IBC SOLAR AeroFix Series User manual

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Installation instructions
IBC AeroFix / AeroFlat
Version 20.01 Date: 20-July-2020

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Version 20.01, 20-July-2020
Contents
1. Introduction................................................................................................................................3
2. Tool list......................................................................................................................................4
3. General information, standards and regulations...........................................................................4
4. System variants..........................................................................................................................8
5. Technical data..........................................................................................................................10
6. System planning.......................................................................................................................11
7. System design/dimensioning ....................................................................................................15
8. System installation AeroFix.......................................................................................................16
9. System installation AeroFlat......................................................................................................44
10. System security device.............................................................................................................56
11. Final inspection........................................................................................................................59
12. Parts list...................................................................................................................................60
13. Appendix..................................................................................................................................67
14. Notes.......................................................................................................................................73

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1. Introduction
Dear customer,
Congratulations, you have chosen an IBC product! Now you can enjoy the quality and reliability of the IBC
AeroFix / AeroFlat flat roof system.
To ensure that you can install and start up your IBC AeroFix / AeroFlat 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
Fig. 1: Playlist all
instalation videos

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2. Tool list
Cordless screwdriver with various bits (Torx 40, SW8 socket, SW15 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)
3. General information, standards and regulations
The IBC AeroFix / AeroFlat flat roof system is for mounting solar modules onto flat roofs and pitched roofs.
The modules are attached on supports or base rails using clamps.
The number of parts varies depending on installation size..
Important information:
Your IBC AeroFix / AeroFlat 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
Note paper from BSW-Solar Securing the position of PV flat roof systems against displacement
due to thermal expansion ("temperature hike")
Solar modules
Framed solar modules may only be used if they fulfill the following criteria:
Module dimensions according to 10 System security device
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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4. System variants
4.1 AeroFix
Southern orientation
East-west orientation
Fig. 2: AeroFix 15-S / AeroFix 15-S Kits
Fig. 3: AeroFix 10-S
Fig. 4: AeroFix 10-EW beginning / ending with wind plates
Fig. 5 AeroFix 10-EW beginning / ending with modules

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4.2 AeroFlat
Parallel to the roof
Fig. 6 AeroFlat

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5. Technical data
IBC AeroFix
15-S
10-S
10-EW
AeroFlat
Application purpose
Flat roof
Flat roof
Flat roof
Pitched roof
Inclination (*)
15
10
10
0
Module orientation
South
South
East-west
Parallel to the
roof
Permissible roof pitch (°)
0 - 10
0 –10
0 –10
0 - 30
Module width (mm)
950-1050*
950-1050*
950-1050*
980-1150
Module length (mm)
1630-1700
1630-1700
1630-1700
1500-2100
Weight (kg/m²)
7
8
11
11
Linear load (kg/m) **
13
14
18
18
Center-to-center distance (m)
1.8
1.6
2.3
2 x Module
width + 0,27
Minimum module field size
zone H
zone F and G
none
2x3 or 3x2
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
14 x 14
Minimum distance to roof edge (m)
no
no
no
0,3
Material
Aluminium
stainless steel
Aluminium
stainless steel
Aluminium
stainless steel
Aluminium
stainless steel
Max. building height (m) *
25
25
25
35
Approx. space reqirement m²/kWp
(1,65 x 0,99 module)
9
8
6
6
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.
* For module width 1001 - 1050 mm or building height >25 m resp. >35 m, project-specific testing and
ballasting by IBC is required!
** Regular weight mounting system including module (18.5 kg), without additional ballast

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6. System planning
The planning and static calculations of AeroFix / AeroFlat 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 determine the part list and ballast plan.
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
See 10. System security device
Roof covering
The AeroFix / AeroFlat flat roof system can be built on bitumen, foil, concrete gravel an green roof.
Basically, the building protection mats of the base rails should lie completely on the roof skin. There should
not be any objectsunder building protection mats that could damage the roof skin, e.g. sharp objects,
stones etc.
For gravel roofs, the gravel should be removed from the base rails. If this is not possible because the
thikness of the gravel, e.g. because the modules are coverd by the gravel, then the base rails can be laid
on the gravel and shaken a little. One must ensure on site that the weight of the PV system does not push
anything through the roof membrane.
For green roofs, it is recommended that a growth barrier is laid over the entire surface and glued to th
joints. This prevents plants from growing in the gaps between the modules. A loss of module yield due to
shade can be avoided.
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). The thermic separations must not be between the
clamping points inside a module. The center to center distance is continued normaly via the separations.

