: ...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 Fi...

Page 86: ...ition the legs of the insertion rails as shown in Figure 151 in relation to the roof pitch Attention The dimension set on the assembly jig does not correspond to the real length Figure 151 Insertion r...

Page 87: ...Version 23 01 As of 01 2023 Page 87 from 119 Figure 153 Positioned assembly jig Figure 154 Detail position assembly jig bottom analog top...

Page 88: ...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 co...

Page 89: ...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...

Page 90: ...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 positio...

Page 91: ...19 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 mo...

Page 92: ...ratting of the modules by wind is prevented bacaus the modules are easily clamped An illegal removal of the modules is prevented Note the gap between the modules in module installation manual 10 mm g...

Page 93: ...2023 Page 93 from 119 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...

Page 94: ...nd 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 Mou...

Page 95: ...Support Rail TF50 5850mm black 6800100064 Support Rail TF50 3550mm 6800100065 Support Rail TF50 2380mm 6800100066 Support Rail TF50 2380mm black 6800100048 Support Rail TF50 m 5500mm 6800100049 Suppo...

Page 96: ...TF27 T 3550mm 6800100074 Support Rail TF27 T 2380mm 6800100034 Insertion Rail 5010mm black 6800100038 Insertion Rail 2010mm black 6800100058 Insertion Rail 5715mm black 6800100059 Insertion Rail 2280m...

Page 97: ...ck End Clamp G3 IBC TopFix 200 6700400170 End Clamp G3 30mm 6700400171 End Clamp G3 30 mm black 6700400127 End Clamp G3 31 mm 6700400128 End Clamp G3 31 mm black 6700400165 End Clamp G3 32mm 670040016...

Page 98: ...8 End Clamp G3 45 mm 6700400139 End Clamp G3 45 mm black 6700400140 End Clamp G3 46 mm 6700400141 End Clamp G3 46mm black 6700400142 End Clamp G3 50 mm 6700400143 End Clamp G3 50 mm black 6700400172 M...

Page 99: ...of 01 2023 Page 99 from 119 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 Ho...

Page 100: ...20 1x 5 0x120 mm drilling screw self tapping countersunk screw galvanised AW 20 type 2 2x 5 0x60 mm drilling screw self tapping screw A2 stainless steel AW 20 type 2 For available types see Mammut For...

Page 101: ...00045 Roof Hook Alu Vario Eco S 6700100038 Roof Hook Alu Mammut S 6700100039 Roof Hook Alu Mammut SV 6700200036 Trapezoidal sheet clamp Without accessories 6700200037 Trapezoidal System Eco 340 mm Wit...

Page 102: ...A2 self locking nuts completely pre assembled 6700200018 Solar fastener 8 M10x80 50 Including bell type seal and nuts pre assembled 6700200019 Solar fastener 8 M10x100 50 Including bell type seal and...

Page 103: ...200 Including screws universal connector 6700300051 Mounting plate duo TopFix 200 Including Connecting Connection Piece M10 6700200049 Universal Metal Seam Clamp G2 6700200027 Original Kalzip clamp I...

Page 104: ...gle 6100300029 Delta support 35 single 6100300030 Delta support 40 single 6100300031 Delta support 45 single Delta support continuous without base rail 6100300032 Delta support 10 continuous 610030003...

Page 105: ...connector TF60 Including 2x M10x25 A2 T head screws 2x DIN 6923 M10 A4 locking nuts 6700300058 Butt connector TF27 T Without accessories 6700300047 Butt Connector Base Rail D S Including 2x M10x25 A2...

Page 106: ...nd cap for TF60 6900300022 Flange Head Screw 6x100 A2 6900300008 Flange Head Screw 8 x 100 A2 6900300010 Flange Head Screw 8 x 140 A2 6900300011 Countersunk screw 8x 100 A2 6900300012 Flange Head Scre...

Page 107: ...700300053 Connection Piece M8 6700300033 Universal Connection Piece TX40 or SW 13 6700200013 Clamp for equipotential bonding 6101100042 Top Support Also used in AeroFix 10 EW with wind plate beginning...

Page 108: ...tem no Item 6101100046 Top Support 6101100047 Bottom Support 6101100016 Wind plate Also used in AeroFix 10 EW with wind plate beginning and ending 6101100019 Wind plate 6000300021 Assembly jig AeroFix...

Page 109: ...t We therefore recommend the following tightening torques Screw connection Tightening torque M6 10 Nm M8 15 Nm M8 connection piece for roof hook profile 30 Nm M10 Self Drilling Screw 5 5x25 approx 4 N...

Page 110: ...e 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 Position hanger bolts in the centre of rafters and...

Page 111: ...pendent heavy storm hail etc inspections of the mounting system into account the points of the maintenance log In the maintenance log not ok points must be repaired to avoid further damage Mechanical...

Page 112: ...urch die PV Anlage No damage to the roof by the PV system Mechanische Verbindungen auf festen Sitz und Anzugsmoment gem Montageanleitung gepr ft Mechanical connections for tight fit and tightening tor...

Page 113: ...perience with electrical systems and works with the mounting systems Das ausgef llte Wartungsprotokoll muss in Kopie der anlagebetreibenden Person ausgeh ndigt werden The completed maintenance log mus...

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