IBC SOLAR TopFix 200 User manual

Instalation manual
TopFix 200
IBC SOLAR AG
Version:23.01
As of: 01/2023

Version: 23.01 As of: 01/2023 Page 2from 119
Table of contents
1. Introduction ................................................................................................................................... 8
2. Tool list ............................................................................................................................................ 9
3. General information, standards and regulations......................................................... 10
4. Mounting diagram .....................................................................................................................14
5. Fitting the various mounting systems...............................................................................17
5.1 General dimensioning information .................................................................................................................................................................. 17
5.2 Fitting the roof hooks..............................................................................................................................................................................................18
5.3 Roof hook types.........................................................................................................................................................................................................20
5.3.1 Standard S+ roof hook.....................................................................................................................................................................................................................20
Generally the "Standard" S+" roof hook is used..........................................................................................................................................................................20
5.3.2 Standard S+ 35 mm" roof hooks ................................................................................................................................................................................................ 21
5.3.3 Mammut S+ roof hooks .................................................................................................................................................................................................................. 22
5.3.4 Mammut XL S+ roof hooks...........................................................................................................................................................................................................23
5.3.5 Mammut SV+ roof hooks............................................................................................................................................................................................................... 24
5.3.6 Vario S+ roof hooks...........................................................................................................................................................................................................................25
5.3.7 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-mounted insulation systems ....................................................................................................31
5.5 Mammut Form S+ roof hook .............................................................................................................................................................................. 33
5.5.1 Fitting "Mammut Form S+" roof hooks...................................................................................................................................................................................33
5.5.2 Fitting Mammut Form S+ roof hooks on bitumen roofs.............................................................................................................................................36
5.5.3 Fitting "Mammut Form S+" roof hooks on plain tile roofing..................................................................................................................................... 37
5.5.4 Fitting „Mammut Form S+“ roof hook for slate and metal shingle roofs..........................................................................................................38
5.6 Installation using M12×300, M12x250 and M10x200 hanger bolts on the timber substructure ..............................40
5.7 Assembly with solar fasteners on a steel substructure .....................................................................................................................42
5.8 Mounting plate duo.................................................................................................................................................................................................44
5.9 Mounting with trapezoidal sheet metal clamps.....................................................................................................................................45

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5.9.1 Introduction............................................................................................................................................................................................................................................45
5.9.2 Required tools/auxiliary agents.................................................................................................................................................................................................45
5.9.3 Dimensioning........................................................................................................................................................................................................................................46
5.9.4 Mounting trapezoidal sheet metal panels ..........................................................................................................................................................................46
5.9.5 Trapezoidal support...........................................................................................................................................................................................................................51
5.9.6 Trapezoidal System Eco 340mm & 430mm.......................................................................................................................................................................62
5.9.7 Trapezoidal System Eco 120 mm..............................................................................................................................................................................................66
5.10 Installation of sheet seam clamps ................................................................................................................................................................69
5.11 Installation of Kalzip® clamps ..........................................................................................................................................................................70
6. Fitting 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
10. Delta support ............................................................................................................................79
10.1 General information ............................................................................................................................................................................................... 79
10.2 Assembly......................................................................................................................................................................................................................80
10.3 Connection to the roof ........................................................................................................................................................................................81
10.4 Mounting modules.................................................................................................................................................................................................83
11 Insertion system.........................................................................................................................84
11.1 General............................................................................................................................................................................................................................84
11.2 System installation ..................................................................................................................................................................................................84
12. Bill of materials .........................................................................................................................95
13 Appendix....................................................................................................................................109
13.1 Notes on IBC TopFix 200..................................................................................................................................................................................109
13.2 Weights/installation times for pitched roof installations ................................................................................................................ 111
13.3 Notes on maintenance ........................................................................................................................................................................................ 111
13.4 Documents................................................................................................................................................................................................................. 112

