Installation Manual: Ibc Topfix 200
Installation Manual: Ibc Topfix 200
Installation Manual: Ibc Topfix 200
1
Dear customer,
Congratulations, you have chosen an IBC product! Experience for yourself the quality and reliability of the
IBC TopFix 200 module mounting system.
To simplify the installation and 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 modules quickly.
Please read these instructions carefully before starting the installation. In case of any questions, please
get in touch with your IBC SOLAR contact who will be pleased to help.
Sunny greetings
Your IBC SOLAR AG team
Pencil
Tape measure
Folding rule
Plumb line
Open-ended spanner
Power drill or cordless screwdriver with wrench socket and torque control
Torque wrench
Section “Required tools/auxiliary agents” lists any additional tools required exclusively for our IBC
trapezoidal sheet metal assembly system as the mounting system fastener type differs from some other
fasteners. For this reason, we have described these in a separate section.
Important information:
Your IBC TopFix 200 mounting system is supplied completely with all accessories.
Before you begin, please check that all parts are included using the packing list and bill of materials.
Comply with the processing guidelines and – in individual cases – specific guidelines from the relevant
roofing and module manufacturers.
Condition for the 10-year guarantee to be granted: this applies with the use of IBC SOLAR AG
components only. No guarantee claims can be accepted if third-party components are used.
Please ensure that installation work takes account of the actual conditions at the installation site and is in
accordance with the generally recognised engineering standards. Local regulations must be complied with.
Please observe all regulations and guidelines under public law during planning, erection, operation and
maintenance of PV plants connected to grids including the following: EN standards, DIN standards, TAB,
accident prevention regulations, the guidelines from the association of property insurers (VDS – fire
protection guidelines), the trade guidelines of the German roofing association (Fachregeln des Deutschen
Dachdeckerhandwerks) and general guidelines (e.g. timber structures, roofing and roof-sealing works).
DIN/VDE 0100, particularly part 712 (erection of power installations with nominal voltage up to 1000V)
VDEW standard (standards for the connection and parallel operation of independent generation
systems on low-voltage grids)
Information on manufacture, planning and implementation of solar plants from the German Institute of
Civil Engineering (DIBt), in the current edition
DIN 4102-1:1998 Fire behaviour of building materials and elements – part 1: building materials;
classification, requirements and tests
DIN EN 13501-1:2010-01 Fire classification of construction products and building elements – part 1:
classification using the results from fire behaviour tests on construction products
EN 1993-1-1 Design of steel structures: general rules and rules for buildings
General certificate of building approval Z-30.3-6: products, connecting devices and structural
components made from stainless steel
VdS 2010.
Please refer to the specified directives and standards for detailed 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 always required if the solar modules used do not comply with protection class II
and/or transformerless inverters are used.
The cross-section of the equipotential bonding conductor must correspond to the cross-section of the DC
main cable; however, it must be at least 6mm² (copper).
If the building is equipped with a lightning protection system and the PV generator is not located within the
protective area of the interception device, the module frame and the mounting system must be integrated
into the external lightning protection system and additional overvoltage protective equipment must be
installed.
The electrically conducting connection must have a minimum core size of 16mm² (copper). Please obtain
information on the currently applicable, technological standards!
To avoid overvoltage couplings from lightning strikes, the resulting conductor loop must be kept to a
minimum.
Routed cables must not obstruct any potential snow and ice from sliding down.
Water must not collect around routed cables, ensure continuous water drainage.
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.
If you do not have the PV Manager available for PV plant dimensioning, please contact your responsible
sales representative to determine and dimension the mounting system.
Important!
Any calculations for the roof construction as well as any existing superstructures do not form part of the
static calculations as part of the PV substructure dimensioning. A structural engineer must inspect and
approve of the increased and rearranged loads caused by the PV plant on site.
Figure 1: View of the IBC TopFix 200 pitched roof mounting system
Important!