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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.
AeroFlat must be separated at the latest after 14 rows and after 14 modules in the row.
Fig. 8 AeroFix South thermal separation between the rows
Fig. 9 AeroFix EW thermal separation between the rows
Fig. 7 thermal separation within the module row

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Load-bearing reserve
In order to apply the additional loads from the PV system onto the roof, the load-bearing capacity of the
roof and the insolation must be assured by a static expert before planning the installation of the
photovoltaic system.
The surface pressure of the AeroFix base rail G2 Eco is higher than that of the AeroFix base rail G2
because of the smaller contact surface.
Important information:
The assembly system including the modules will load 7 kg/m² (11 kg/m²) to the surface of the roof.
Any additional ballast required to secure the system must also be taken into consideration in accordance
with static calculations. On average, loadings of approx. 5-10 kg/m² are to be expected.
Fig. 10 AeroFlat thermal separation

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Static friction coefficients
In terms of proof of stability, analysis of the
position stability must be carried out in
addition to the component analysis. For
this, the system must be adequately
secured against lifting off and shifting. A
key factor influencing the proof of position
stability is the static friction coefficient µ
between the solar power system and roof.
The static friction coefficient depends on the materials used, the surface condition (rough, smooth, wet,
dry, weathered), the temperature, the age and the general condition of the roof waterproofing. These
factors must each be incorporated into the consideration of the static friction coefficients and if necessary
lead to reductions.
For preliminary planning purposes, depending on the material combination the following values can be
used as an approximation:
Fleece*
(polyester)
Building protection
mat (rubber-based)
Building protection mat
(aluminium-laminated)
PVC
0,2
0,5**
0,5
Polyolefin (e.g. TPO)
0,2
0,5**
0,5
PE
0,2
0,5**
0,5
PVC, modified
0,2
0,5**
0,5
EVA
0,2
0,5**
0,5
Polypropylene
0,2
0,5**
0,3
Bitumen elastomer/polymer bitumen
0,6
0,6
0,2
EPDM
0,6
0,6
0,7
Tab. 2: Coefficient of static friction µ
* Fleece only partially recommended due to risk of rotting
** Only with the manufacturer’s approval for roof waterproofing regarding the chemical compatibility
(plasticizer migration)
Important information:
The values shown in the table are intended for preliminary planning only!
It is not possible to assess the actual existing and applicable static friction coefficients to prove position
stability without on-site verification
Determining the static friction coefficients
Fig. 11: Coefficient of static friction

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To determine the static friction coefficient between the building protection mat and roof cladding:
Clean roof cladding
Place test specimen on roof cladding
Draw the test specimen parallel to the roof using measurement device
Record result
The testing is based on DIN EN ISO 8295 Plastics –Film and sheeting –Determination of coefficient of
friction, issue October 2004.
It is necessary to carry out 10 tests, 5 in a dry state, 5 in the wet state. The arrangement of the test has to
be carried out uniformly on the roof surface. Visually different roof areas should be examined separately.
In this case tests have to be repeated accordingly. The roof areas where the test will be made have to be
cleaned before testing. Place the specimen on the roof and wait 30 seconds afterwards. In the next step
the force (F) has to be applied steadily and parallel to the centre of the specimen and measured by the
dynamometer. To determine the coefficient of friction, the decisive force is the maximum force that occurs
prior to the movement of the specimen.
G
Static friction coefficient µ = F/G
Important information:
You can use the IBC test protocol “Determining static friction coefficients” to help you determine the static
friction coefficients!
7. System design/dimensioning
Proof of the load-bearing capacity of the assembly system is based on valid EN standards. Security
against slipping and lifting off (position stability) is also proven.
The aerodynamic coefficients of the entire system were calculated in a boundary layer wind tunnel in order
to optimise and reduce loading on the system, in accordance with the information sheet „Information on
the manufacture, planning and implementation of solar plants“ from the DIBt.
Fig. 12: : Static friction measuring device

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8. System installation AeroFix
Before constructing the PV system the roof must be cleared of dirt, snow and ice.
Base rails
The assembly of the base rail G2 and G2 Eco is idendical.
Measure roof and mark out edge and corner areas
Install base rails with integrated building protection mat
Fig. 13 Roof preperation
Fig. 14 Installation base rails

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Fig. 15 Installation base rails
Fig. 16 Installation base rails

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Extend base rails
Fig. 17: Insert base rail connectors up to half-way into the base rail
Fig. 18 Secure each base rail connector with a sheet-metal screw

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Base rail alignment
Fig. 19 Join the base rails together and screw in 2 more sheet-metal screws
Fig. 20 Align the base rails so that they are parallel and vertical.

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Important information:
On very uneven roofs, it can happen that the base rail rests on the roof covering.
In this case additional protection mats must be placed. Building protection mats can be ordered separately.
Fig. 21 Distance between base rails: module length + 20 mm or module length - 160 mm