1
Installation manual
IBC TopFix 200
Version 17.01, as of: 27-June-2017
Page 1: ...1 Installation manual IBC TopFix 200 Version 17 01 as of 27 June 2017...
Page 2: ...commissioning of your IBC TopFix 200 mounting system we have included these detailed installation instructions They are intended to help you to become familiar with how to fit the frame and the modul...
Page 3: ...and regulations 5 03 Mounting diagram 9 04 Fitting the various mounting systems 12 05 Fitting carrier rails 50 06 Fitting PV modules 52 07 Fitting cable clips 55 08 Fitting the two layer carrier syste...
Page 4: ...cordless screwdriver with wrench socket and torque control Angle grinder with diamond cutting disc Torx screwdriver with T grip size TX40 TX25 Torque wrench Section Required tools auxiliary agents lis...
Page 5: ...ds relating to dimensioning The entire photovoltaic PV system must be installed in accordance with the generally recognised engineering standards Comply with accident prevention regulations of the Ger...
Page 6: ...ation on manufacture planning and implementation of solar plants from the German Institute of Civil Engineering DIBt in the current edition DIBt building regulation list in the current edition DIN 410...
Page 7: ...led information We generally recommend integrating the mounting system and the module frame into the on site equipotential bonding and using overvoltage protective equipment Equipotential bonding is a...
Page 8: ...ng 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 desig...
Page 9: ...TF50 carrier 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 Im...
Page 10: ...e 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 Description A Solar module B Roof ho...
Page 11: ...m Carrier rail length MB 24 mm number of modules per row 32 mm MB Module width MH Module height A Type TF50 TF50m TF60 carrier rail B Roof hooks C Middle clamp D Outside clamp E Max 400mm X X selected...
Page 12: ...t a structural engineer Before starting installation the existing wooden substructure must be checked for sufficient stability The wooden substructure must have a service life of more than 20 years In...
Page 13: ...on the rafter dimensions required as per EN 1995 1 1 Fitting steps Remove the roof tile above the rafter Place the roof hook in the depression in the pantile and align it centrally Screw the roof hook...
Page 14: ...here the 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 th...
Page 15: ...ngth width height 135 70 4 mm Dimensions hook width height 30 6 mm Drilling holes baseplate 9 mm Drilling holes hook slot 11 mm L 30 mm Hook distance from the base plate 45 mm weight 0 830 kg General...
Page 16: ...istance from the base plate 35 mm weight 0 820 kg General construction approval Z 14 4 661 Maximum ch load roof hook kN not specified not specified not specified Accessories flat head screw 6x100 A2 T...
Page 17: ...h fy k 460 N mm Dimensions base plate length width height 135 70 5 mm Dimensions hook width height 35 6 mm Drilling holes baseplate 9 mm Drilling holes hook slot 11 mm L 30 mm Hook distance from the b...
Page 18: ...g 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 Maximum ch load roof hook kN not specified not specified not specified A...
Page 19: ...55 mm Horizontal adjustment at the base plate 55 5 mm weight 1 355 kg General construction approval Z 14 4 661 Maximum ch load roof hook kN not specified not specified not specified Incl 1x coach bol...
Page 20: ...height 280 30 6 mm Dimensions hook width height 30 6 mm Drilling holes baseplate 8 5 mm Drilling holes hook slot 11 mm L 30 mm Hook distance from the base plate not specified weight 0 55 kg General co...
Page 21: ...ing holes hook slot 11 mm L 30 mm Hook distance from the base plate 45 mm weight 0 970 kg General construction approval Z 14 4 661 Maximum ch load roof hook kN not specified not specified not specifie...
Page 22: ...ht 35 6 8 mm Drilling holes baseplate 7 mm Drilling holes hook slot 9 mm L 25 mm Hook distance from the base plate 40 6 55 6 mm Horizontal adjustment at the base plate 70 mm stufenlos weight 0 465 kg...
Page 23: ...dth height 35 6 8 mm Drilling holes baseplate 7 mm Drilling holes hook slot 9 mm L 25 mm Hook distance from the base plate 46 mm weight 0 465 kg General construction approval Z 14 4 515 Maximum ch loa...
Page 24: ...illing holes hook slot 9 mm L 25 mm Hook distance from the base plate 46 mm weight 0 500 kg General construction approval Z 14 4 515 Maximum ch load roof hook kN pressure FR k x 2 85 suction FR k x 1...
Page 25: ...er 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 not impaired Observe the...
Page 26: ...ten one roof hook Each roof hook connection must additionally be secured by a ASD countersunk screw to absorb sliding forces at an angle of 60 Figure 34 Inserting flat head screws Figure 35 Inserted f...
Page 27: ...ic nor anti corrosion properties of the roof hook shall not be accepted as a valid reason for complaints IBC SOLAR AG recommends to test one Mammut Form S on the available roof tiles as there may be m...