We would like to once again point out that the applicable accident prevention regulations (UVV) must be
observed when working on the roof (including VBG 37 construction work, paragraph 12 "Fall protection
equipment").
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 hooks
C Rafters
D module clamp
10
Description
MB Module width
MH Module height
B Roof hooks
C Middle clamp
D Outside clamp
E Max. 400mm
11
Please see the PV Manager for the degree of utilisation and hence the specific suitability of the
corresponding mounting components for your roof and take into account on-site conditions as well as
applicable standards and regulations.
12
The number of fixing points on the roof is always dependent on the particular design of the roof, building
height, roof pitch, the wind and snow load zone and a large number of other factors.
Edges and corner areas must be particularly taken into account as per DIN 1055-4 or EN 1991-1-4 (Euro
code 1) as increased loads may apply due to wind dynamics, depending on the building type. For more
detailed information, please see the graphical indications of fixing points in our PV Manager software.
Calculate and verify any specific details according to the applicable standards. In this process, we
recommend you consult 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 case of doubt, consult a roofer or
joiner and a structural engineer.
As a rule, verify on-site static conditions and whether or not the outer roofing in conjunction with the
substructure (steel beams/purlins) is able to bear the additional pressure and dynamic loads of the PV
plant.
We shall not assume any system liability for the integrity of the roof as this mainly depends on the quality
of mounting or subsequent sealing procedures. The rules of the building trade as well as guidelines and
instructions of the roofing manufacturer are to be observed. Mounting system parts must not be treated
with additional anti-corrosion protection in normal, atmospheric conditions (mainland atmosphere). Take
additional, suitable anti-corrosion protection measures in the event of other assembly locations (e.g.
contact with grit, direct vicinity to the coast, acidic or alkaline environments).
Modifications that are not permitted and improper use of our components during assembly and
construction shall render and liability and guarantee claims void.
13
Fitting steps:
Place the roof hook in the depression in the pantile and align it centrally.
Screw the roof hook to the rafter using two flat head screws. There is no need
to drill holes beforehand.
Important!
Do not use fitted roof hooks as a step ladder, as the pantile below could be damaged by the extreme
concentrated load!
14
Important!
The leg of the roof hook lies in the depression in the pantile and must have a clearance of 5mm from the
surface of the tile. If necessary an underlay of suitable material should be installed in the space between
the rafter and the roof hook’s base plate as per Figure 10.
The roofing must not be damaged by loads arising from the fitted roof hooks! If there is a risk of this
occurring, additionally install suitable supports to distribute the load. Especially with older tiles, plain tiles
and slate roofs and where 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 the rafters and the rafters themselves are extremely important for the overall
system stress. Chipboard screws are not suitable owing to their smaller head diameter. We recommend
screwing the roof hook to the rafter using two approved 8x100 flat head screws from our product range,
where no pre-drilling is required, or using the optionally available DIN 571 8x100 wood screws. Grease
screws to facilitate fastening.
Roof hooks are suitable for most tile types. In individual cases, it may be necessary to remove small
pieces from the roof tiles using an angle grinder and suitable cutting disc to ensure that the tile sits flush.
The guidelines of the roofing manufacturer must be observed. Particular attention must be paid to the
accident prevention regulations when undertaking this work. If applicable, use wooden base blocks on
eccentric roof hook connections to distribute the load according to the following figure.
15
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.