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Table of figures
Figure 1 View of the IBC TopFix 200 pitched roof mounting system .............................................................................................................................14
Figure 2 Fastenings for the IBC TopFix 200 pitched roof mounting system .............................................................................................................15
Figure 3 Module fastening of the IBC TopFix 200 pitched roof mounting system.................................................................................................15
Figure 4 Layout of the IBC TopFix 200 pitched roof mounting system........................................................................................................................16
Figure 5 Roof hook ....................................................................................................................................................................................................................................18
Figure 6 Roof hook on the rafter........................................................................................................................................................................................................18
Figure 7 Fitted roof hook........................................................................................................................................................................................................................18
Figure 8 Fitted roof hook........................................................................................................................................................................................................................18
Figure 9 Alignment with piece of string .........................................................................................................................................................................................18
Figure 10 Roof hook load distribution..............................................................................................................................................................................................19
Figure 11 : Standard S+ roof hook......................................................................................................................................................................................................20
Figure 12 Parameters roof hook Standard S+ .............................................................................................................................................................................20
Figure 13 Standard S+ 35 mm roof hook ........................................................................................................................................................................................ 21
Figure 14 Parameters roof hook “Standard S+ 35 mm“...........................................................................................................................................................21
Figure 15 Mammut S+ roof hook........................................................................................................................................................................................................ 22
Figure 16 Parameters roof hook Mammut S+..............................................................................................................................................................................22
Figure 17 Mammut XL S+ roof hook ................................................................................................................................................................................................. 23
Figure 18 Parameters roof hook Mammut XL S+....................................................................................................................................................................... 23
Figure 19 Mammut SV+ roof hook..................................................................................................................................................................................................... 24
Figure 20 Parameters roof hook „Mammut SV+........................................................................................................................................................................24
Figure 21 Vario S+ roof hook................................................................................................................................................................................................................25
Figure 22 Parameters roof hook Vario S+.....................................................................................................................................................................................25
Figure 23 Schiefer 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 Alu-Vario Eco S+ roof hook............................................................................................................................................................................................28
Figure 29 Parameters roof hook Alu-Vario Eco S+..................................................................................................................................................................28
Figure 30 Alu-Mammut S+ roof hook .............................................................................................................................................................................................29
Figure 31 Parameters roof hook Alu-Mammut S+.....................................................................................................................................................................29
Figure 32 Alu-Mammut SV+ roof hook...........................................................................................................................................................................................30
Figure 33 Parameters roof hook Alu-Mammut SV+.................................................................................................................................................................30
Figure 34 Overview of screw lengths...............................................................................................................................................................................................31
Figure 35 Roof hooks on rafter-mounted insulation systems............................................................................................................................................. 31
Figure 36 Inserting flat head screws............................................................................................................................................................................................... 32
Figure 37 Inserted flat head screws................................................................................................................................................................................................. 32
Figure 38 Inserting countersunk screws to absorb sliding forces ..................................................................................................................................32
Figure 39 Mammut Form S+ roof hook ..........................................................................................................................................................................................33
Figure 40 Fastening the reinforcing runner in the rafter with drilling screw 5.0×120 mm .................................................................................34
Figure 41 Fastening the reinforcing runner in the counter battens with drilling screw 5.0×70 mm ............................................................. 34
Figure 42 Connecting sheet metal roof tiles with batten rail.............................................................................................................................................35
Figure 43 Possible position of the ASD countersunk and flat head screws...............................................................................................................35
Figure 44 Mammut Form S+ Bitumen.............................................................................................................................................................................................36
Figure 45 Mammut Form S+ plain tile dual roofing................................................................................................................................................................. 37
Figure 46 Mammut Form S+ plain tile crown roofing............................................................................................................................................................. 37
Figure 47 Insert the metal plate (slte roof only) ........................................................................................................................................................................38

