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

Version: 23.01 As of: 01/2023 Page 3from 119
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

Version: 23.01 As of: 01/2023 Page 4from 119
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

Version: 23.01 As of: 01/2023 Page 5from 119
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

Version: 23.01 As of: 01/2023 Page 6from 119
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

Version: 23.01 As of: 01/2023 Page 7from 119
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.

Version: 23.01 As of: 01/2023 Page 8from 119
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

Version: 23.01 As of: 01/2023 Page 9from 119
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.

Version: 23.01 As of: 01/2023 Page 10 from 119
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).