parameters value
Material Stainless steel 1.4301 S460
yield strength fy,k = 460 N/mm²
Dimensions base plate (length / 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 construction approval Z-14.4.-661
Maximum ch. load / roof hook [kN] not specified not specified not specified
Accessories
flat head screw 6x100-A2 TX25
flat head screw 8x100-A2 TX40
flat head screw 8x140-A2 TX40
flat head screw ASD 8x240-A2 TX40
countersunk screw 8x280 TX40
flat head screw ASD 8x300-A2 TX40
countersunk screw 8x340 TX40
connection piece for roof hook profile M10
Figure 12: Parameters roof hook Standard S+
16
parameters value
Material Stainless steel 1.4301 S460
yield strength fy,k = 460 N/mm²
Dimensions base plate (length / 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 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 TX25
flat head screw 8x100-A2 TX40
flat head screw 8x140-A2 TX40
flat head screw ASD 8x240-A2 TX40
countersunk screw 8x280 TX40
flat head screw ASD 8x300-A2 TX40
countersunk screw 8x340 TX40
connection piece for roof hook profile M10
Figure 14: parameters roof hook “Standard S+ 35 mm“
17
parameters value
Material Stainless steel 1.4301 S460
yield strength fy,k = 460 N/mm²
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 base plate 45 mm
weight 0,985 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 TX25
flat head screw 8x100-A2 TX40
flat head screw 8x140-A2 TX40
flat head screw ASD 8x240-A2 TX40
countersunk screw 8x280 TX40
flat head screw ASD 8x300-A2 TX40
countersunk screw 8x340 TX40
connection piece for roof hook profile M10
Figure 16: parameters roof hook “Mammut S+”
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parameters values
Material Stainless steel 1.4301 S460
yield strength fy,k = 460 N/mm²
Dimensions base plate (length / width / height) 157/ 65/ 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 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
Accessories
flat head screw 6x100-A2 TX25
flat head screw 8x100-A2 TX40
flat head screw 8x140-A2 TX40
flat head screw ASD 8x240-A2 TX40
countersunk screw 8x280 TX40
flat head screw ASD 8x300-A2 TX40
countersunk screw 8x340 TX40
connection piece for roof hook profile M10
Figure 18: parameters roof hook „Mammut SV+“
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parameters value
Material Stainless steel 1.4301 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
Drilling holes baseplate ∅ 9 mm
Drilling holes hook slot ∅ 11 mm, L=30 mm
Hook distance from the base plate 42 mm – 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 bolt M10x25 A2 / 70
Incl. 1x hexagon nut M10 A4 / 70 with locking teeth
Accessories
flat head screw 6x100-A2 TX25
flat head screw 8x100-A2 TX40
flat head screw 8x140-A2 TX40
flat head screw ASD 8x240-A2 TX40
countersunk screw 8x280 TX40
flat head screw ASD 8x300-A2 TX40
countersunk screw 8x340 TX40
connection piece for roof hook profile M10
Figure 20: parameters roof hook “Vario S+”
20
Special roof hooks designed for the particular roofing tile shape are used for slate tiles.
parameters value
Material Stainless steel 1.4301 S460
yield strength fy,k = 460 N/mm²
Dimensions base plate (length / width / 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 construction approval Z-14.4.-661
Maximum ch. load / roof hook [kN] not specified not specified not specified
Accessories
countersunk screw 8x100 A2 TX40
connection piece for roof hook profile M10
Figure 22: parameters roof hook “Schiefer S+”
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parameters value
Material Stainless steel 1.4301 S460
yield strength fy,k = 460 N/mm²
Dimensions base plate (length / 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 0,970 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 TX25
flat head screw 8x100-A2 TX40
flat head screw 8x140-A2 TX40
flat head screw ASD 8x240-A2 TX40
countersunk screw 8x280 TX40
flat head screw ASD 8x300-A2 TX40
countersunk screw 8x340 TX40
connection piece for roof hook profile M10
Figure 25: parameters roof hook „Biber S+“
22
parameters value
Material hook: Alumnium EN AC-42100 (DIN EN 1706)
base plate: Alumnium EN AC-43000 (DIN EN 1706)
yield strength hook: fy,k = 210 N/mm²
base plate: 220 N/mm²
Dimensions base plate (length / 100/ 70/ (9) mm
width / height)