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Figure 48 Fix the mounting plate......................................................................................................................................................................................................38
Figure 49 Cover cap and roof hook.................................................................................................................................................................................................39
Figure 50 Roof hook fixing ...................................................................................................................................................................................................................39
Figure 51 Hanger bolt.............................................................................................................................................................................................................................40
Figure 52 Pre-drilling diameters for plate and substructure; screwing depths for substructure ...................................................................40
Figure 53 Correctly fitted hanger bolt with universal connector .....................................................................................................................................41
Figure 54 Fixing distance.......................................................................................................................................................................................................................41
Figure 55 Mounted hanger bolt with "universal connector" ...............................................................................................................................................41
Figure 56 Solar fastener......................................................................................................................................................................................................................... 42
Figure 57 Steel substructure pre-drilling diameter.................................................................................................................................................................42
Figure 58 Mounting plate Duo with universal connector ....................................................................................................................................................44
Figure 59 Mounting plate duo with connecting element RH-profile .........................................................Fehler! Textmarke nicht definiert.
Figure 60 Marking fixing points .........................................................................................................................................................................................................46
Figure 61 Removing the protective foil.......................................................................................................................................................................................... 47
Figure 62 Affixing the trapezoidal clamp ...................................................................................................................................................................................... 47
Figure 63 Distribute the clamps according to the instructions ........................................................................................................................................ 47
Figure 64 Insert the support rail ........................................................................................................................................................................................................48
Figure 65 Align the support rail .........................................................................................................................................................................................................48
Figure 66 Close the clamp ...................................................................................................................................................................................................................48
Figure 67 Mount support rail...............................................................................................................................................................................................................48
Figure 68 Drilling clamps.......................................................................................................................................................................................................................48
Figure 69 : Inserting blind rivets........................................................................................................................................................................................................48
Figure 70 Riveting using a standard rivet head.........................................................................................................................................................................48
Figure 71 Apply the screw .....................................................................................................................................................................................................................49
Figure 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 transverse securing clamps .......................................................................................................................................................................50
Figure 77 Insert butt connectors........................................................................................................................................................................................................51
Figure 78 Joining together the support rails ...............................................................................................................................................................................51
Figure 79 Gap = Module length + 20 mm .....................................................................................................................................................................................51
Figure 80 Mark the position of the Bottom Support in the grid spacing.....................................................................................................................52
Figure 81 Bottom Support with screw and rhombus nut......................................................................................................................................................52
Figure 82 Mounted Bottom Support...............................................................................................................................................................................................52
Figure 83 Distance AeroFix 15-S supports...................................................................................................................................................................................53
Figure 84 Distance AeroFix 10-S supports...................................................................................................................................................................................54
Figure 85 Distance AeroFix 10-EW supports ..............................................................................................................................................................................55
Figure 86 Fasten Top Support with two screws and rhombus nuts...............................................................................................................................56
Figure 87 Mounted Top Support.......................................................................................................................................................................................................56
Figure 88 Insert the module in the Bottom Support and Top Support......................................................................................................................... 57
Figure 89 The module must rest against the Top Support (with wind plate-end).................................................................................................. 57
Figure 90 Module at the stop of the Top Support and clamped .....................................................................................................................................58
Figure 91 Mounted modules................................................................................................................................................................................................................58
Figure 92 Wind plate assembly starting from the left............................................................................................................................................................59
Figure 93 Insert wind plate...................................................................................................................................................................................................................60
Figure 94 Fixed wind plates within the row.................................................................................................................................................................................60
Figure 95 Fixed wind plate on the Top Support at the beginning / ending of the row ........................................................................................61
Figure 96 Marking fixing points..........................................................................................................................................................................................................62
Figure 97 Removing the protective foil .........................................................................................................................................................................................63
Figure 98 Affixing the "Trapezoidal System Eco" .....................................................................................................................................................................63

