IBC TopFix 200 User manual

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Installation manual
IBC TopFix 200
Version 17.01, as of: 27-June-2017

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Version 17.01, as of: 27-Jun-2017
Dear customer,
Congratulations, you have chosen an IBC product! Experience for yourself the quality and reliability of the
IBC TopFix 200 module mounting system.
To simplify the installation and commissioning of your IBC TopFix 200 mounting system, we have included
these detailed installation instructions. They are intended to help you to become familiar with how to fit the
frame and the modules quickly.
Please read these instructions carefully before starting the installation. In case of any questions, please
get in touch with your IBC SOLAR contact who will be pleased to help.
Sunny greetings
Your IBC SOLAR AG team

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Version 17.01, as of: 27-Jun-2017
Contents
01. What you will need: tool list.........................................................................................................4
02. General information, standards and regulations...........................................................................5
03. Mounting diagram.......................................................................................................................9
04. Fitting the various mounting systems.........................................................................................12
05. Fitting carrier rails.....................................................................................................................50
06. Fitting PV modules...................................................................................................................52
07. Fitting cable clips......................................................................................................................55
08. Fitting the two-layer carrier system............................................................................................56
09. Delta support............................................................................................................................58
10. IBC FrameFix module frame reinforcements..............................................................................63
11. Bill of materials.........................................................................................................................65
12. Appendix..................................................................................................................................77

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01.What you will need: tool list
Cordless screwdriver with a variety of bits (Torx, Phillips, etc.)
Drill bits (up to Ø 15 mm)
Pencil
Tape measure
Folding rule
Plumb line
Open-ended spanner
Power drill or cordless screwdriver with wrench socket and torque control
Angle grinder with diamond cutting disc
Torx screwdriver with T-grip, size TX40, TX25
Torque wrench
Section “Required tools/auxiliary agents” lists any additional tools required exclusively for our IBC
trapezoidal sheet metal assembly system as the mounting system fastener type differs from some other
fasteners. For this reason, we have described these in a separate section.

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02. General information, standards and regulations
The IBC TopFix 200 mounting system is used for installing your solar modules. The modules are fastened
by means of clamps and carrier rails.
The number of components varies according to the size of the system.
Important information:
Your IBC TopFix 200 mounting system is supplied completely with all accessories.
Before you begin, please check that all parts are included using the packing list and bill of materials.
Electrical work must be carried out by qualified electricians only!
Comply with the processing guidelines and –in individual cases –specific guidelines from the relevant
roofing and module manufacturers.
Condition for the 10-year guarantee to be granted: this applies with the use of IBC SOLAR AG
components only. No guarantee claims can be accepted if third-party components are used.
General important information and standards relating to dimensioning
The entire photovoltaic (PV) system must be installed in accordance with the generally recognised
engineering standards. Comply with accident prevention regulations of the German employer's liability
insurance associations (Berufsgenossenschaften), in particular:
BGV A1 General instructions
BGV A2 Electrical systems and equipment
BGV C22 Construction work
BGV D36 Ladders and steps
Please ensure that installation work takes account of the actual conditions at the installation site and is in
accordance with the generally recognised engineering standards. Local regulations must be complied with.
Please observe all regulations and guidelines under public law during planning, erection, operation and
maintenance of PV plants connected to grids including the following: EN standards, DIN standards, TAB,
accident prevention regulations, the guidelines from the association of property insurers (VDS –fire
protection guidelines), the trade guidelines of the German roofing association (Fachregeln des Deutschen
Dachdeckerhandwerks) and general guidelines (e.g. timber structures, roofing and roof-sealing works).

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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 1000V)
DIN/VDE 0298 (electrical wiring)
VDI 6012 (distributed energy systems in buildings –photovoltaic)
DIN/VDE 0126 (solar energy systems for domestic use)
DIN/VDE 0185 parts 1 to 4 (lightning protection)
DIN 18338 Roof covering and roof sealing works
DIN 18451 Scaffolding works
DIN 18015 Planning and erection of electrical installations in residential buildings
TAB (utility companies' technical low-voltage grid connection conditions)
VDEW standard (standards for the connection and parallel operation of independent generation
systems on low-voltage grids)
Information on manufacture, planning and implementation of solar plants from the German Institute of
Civil Engineering (DIBt), in the current edition
DIBt building regulation list, in the current edition
DIN 4102-1:1998 Fire behaviour of building materials and elements –part 1: building materials;
classification, requirements and tests
DIN EN 13501-1:2010-01 Fire classification of construction products and building elements –part 1:
classification using the results from fire behaviour tests on construction products
EN 1991-1-3 (General actions –snow loads)
EN 1991-1-4 (General actions –wind loads)
EN 1993-1-1 Design of steel structures: general rules and rules for buildings
EN 1995-1-1 Design of timber structures
EN 1999-1-1 Design of aluminium structures
General certificate of building approval Z-30.3-6: products, connecting devices and structural
components made from stainless steel
General building authority approval for individual system components