Dimensions hook (width / 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 40,6 – 55,6 mm
Horizontal adjustment at the base 70 mm stufenlos
plate
weight 0,465 kg
General construction approval Z-14.4.-515 (in preparation)
Maximum ch. load / roof hook [kN] pressure FR,k,-x= 2,06 suction FR,k,+x= 2,15 shear FR,k,y= 1,96
Incl. coach bolt M10x40 A2/70 + locking nut
Accessories
Flat head screw 6x100-A2 TX25
connection piece for roof hook profile M8
Figure 27: parameters roof hook “Alu-Vario S+”
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parameters value
Material Alumnium EN AC-42100 (DIN EN 1706)
yield strength hook: fy,k = 210 N/mm²
Dimensions base plate (length / width 150/ 63,5/ (12) mm
/ height)
Dimensions hook (width / 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. load / roof hook [kN] pressur FR,k,-x= 3,04 suction FR,k,+x= 3,14 shear FR,k,y= 3,17
Accessories
Flat head screw 6x100-A2 TX25
connection piece for roof hook profile M8
Figure 29: parameters roof hook “Alu-Mammut S+”
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parameters value
Accessories
flat head screw 6x100-A2 TX25
flat head screw 8x100-A2 TX40
flat head screw 8x140-A2 TX40
flat head screw ASD 8x240-A2 TX40
countersunk screw 8x280 TX40
flat head screw ASD 8x300-A2 TX40
countersunk screw 8x340 TX40
connection piece for roof hook profile M10
Figure 31: parameters roof hook “Alu-Mammut SV+”
25
Two ASD flat head screws are required to fasten one roof hook.
Figure 33: Inserting flat head screws Figure 34: Inserted flat head screws
26
Select the required screw length according to Figure 36 or using the IBC SOLAR AG PV Manager
dimensioning software. It is not required to drill bores before inserting the screws.
27
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.
Note:
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 recommends to test one "Mammut Form S+" on the available roof tiles as there may be
manufacturer-specific dimensions despite the designations being identical (e.g. Tegalit prior to 1996).
Step 1:
Legend:
(1) Hook
(2) Reinforcing runner
(3) Support member
(4) 4.2×32 mm drilling screw
(5) 5.0×120 mm drilling screw
(6) 5.0×60 mm drilling screw
Figure 37: "Mammut Form S+" roof hook
Specify the roof hook position so that you do not exceed a distance of 150 mm between fastener
element (1) and the centre of the rafter.
28
Step 3:
Figure 39: 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).
29
Legend:
(1) Roof hook
(2) 4.8×32 mm drilling screw
(3) 4.8×60 mm drilling screw
Figure 40: "Mammut Form S+ Bitumen"
Specify the roof hook position so that the roof hook (1) can be attached to the rafter using screws (3).
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 roofers (Deutsches Dachdecker Handwerk) the roof sealing must be
certified by a specialist.
The seal may be applied as follows:
o Separately (polymer bitumen shingles)
30
31
Compensate for any difference in height of the purlins/rafters using the thread of the
hanger bolts.
Comply with the valid, generally applicable building surveillance certificate Z-14.4-602
and the regulations contained therein for the use on trapezoidal roofs.
The roofing must not be damaged by pressure from the installed hanger bolts. If there is a risk of this,
suitable measures must be taken to spread the load. Furthermore, the penetration point of the hanger
bolts through the water conducting level should be sealed in accordance 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 roofing.
Do not drill into the water bearing depressions, but into the protruding parts.
Use the pre-drilling diamters and screwing depths illustrated in Figure 44.
Figure 44: pre-drilling diameters for plate and substructure; screwing depths for substructure
Determine the rafter position (potentially mark using a piece of string). Drill the bores into the outer
roofing (e.g. sheet metal, corrugated eternit) and rafters. Subsequently drill 15mm bores into the
outer roofing.
Tighten the lower nut on the machine thread to press the rubber seal against the outer roofing, thus
sealing the hole.
For stress reasons, the distance to the roofing must be kept as small as possible.
32
For stress reasons, the universal connector must always be mounted in the direction of the roof
ridge.
Important!