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Figure 99 "Trapezoidal system Eco 340mm & 420mm" distributed as specified ....................................................................................................63
Figure 100 Drilling clamps.....................................................................................................................................................................................................................64
Figure 101 Inserting blind rivets..........................................................................................................................................................................................................64
Figure 102 Riveting using a standard rivet head.......................................................................................................................................................................64
Figure 103 Apply the screw..................................................................................................................................................................................................................64
Figure 104 Trapezoidal System Eco screwed .............................................................................................................................................................................64
Figure 105 Aligning PV modules........................................................................................................................................................................................................65
Figure 106 Marking fixing points........................................................................................................................................................................................................66
Figure 107 Removing the protective foil .......................................................................................................................................................................................66
Figure 108 Affixing the " Trapezoidal System Eco 120mm"..................................................................................................................................................66
Figure 109 "Trapezoidal System Eco 120mm " distributed as specified ...................................................................................................................... 67
Figure 110 Apply the screw................................................................................................................................................................................................................... 67
Figure 111 Trapezoidal System Eco 120mm screwed............................................................................................................................................................... 67
Figure 112 Place the clamps on the center of the Trapezoidal Tystem Eco 120mm ..............................................................................................68
Figure 113 Aligning PV modules .........................................................................................................................................................................................................68
Figure 114 Universal Metal Seam Clamp G2 ................................................................................................................................................................................69
Figure 115 Direct assembly....................................................................................................................................................................................................................69
Figure 117 standing seam variants.....................................................................................................................................................................................................69
Figure 118 Kalzip® clamp with universal connector ................................................................................................................................................................70
Figure 119 Support rail, fitted................................................................................................................................................................................................................ 71
Figure 120 Mounting support rails..................................................................................................................................................................................................... 71
Figure 121 Fitting support rails ............................................................................................................................................................................................................. 71
Figure 122 Butt connector TF50+ / TF50+m inside ................................................................................................................................................................ 72
Figure 123 Insert butt connector (blue) and leaf spring for potential equalization (red) into the support profile................................. 72
Figure 124 Butt connector TF50 + / TF50+m inside (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
Figure 128 Inserting the middle clamp G5 ................................................................................................................................................................................... 74
Figure 129 EC adapter 30-40 mm with middle clamp G5 and secure clip ................................................................................................................. 75
Figure 130 EC adapter 30-40 mm frame hights........................................................................................................................................................................ 75
Figure 131 Cable Clip 0° ......................................................................................................................................................................................................................... 76
Figure 132 Cable Clip 90°...................................................................................................................................................................................................................... 76
Figure 133 Cable Clip MC4-Plug....................................................................................................................................................................................................... 76
Figure 134 Cable Clip 0° on module frame .................................................................................................................................................................................. 76
Figure 135 Roof hook connecting support profiles and support profiles as a unit..................................................................................................77
Figure 136 Cross section of a two-layer system structure................................................................................................................................................... 78
Figure 137 Delta support with single base rail ............................................................................................................................................................................ 79
Figure 138 Delta support with continuous base rail ................................................................................................................................................................ 79
Figure 139 Assembling Delta supports at the base rails........................................................................................................................................................80
Figure 140 Centering groove for drilling .......................................................................................................................................................................................80
Figure 141 Fixation by hanger bolt.....................................................................................................................................................................................................81
Figure 142 Fixation by universal connector.................................................................................................................................................................................82
Figure 143 Two--layer fixation (two-layer connector)............................................................................................................................................................82
Figure 144 Vertically mounted modules with module support rail ..................................................................................................................................83
Figure 145 Horizontally mounted modules with module support rail.............................................................................................................................83
Figure 146 Horizontally mounted modules without module support rail .....................................................................................................................83
Figure 147 Example roof hook Mammut SV+ ..............................................................................................................................................................................84
Figure 148 Roof connector rail assembly......................................................................................................................................................................................85
Figure 149 Butt connector for carrier rail TF50+ ......................................................................................................................................................................85
Figure 150 Insertion rails distance: Module length / -width + 10 mm, or module length / width - 64 mm.................................................86

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Figure 151 Adjusting the assembly jig .............................................................................................................................................................................................86
Figure 152 Positioned assembly jig ..................................................................................................................................................................................................87
Figure 153 Detail position assembly jig bottom, analog top................................................................................................................................................87
Figure 154 Position two-layer connector......................................................................................................................................................................................88
Figure 155 Two-layer connector........................................................................................................................................................................................................88
Figure 156 Side view two-layer connector...................................................................................................................................................................................88
Figure 157 Butt connector insertion rail ........................................................................................................................................................................................89
Figure 158 Mounted butt connector insertion 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..............................................................................................................................................................................................91
Figure 164 Attach spacer.......................................................................................................................................................................................................................92
Figure 165 Insert spacer.........................................................................................................................................................................................................................92
Figure 166 Mounted spacer.................................................................................................................................................................................................................92
Figure 167 Side plate................................................................................................................................................................................................................................93
Figure 168 Mounted side plate...........................................................................................................................................................................................................93
Figure 169 Attach the end cover and click in.............................................................................................................................................................................94
Figure 170 Mounted end cover at the bottom...........................................................................................................................................................................94
Figure 171 Mounted end cover at the top.....................................................................................................................................................................................94
Figure 1: Tabel I........................................................................................................................................................................Fehler! Textmarke nicht definiert.
Figure 2: Tabel II......................................................................................................................................................................Fehler! Textmarke nicht definiert.

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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 TopFix 200 module
mounting system.
To ensure that you can install 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 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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2. Tool list
•Power drill or cordless screwdriver with wrench socket, a variety of bits (TX 25, TX 30, TX 40, socket SW8, SW10.) and
torque control
•Drill bits (up to Ø 15 mm)
•Pencil
•Tape measure
•Folding rule
•Plumb 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 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.

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3. General information, standards and regulations
The IBC TopFix 200 mounting system is is used for installing your solar modules.
The number of components varies according to the size of the system.
Important information
•Your IBC TopFix 200 mounting 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!
•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 recognized technical regulations. Please ensure that you
observe the national accident prevention regulations e.g. of the German employer‘s liability insurance associations
(Berufsgenossenschaften), in particular.
•DGUV Regulation 1 Principles of Preventation
•DGUV Regulation 3 Electrical installations and equipment
•DGUV Regulation 38 Construction work
•DGUV Information 208-016 the use of 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).

