IBC SOLAR AeroFix 15-S User manual

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

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Version 18.01, 1-Mar-2018
Contents
0. Introduction.........................................................................................................................................3
01. Tool list.............................................................................................................................................4
02. General information, standards and regulations..................................................................................4
03. System variants ................................................................................................................................8
04. Technical data...................................................................................................................................9
05. System planning .............................................................................................................................10
06. System design/dimensioning...........................................................................................................13
07. System installation..........................................................................................................................14
08. System security device....................................................................................................................42
09. Final inspection...............................................................................................................................44
10. Parts list..........................................................................................................................................45
11. Appendix ........................................................................................................................................51
12. Notes..............................................................................................................................................57

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Version 18.01, 1-Mar-2018
0. Introduction
Dear customer,
Congratulations, you have chosen an IBC product! Now you can enjoy the quality and reliability of the IBC
AeroFix flat roof system.
To ensure that you can install and start up your IBC AeroFix flat roof 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.
Please read these instructions carefully before installation. If you still have questions after reading them,
please contact your IBC partner, who will be happy to assist you.
We wish you a sunny day!
Your team
IBC SOLAR AG

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01. Tool list
Cordless screwdriver with various bits (Torx 40, SW8 socket, ...)
Bit holder 300 mm
Pencil
Tape measure
Folding rule
Plumb line
Angle grinder with diamond grinding wheel
Torx screwdriver with T-handle, size TX40
Torque wrench
Assembly gloves
Assembling jig
Static friction measureing device (in the planning phase)
02. General information, standards and regulations
The IBC AeroFix flat roof system is for mounting solar modules onto flat roofs.
The modules are attached on supports using clamps.
The number of parts varies depending on installation size..
Important information:
Your IBC AeroFix flat roof system will be delivered complete with all accessories!
Before you begin, please check that all parts are included by using the attached packing list and
parts list.
Electrical work must be carried out by a qualified electrician!
The processing guidelines and in individual cases specific guidelines from the relevant
manufacturer for the roofing and modules must be adhered to!

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Condition for the 10-year guarantee to be granted: this only applies with the use of IBC
components. The guarantee is not valid for components from other suppliers. Complete
guarantee conditions are stated in the guarantee document.
We advise the use of gloves to avoid injuries.
During the entire assembly time, it must be ensured that at least one copy of 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 recognised technical regulations.
Please ensure that you observe the accident prevention regulations of the German employer‘s liability
insurance associations (Berufsgenossenschaften), in particular:
BGV A1 General instructions
BGV A3 Electrical systems and equipment
BGV C22 Construction work
BGV D36 Ladders and steps
Please ensure that installation is adapted to on-site conditions and corresponds to the respective generally
recognised technical regulations. Local regulations must be observed.
Please observe all regulations and guidelines under public law during planning, erection, operation and
maintenance of grid-connected PV plants including the following: EN standards, DIN standards, TAB,
accident prevention regulations, the guidelines from the association of property insurers (VDS –fire
protection guidelines), the professional guidelines of the roofing association and general guidelines (e.g.
timber structures, roofing and roof-sealing works).
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 (local energy systems in buildings –photovoltaic)
DIN / VDE 0126 (solar energy systems for domestic use)
DIN / VDE 0185 part 1 to 4 (lightning protection)
DIN 18338 Roof covering and roof sealing works
DIN 18451 Scaffolding work
DIN 18015 Planning and erection of electrical installations in residential buildings

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TAB (technical closing conditions for connecting to the low-voltage grid of power supply
companies)
VDEW guidelines (guidelines for connection and parallel operation of decentralised power
generation in the low-voltage grid)
Notes on solar from the German Institute of Civil Engineering (DIBt), in the current edition
DIBt building regulation list, 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 1991-1-3 (General actions –snow loads)
EN 1991-1-4 (General actions –wind loads)
EN 1993-1-1 Design of steel structures: General rules and rules for buildings
EN 1995-1-1 Design of timber structures
EN 1999-1-1 Design of aluminium structures
General certificate of building approval Z-30.3-6: Products, connecting devices and structural
components made from stainless steel
DIN 4426 Equipment for building maintenance - Safety requirements for workplaces and
accesses - Design and construction
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:
Module width: 950 –1000 mm
Module length: 1630 –1700 mm
Module manufacturers approval regarding module clamping
Hold valid IEC 61215 / IEC 61646 and protection class II / IEC 61730