The stress values for the 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 Manager
software is based on a fixing distance of l = 100 mm.
l =100 mm
If you use trapezoidal roofing, the application rules as per the general Z-14.4-
602 building surveillance certificate apply.
Important!
Always install universal connectors in each row of modules, as shown on the figure.
33
Just as with hanger bolts, solar fasteners are inserted through the roofing and fastened to the
substructure.
Comply with the valid, generally applicable building surveillance certificate Z-14.4-638 and the
regulations contained therein for the use on trapezoidal sheet metal and sandwich roofs.
Do not drill into the water bearing depressions, but into the protruding parts.
Depending on the thickness of the steel, drill into the metal substructure accordingly to fasten the
solar fasteners. For this purpose, take into account the data illustrated in Figure 49 below.
Screw the solar fastener into the steel substructure to safeguard it demonstrates secure static
properties.
Tighten the lower nut on the machine thread to press the rubber seal against the outer roofing, thus
sealing the hole.
34
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.
Please note:
Comply with the following requirements regarding the roof profile type:
The nominal sheet metal profile panel thickness around the fasteners is ≥ 0.4 mm for steel and ≥ 0.5
mm for aluminium.
The nominal width of the outer layer of the sandwich element around the fasteners is ≥ 0.4 mm.
The nominal width of the steel substructure (rafters/purlins) around the fasteners is ≥ 1.5 mm.
When putting a load on solar fasteners in a transverse direction to the profile panels, the profile
panels must be fastened to the corrugated elements on the substructure that are in the vicinity and at
the same height.
l = 100mm
For additional framework conditions, see the valid version of the Z-14.4-638 certificate.
35
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. For fixing a TF60 profile, only a RH-profile
connecting element is required in accordance with Figure 51. For fixing the profiles TF50, TF50+ and
TF50m, on the other hand, a universal connector and additional screws for fixing the universal connector
are required in accordance with Figure 50.
The mounting plate duo can be used for trapezoidal sheet or corrugated eternit roof coverings. The
maximum high-beading space must be 330 mm.
36
Please note:
The minimum trapezoidal sheet metal or aluminium thickness must be 0.5 mm.
The enclosed special 4.8×15 blind rivets with flat, round head are certified for a sheet metal thickness
of between 0.5 mm and 1.9 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 system
and fixing points (fixed-points) and wind suction, the installer (contractor) has to check the statics of
the load capacity of the roofing and the substructure, which normally requires the services of a
structural engineer.
Special-purpose assembly on narrow raised beads, sandwich elements and elevations must be
verified on-site as part of individual statics inspections and a certificate for sandwich profiles may
have to be obtained from building surveillance authorities.
Important: Do not mount trapezoidal sheet clamps on the trapezoidal sheet metal panel blocks (two layers
of sheet metal)!
Drill, Ø 5.0 mm
* The listed tools and auxiliary agents are required exclusively for installation and processing of the
trapezoidal sheet metal panels.
Information about tools for module and carrier rail mounting is provided in section 1 in these installation
instructions.
37
Important:
Do no exceed a maximum carrier profile length of 3 beams (approximately 15.60 m) for continuous carrier
rails due to thermal expansion.
Important: Please observe the safety regulations when handling solvents and chemicals.
38
Note:
The heavy-duty adhesive tape can be used from an object and working temperature of 0° C; final adhesio n
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. After adhesion has taken place, low temperatures do 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 different
temperatures.
TRAPEZOIDAL CLAMPS are aligned with the adjustable element towards the ridge and affixed to
the surface so that the type TF27 carrier rail can be mounted without tension and it is in contact with
the trapezoidal sheet clamp. Please fully remove the protective foil!
Figure 53: Removing the protective foil Figure 54: Affixing the trapezoidal clamp
39
Figure 56: Insert the carrier rail Figure 57: Align the carrier rail Figure 58: Close the clamp
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.
Important:
A drill with a diameter of 5.0 mm
is mandatory to maintain static properties!