Page 28: ...he reinforcing 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 usi...
Page 29: ...using screws 2 3 In accordance with the valid specialist professional code and directives governing flat roofs set out by the association of German roofers Deutsches Dachdecker Handwerk the roof seal...
Page 30: ...30 Version 17 01 as of 27 Jun 2017 4 5 3 Fitting Mammut Form S roof hooks on plain tile roofing Figure 41 Mammut Form S plain tile dual roofing Figure 42 Mammut Form S plain tile crown roofing...
Page 31: ...1 Replace the slate plate with an individual manufactured metal plate 1 Not necessary for metal shingle roofs Step 2 Position the mounting plate 2 an d fix it with the wood screws 3 in the rafter Impo...
Page 32: ...2 Version 17 01 as of 27 Jun 2017 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 45 Cover cap and roof hook Figure 46 Roof hook fixin...
Page 33: ...nce with roofing trade regulations For this reason we recommend having hanger bolts fitted by a roofing company Please also observe the guidelines and regulations of the manufacturer of the respective...
Page 34: ...M12x300 hanger bolt relate to a fixing distance l 100mm for a use of corrugated eternit panels Exceeding the fixing distance has a detrimental effect on static values The calculation in the PV Manage...
Page 35: ...ll 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 account...
Page 36: ...e nominal width of the steel substructure rafters purlins around the fasteners is 1 5 mm The available rib height h for sandwich roofs is 35 mm h 45 mm The available upper belt width b for sandwich ro...
Page 37: ...le only a RH profile connecting element is required in accordance with Figure 55 For fixing the profiles TF50 and TF50m on the other hand a universal connector and additional screws for fixing the uni...
Page 38: ...l below the raised bead support width of 15 mm The maximum width b of the raised bead must not exceed 40 mm Because additional loads are created by the PV system in connection with the IBC mounting sy...
Page 39: ...4 9 4Mounting trapezoidal sheet metal panels Step 1 Dimensioning using PV Manager Step 2 Mark the fixing points of the clamp Step 3 Clean the roofing Exclusively clean the roofing in areas where you...
Page 40: ...not normally create any problems Prevent the formation of condensation to safeguard appropriate adhesive properties for instance in the event that the materials to be bonded together are at very diff...
Page 41: ...ory to maintain static properties When using the rivets drill two bores with a diameter of 5 0 mm per TRAPEZOIDAL CLAMP In this process make sure you drill carefully to maintain static properties Now...
Page 42: ...with a diameter of 5 0 mmis mandatory to maintain static properties Step 8A Insert and affix the transverse securing clamp with blind rivets The transverse securing clamps are affixed next to the tra...
Page 43: ...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 minimum of two tr...
Page 44: ...ector Butt connectors are inserted via the TF27 carrier rail and fixed Figure 73 Insert butt connectors Figure 74 Joining together the carrier rails The butt connector is either attached using two 4 8...
Page 45: ...lean 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 int...
Page 46: ...ng the riverts 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 Now insert the 4 8x15mm sheet blind rivets into the...
Page 47: ...e outer roofing with blind rivets 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 The enclosed self...
Page 48: ...48 Version 17 01 as of 27 Jun 2017 Step 7 Alignment of PV modules Figure 84 Aligning PV modules...
Page 49: ...Keep the alternator size to a minimum to minimise occurring voltage values A connection on titan s zinc roofs or copper roofs is not recommended In advance the clamp should be checked for correct fit...
Page 50: ...rrier rail have engaged in the recess Start with the top or the bottom carrier rail Align the screws with the fixing points e g roof hooks and secure them See Figure 87 If required extend the carrier...
Page 51: ...ooks and type e g TF50 carrier rails to compensate for differences in height on uneven roofs Any carrier rails installed above each other must be in parallel For this purpose align the bottom carrier...
Page 52: ...replaces the traditional outer clamp G4 middle clamp and EC adapter Important information Depending on the height of the module frame a different version of the outer clamp G3 will be required The EC...
Page 53: ...om the top into the position where they are required The middle clamp G4 is swiveled into the carrier rail where it is needed Important The slot nut of the G4 clamp must be aligned as shown in the Fig...
Page 54: ...se a piece of string to facilitate alignment Then tighten the clamps to the tightening torque specified in Figure 120 in the Appendix For this purpose we recommend using a torque wrench with TX40 Torx...
Page 55: ...s can be clamped to the carrier rails of the mounting system TopFix 200 or to the photovoltaic module frames without any tools Figure 96 shows the attachment of the cable clips 0 at the PV module fram...
Page 56: ...actual carrier rail is fitted 8 2 Type e g TF50 roof hook connecting rails Description L MB 24 mm n 32 mm Carrier rail length MB 24 mm number of modules per row 32 mm L2 MH 20 mm n2 20 mm Roof hook c...