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Framed solar modules
Please note that the guarantee for the solar modules will expire if modifications are made to the module
frames (e.g. by drilling additional holes). For warranty reasons, the assembly instructions from the
respective solar module manufacturer must be strictly adhered to.
Lightning and surge protection
Please note that the lightning and surge protection of the PV system is to meet the current requirements
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.
In general we recommend that you integrate the assembly system and the module frames into the local
potential equalisation and use surge protection devices.
Potential equalisation is always necessary if the solar modules used do not meet requirements for
protection class II and/or transformerless inverters are used.
The cross-section of the potential equalisation conductor must correspond to the main DC cables but must
be at least 6 mm² (copper).
If the building has a lightning protection system and the PV generator is not in the protection area of the
arresting device, then the module frame and assembly system must be integrated into the external
lightning protection and surge protection devices must also be installed.
The electroconductive connection must be implemented with at least 16 mm² (copper).
Cable routing
Even when you are installing the frame, certain points regarding cable routing and wiring should be kept in
mind.
To avoid surge voltage couplings from lightning strikes, the resulting conductor loop must be kept
as small as possible.
The cable routing must allow for any future slipping caused by snow and ice.
Water must not be allowed to collect around the wiring, continuous water drainage must be
provided.
The wires must be installed with maximum possible UV and weather protection.

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

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04. Technical data
IBC AeroFix
15-S
10-S
10-EW
Application purpose
Flat roof
Flat roof
Flat roof
Inclination (*)
15
10
10
Module orientation
South
South
East-west
Max. permissible roof pitch (*)
10
10
10
Module width (mm) *A
950-1000
950-1000
950-1000
Module length (mm) *B
1630-1700
1630-1700
1630-1700
Weight (kg/m²) *C
7
8
11
Linear load (kg/m) *D
13
14
18
Center-to-center distance (m)
1.8
1.6
2.3
Minimum module field size zone H
zone F and G
none
2x3 or 3x2
none
2x3 or 3x2
none
2x3 or 3x2
Maximum layout (thermal separation)
15 x 15
15 x 15
14 x 15
Minimum distance to roof edge (m)
no
no
no
Material
Aluminium
stainless steel
Aluminium
stainless steel
Aluminium
stainless steel
Max. building height (m) *E
25
25
25
Approx. space reqirement m²/kWp
(1,65 x 0,99 module)
10
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Tab. 1: Technical data
Product guarantee in accordance with complete guarantee conditions in the version valid at the time of
assembly that you received from your IBC SOLAR trade partner. Guarantee assumes assembly is in
accordance with applicable assembly instructions. We reserve the right to make modifications which will
improve our product.
*A Approval required from module manufacturer
*B Other lengths on request
*C regular weight including mountings systems, roof protection matt and module (20 kg)
*D Depending on rail distance
*E Building heights >25 m are possible after isolated case check.

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05. System planning
The planning and static calculations of AeroFix flat roof systems is carried out using IBC PV Manager
software or based on the checklist to be submitted with the associated module layout plan, which can be
used to assess the degree of utilisation and the suitability of the assembly components for your roof.
The proof of the plant safety and the static load capacity of the system components have to be
calculated for every single project!
Before initiating the planning phase, there must be an extensive check of the existing building and
technical documentation must be completed. In particular, the constructor should be informed of any
damage to the roof cladding. The functionality of existing roof waterproofing should be provided for the
operating period of the new PV system to be installed.
Drainage
The customer must check that the structural condition is consistent with the design (building size, roof
pitch, roof cladding, obstacles etc.).
It must be ensured at all times that rain water is discharged to drainage collection points and this should be
incorporated into the planning of the PV system.
Pitched roofs
For roof pitches >3° is required securing the module fields in the direction of the roof pitch. This can be
done for example with east-west orientated roofs using a ground rail coupling to be taken across the roof
ridge.
Restriction of module field sizes
Due to different linear expansion coefficients for the structural profiles compared to those for the roof
cladding, there may be thermal constraints on the roof waterproofing. This is excluded by restricting the
module field sizes (splitting individual module fields).
AeroFix 15-S and AeroFix 10-S must be separated at the latest after 15 rows and after 15 modules in the
row.
AeroFix 10-EW must be separated at the latest after 14 rows (7-V rows) and after 15 modules in the row.
The field beginning and ending with modules is not counted as a row.