Now insert the 4.8x15mm sheet blind rivets into the bores and rivet.
The enclosed 4.8x15 mm sheet blind rivets are approved for a sheet thickness of between 0.5 mm
and 1.9 mm.
40
There must be a minimum of two transverse securing clamp per string (15.60 m).
Important:
Mount additional transverse securing clamps on roofs that are particularly exposed to wind.
Figure 63: Insert transverse securing clamps Figure 64: Drilling transverse securing clamps
Now insert the 4.8x15mm sheet blind rivets into the bores and rivet.
Butt connectors are inserted via the TF27 carrier rail and riveted
Figure 66: Insert butt connectors Figure 67: Joining together the carrier rails
The butt connector is attached using two 4.8x15mm sheet blind rivets.
42
Important:
Thermal expansion dictates a thermal separation after 15 modules in one row.
Important: Please observe the safety regulations when handling solvents and chemicals.
43
Figure 69: Removing the protective foil Figure 70: Affixing the "ECO trapezoidal system"
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.
Important:
A drill with a diameter of 5.0 mm
is mandatory to maintain static properties!
Now insert the 4.8x15mm sheet blind rivets into the bores and rivet.
44
Figure 73: Inserting blind rivets Figure 74: Riveting using a standard rivet head
45
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 clamps are mounted vertically according to the number of carrier rails. As a
rule, fit one standing seam to each clamp. On each side the carrier rail must
protrude by a maximum of 0.3 m.
Important!
Clarify on site whether the roof and the substructure are able to withstand the additional forces caused by
installing the PV system. If you intend to assemble PV plants on standing seam 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 (sheet seam clamps) according to the on-site conditions. Keep the
alternator size to a minimum to minimise occurring voltage values.
Please also take into account the manufacturer's specifications for the corresponding roofing, as
well as the specifications of the corresponding general building approval Z-14.4-560!
46
Important: Please ensure all teeth of the type TF50 carrier rail have engaged in the recess!
Start with the top or the bottom carrier rail. Align the screws with the fixing points (roof hooks) and
secure them. See Figure 78.
If required, extend the carrier profiles using butt connectors. Butt connectors enable ideal alignment
of the carrier rails.
Do no exceed a maximum carrier rail length of 3 rods (approximately 15,60 m) for continuous carrier
rails due to thermal expansion.
Prevent any water from collecting in the carrier rails to prevent frost damage.
Figure 78: Carrier rail, fitted Figure 79: Mounting carrier rails
1. 2. 3. 4. 5.
Figure 80: Fitting carrier rails
47
Important!
Ensure that all T-head screws and hammer nuts have engaged with the rail so they are completely
inserted.
Note:
Interlocking has been provided on roof hooks and type 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 rail horizontally first.
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.
48
Important!
Depending on the height of the module frame, a different version of the outside clamp will be required.
A Solar module
B Middle clamp
C TF50 carrier rail
D Outside clamp
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Subsequently place the first module onto both carrier rails, loosely tighten it to the outside clamps
and align with the row of roof tiles. You may also use a piece of string to facilitate alignment. Then
tighten the clamps to the tightening torque specified in Figure 104 in the Appendix. For this purpose,
we recommend using a torque wrench with TX40 Torx bit size.
Also tighten all remaining modules in this way. We recommend you start with the bottom row of
modules. Assemble all other rows above once it has been exactly aligned.
Please observe the specifications of the currently valid Z-14.4-660 building surveillance certificate.
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Figure 87: Roof hook connecting rails and carrier rails as a unit
Description
MB Module width
MH Module height
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D Two-layer connector
E Max. 400mm
F As per PV Manager
Dimensioning:
Two-layer systems are dimensioned in the same way as single-layer systems. However, the following
special features must be taken into account:
Plan for one roof hook per area where carrier rail and roof hook connecting rail meet.
Please also take 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 exceed a maximum carrier rail length of 3 rods (approximately 15,60 m)
due to thermal expansion.