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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 Blatt 1.4 (Integration of distributed and renewables-based energy systems in buildings - Fundamentals - Fixing
of solar modules and solar collectors on buildings)
•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 18531 Waterproofing of roofs
•DIN 18015 Planning and erection of electrical installations in residential buildings
•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 1990 (Basis of structural design)
•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 aluminum 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

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•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:
•Hold valid IEC 61215 / IEC 61646 and protection class II / IEC 61730
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 used solar modules 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).

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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.
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.
Attention!
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 civil engineer must inspect and approve of the increased and rearranged loads caused by
the PV plant on site.

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4. Mounting diagram
There are various possibilities for the arrangement 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
mounting procedures describe such an arrangement.
Figure 1 View of the IBC TopFix 200 pitched roof mounting system

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We have illustrated the layout of the IBC TopFix 200 mounting system to improve 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 the IBC TopFix 200 pitched roof mounting system
Figure 3 Module fastening of the IBC TopFix 200 pitched roof mounting system

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Description
L = (MB + 20 mm) × n + 48 mm
Support rail=
(MB + 20 mm) × number of modules per row + 48 mm
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 software)
Z
Please observe module manufacturer specifications
Figure 4 Layout of the IBC TopFix 200 pitched roof mounting system

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5. Fitting the various mounting systems
5.1 General dimensioning information
The PV system on your roof is subject to considerable forces caused by snow and, most of all, wind. Improper fastening of the PV
system, particularly the modules, may cause significant damage to objects as well as personal injury. For this purpose, it is crucial
you observe the following section.
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.
The compatibility of the material pairings between the roof and the PV system must be checked before the installation.
Edges and corner areas must be particularly taken into account as per 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 civil engineer.
Before starting installation, the existing substructure 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 a rule, verify on-site static conditions and whether or not the outer roofing in conjunction with the substructure (steel
beams/purlins, rafters, roof battens,etc.) 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 (corrosivity categories C1-C3 according to EN ISO 12944-2 and surrounding temperatures of -30°C to +50°C). 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).
The maximum allowed roof inclination for the mounting system is 75°. It is limited by the permissible inclination of the modules.
Modifications that are not permitted and improper use of our components during assembly and construction shall render and
liability and guarantee claims void.

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5.2 Fitting the roof hooks
In order to comply with warranty conditions (rain-proofing etc.) we recommend having the roof hooks fitted by a
professionally trained personal e.g. roofing firm. Please also take into account the manufacturer's regulations and
specifications for the corresponding roofing, in particular with regard to the use of manufacturer accessories for
roofing as well as the overview in section 11 containing data 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 to the rafter using two offset flat head screws. There is no need to drill
holes beforehand. Observe edge distances under Figure 175.
•Align other roof hooks using a piece of string.
•Reinsert roofing tile that has been bent out.
Different country-specific roof constructions can result in mounting variants. Please take these variants from separate installation
manuals.
Attention!
Do not use fitted roof hooks as a step ladder, as the pantile below could be damaged by the extreme concentrated load! A
deformation of the roof hook itself cannot be excluded.
Figure 5 Roof hook
Figure 6 Roof hook on the rafter
Figure 7 Fitted roof hook
Figure 8 Fitted roof hook
Figure 9 Alignment with piece of string

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If the roof hook cannot be fitted as shown above due to the form of the tile or the position of the depression, it is imperative that a
roofer is engaged. Changes to roof covering materials (roof tiles, clay tiles, roof panels, cast stone, etc.) may only be made in
accordance with the applicable roofing trade regulations and the manufacturer’s guidelines.
Attention!
The leg of the roof hook lies in the depression in the pantile and must have a clearance of minimum 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. It must screwing the roof hook to the rafter using two approved
8x100 respectively 6x100 flat head screws from our product range, where no pre-drilling is required. 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 or other
professional solutions.
Figure 10 Roof hook load distribution

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5.3 Roof hook types
Attention!
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.
5.3.1 Standard S+ roof hook
Generally the "Standard" S+" roof hook is used.
It is suitable for the most commonly used types of pantiles.
Parameters
Value
Material
Stainless steel 1.4307 S275 + S460
yield strength
Stirrup: fy,k = 460 N/mm²
Ground plate: 275 N/mm²
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 plate
45 mm
weight
0,830 kg
General construction approval
Z-14.4.-661
Maximum ch. load / roof hook [kN]
Calculation via PV Manager
Accessories
flat head screw 6x100-A2 TX30
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+
Figure 11 : Standard
S+ roof hook