Page 57: ...into account the static values of roof hook connecting rails in addition to the roof hooks and carrier profiles Use the PV Manager software to determine the static dimensions We do not recommend you e...
Page 58: ...BC 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...
Page 59: ...m Assembling continuous Delta support Figure 104 Delta support with continuous base rail Figure 105 Centering groove for drilling Delta supports with continuous base rail are delivered as pre assemble...
Page 60: ...ilable roof seal and roof substructure Fixation by hanger bolt Fixation by universal connector Fixation by additional weight e g positioning walkways etc Fixation by trapezoidal clamps two layer conne...
Page 61: ...61 Version 17 01 as of 27 Jun 2017 Figure 108 Two layer fixation two layer connector...
Page 62: ...n this case Delta supports are connected using two carrier rails TF50 TF50m TF60 Modules are then mounted on said carrier rails Please ensure that the modules have been approved for clamping on the sh...
Page 63: ...ule frame dimensions with adatper length width height 1660 1680 mm 990 mm 40 50 mm 1640 1659 mm ca 990 mm 40 50 mm 1580 1620 mm 800 mm 40 50 mm 1310 1340 mm 990 mm 40 50 mm Cable capacity up to 8 kN 8...
Page 64: ...mbling adapter Figure 113 Corner bracket Figure 114 Tensioning piece Figure 115 Tensioning piece an adapter Figure 116 Disconnect the cable from the tensioning piece Figure 117 Insert the adapter unde...
Page 65: ...mm 6800100027 Support rail TF50 uncut length L 2100 mm 6800100033 Support rail TF50 black uncut length L 5200 mm 6800100019 Support rail TF50 m uncut length L 5200 mm 6800100020 Support rail Type TF6...
Page 66: ...clamp G3 32mm black 6700400129 End clamp G3 33 mm 6700400130 End clamp G3 35mm 6700400131 End clamp G3 35 mm black 6700400132 End clamp G3 38 mm 6700400133 End clamp G3 38 mm black 6700400134 End clam...
Page 67: ...thickness from 6 8 to 8 mm 6700500006 Laminate end clamp G2 for module thickness from 6 8 to 8 mm 6700400144 Middle clamp G4 33 46mm 6700400145 Middle clamp G4 33 46mm black 6700400161 EC adapter 33 4...
Page 68: ...as of 27 Jun 2017 Illustration Item no Item 6700100027 Mammut S roof hook 6700100028 Mammut SV roof hook 6700100029 Vario S roof hook 6700100030 Biber S plain tile roof hook 6700100031 Schiefer S slat...
Page 69: ...2x 5 0x60 mm drilling screw self tapping screw A2 stainless steel AW 20 type 2 For available types see Mammut Form S leaflet 6700700021 Mammut Form S roof hook for bitumen roofs Includes 1x roof hook...
Page 70: ...Mammut SV roof hook 6700200036 Trapezoidal sheet clamp Without accessories 6700200037 ECO trapezoidal system 340 mm Without accessories 6700200038 ECO trapezoidal system 420 mm Without accessories 670...
Page 71: ...fastener 8 M10x80 50 Including bell type seal and nuts pre assembled 6700200019 Solar fastener 8 M10x100 50 Including bell type seal and nuts pre assembled 6700200020 Solar fastener 8 M10x125 50 Incl...
Page 72: ...rews universal connector 6700300051 Mounting plate duo TopFix 200 Including Connecting Connection Piece M10 6700200011 Standing Seam Clamp Including universal connector 6700200027 Original Kalzip clam...
Page 73: ...35 single 6100300030 Delta support 40 single 6100300031 Delta support 45 single Delta support continuous Pre assembled without base rail 6100300032 Delta support 10 continuous 6100300033 Delta support...
Page 74: ...ding 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 T head screws 2x DIN...
Page 75: ...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 Screw 8x 40 A2 6900300014 ASD Flange H...
Page 76: ...0300032 Connection Piece M10 For roof hooks 6700300053 Connection Piece M8 For roof hooks 6700300033 Universal Connection Piece 6700200013 Clamp for equipotential bonding 6700300042 FrameFix 60 cell u...
Page 77: ...dimensioning in accordance with DIN ISO 3506 can prove difficult We therefore recommend the following tightening torques Screw connection Tightening torque M8 15 Nm M8 connection piece for roof hook p...
Page 78: ...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 outsi...
Page 79: ...g m 35 50 kg kWp Values are based on crystalline solar modules the weight of the mounting system increases with thin film solar modules Installation times It will take two installers approximately 1 2...
Page 80: ...mly secured re tightening screw connections Mounting system and module frame for mechanical damage caused by snow and ice loads Integrity of the outer roofing All electrical cables for damage e g by a...
Page 81: ...81 Version 17 01 as of 27 Jun 2017 IBC SOLAR AG Am Hochgericht 10 D 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...