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Delta supports are available with single as well as continuous base rails. Inclination angles between 10°
and 45° can be adjusted in 5° steps.
Figure 90: Delta support with single base rail Figure 91: Delta support with continuous base rail
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Delta supports with single base rails are supplied as complete, folded and pre-assembled units, including
three M8×50 hex screws with self-locking nut and tube sleeves. Secure the unfolded support using screw
connections. After having finished assembling, all screw connections must be tightened to 15 Nm.
Delta supports with continuous base rail are delivered as pre-assembled units without base rail. The
continuous base rail is individually manufactured according to the project. Connect pre-assembled Delta
supports to the base rail using two screw connections. After having finished assembling, all screw
connections must be tightened to 15 Nm.
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In this case, Delta supports are connected using two carrier rails
(TF50/TF50m/TF60). Modules are then mounted on said carrier rails.
In 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 short sides.
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IBC FrameFix counteracts this and reinforces the frame from the rear. The structure is not visible and it
does affect the mounting system.
Frame reinforcement for large-scale, vertically mounted PV modules (modules with 60 cells)
For module frame dimensions: Length 1660–1680 mm/width 990 mm/height 40–50 mm
In the event of subsequent repairs to the PV generator it is merely required to remove the
module, not the entire mounting system
Insert FrameFix corner bracket into the module frame from the rear
Pre-tighten FrameFix to 5 Nm
Important!
Prevent advance frame deformation caused by FrameFix.
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(cut to length)
(cut to length)
(cut to length)
(cut to length)
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Includes:
1x roof hook with sheet metal tile
1x reinforcing runner
3x 4.2x32 mm drilling screw (tallow-drop
screw, galvanised, AW 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)
Includes:
1x roof hook with sheet metal tile
8x 4.8x32 mm drilling screw (tallow-drop
screw, galvanised, AW 25)
2x 4.8x60 mm drilling screw (tallow-drop
screw, galvanised, AW 25)
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Includes:
3x blind rivet, mushroom head, 4.8x15
Including accessories
Including accessories
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Including
1x EPDM seal
3x M12 A2 self-locking nuts
completely pre-assembled
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Including
universal connector
Including
universal connector
Including
universal connector
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Pre-assembled
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Including
2x M10x25 A2 T-head screws
2x DIN 6923 M10 A4 locking nuts
Including
2x M10x25 A2 T-head screws
2x DIN 6923 M10 A4 locking nuts
Including accessories
Including
2x M10x25 A2 T-head screws
2x DIN 6923 M10 A4 locking nuts
Including accessories
Including
1x M10x35 A2 T-head screw
1x M10 A4 locking nut
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for TF60
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M8 15 Nm
M10 30 Nm
Figure 104: Pre-tension for screws
We do not recommend using a wrench as this may quickly cause you to exceed the tightening
torque. It is sufficient to use a torque wrench or a hex spanner with T-grip.
Important!
When using laminate clamps, please clarify the tightening torque for the corresponding assembly situation
with the laminate manufacturer.
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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 outside the
centre on purlins.
Figure 106: Defining the distance to the edge of rafters Figure 107: Defining the distance to the edge of purlins
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* 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 hours to install a PV system with an output of 1 kWp (under
normal conditions).
All specified values are theoretical values. In practical application, installation times and weights may vary,
depending on the system version. Weights and installation times for DC cabling, ground and lightning
protection have not been taken into account.
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In addition to the electrical inspections prescribed for the entire PV system, we recommend inspections of
the PV generator every two years, considering the following points.
Check:
Solar modules for damage and dirt
Mounting system and module frame for mechanical damage caused by snow and ice loads
All electrical plug and screw connections are secure and protected against accidental contact
If it becomes necessary to clean the modules, this must be done without chemical cleaning products and
using clear water only.
The modules can easily be replaced by removing the module cabling and undoing the corresponding
module clamps. In this process, please observe the relevant safety requirements.
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