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Solar modules
Solar modules may only be used if they hold the following valid certification:
IEC 61215/IEC 61646 and protection class II/IEC 61730
Framed solar modules
Please note that the guarantee for the solar modules will be rendered void if modifications are made to the
module frames (e.g. by drilling additional holes). In order to comply with warranty conditions, the
installation instructions of the respective solar module manufacturer must be strictly observed.
Lightning and overvoltage protection
The lightning and overvoltage protection of the PV system must comply with the current specifications of
DIN/VDE 0185 parts 1 to 4
DIN/VDE 0100 part 712
VdS 2010.
Please refer to the specified directives and standards for detailed information. We generally recommend
integrating the mounting system and the module frame into the on-site equipotential bonding and using
overvoltage protective equipment.
Equipotential bonding is always required if the solar modules used do not comply with protection class II
and/or transformerless inverters are used.
The cross-section of the equipotential bonding conductor must correspond to the cross-section of the DC
main cable; however, it must be at least 6mm² (copper).
If the building is equipped with a lightning protection system and the PV generator is not located within the
protective area of the interception device, the module frame and the mounting system must be integrated
into the external lightning protection system and additional overvoltage protective equipment must be
installed.
The electrically conducting connection must have a minimum core size of 16mm² (copper). Please obtain
information on the currently applicable, technological standards!

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Laying the cables
Starting with the frame installation, several points concerning the direction of power lines and laying of
cables should be observed.
To avoid overvoltage couplings from lightning strikes, the resulting conductor loop must be kept to a
minimum.
Routed cables must not obstruct any potential snow and ice from sliding down.
Water must not collect around routed cables, ensure continuous water drainage.
Route cables 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.
Important!
Any calculations for the roof construction as well as any existing superstructures do not form part of the
static calculations as part of the PV substructure dimensioning. A structural engineer must inspect and
approve of theincreased and rearranged loads caused by thePV plant on site.

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03.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+ carrier 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
Important!
We would like to once again point out that the applicable accident prevention regulations (UVV) must be
observed when working on the roof (including VBG 37 construction work, paragraph 12 "Fall protection
equipment").

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We have illustrated the layout of the IBC TopFix 200 mounting system to improve transparency:
Figure 2: Fastenings for the IBC TopFix 200 pitched roof mounting system
Figure 3: Module fastening of the IBC TopFix 200 pitched roof mounting system
Description
A
Solar module
B
Roof hooks
C
Rafters
D
module clamp
E
Type TF50+/TF50m/TF60 carrier rail
F
M10x25 A2 T-head screw and M10 A4 locking nut

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Figure 4: Layout of the IBC TopFix 200 pitched roof mounting system
Description
L = (MB + 24 mm) × n + 32 mm
Carrier rail length =
(MB + 24 mm) × number of modules per row + 32 mm
MB
Module width
MH
Module height
A
Type TF50+/TF50m/TF60 carrier rail
B
Roof hooks
C
Middle clamp
D
Outside clamp
E
Max. 400mm
X
X –selected fixing interval
(dimensioned using PV Manager software)
Z
Max. ¼ of the module height (please observe module
manufacturer specifications)

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04.Fitting the various mounting systems
4.1General 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
instalation.
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 structural engineer.
Before starting installation, the existing wooden substructure must be checked for sufficient stability. The
wooden substructure must have a service life of more than 20 years. In case of doubt, consult a roofer or
joiner and a structural engineer.
As a rule, verify on-site static conditions and whether or not the outer roofing in conjunction with the
substructure (steel beams/purlins) is able to bear the additional pressure and dynamic loads of the PV
plant.
We shall not assume any system liability for the integrity of the roof as this mainly depends on the quality
of mounting or subsequent sealing procedures. The rules of the building trade as well as guidelines and
instructions of the roofing manufacturer are to be observed. Mounting system parts must not be treated
with additional anti-corrosion protection in normal, atmospheric conditions (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).
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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4.2 Fitting the roof hooks
In order to comply with warranty conditions (rain-proofing etc.) we recommend having the roof hooks fitted
by a 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 flat head screws. There is no need
to drill holes beforehand.
Align other roof hooks using a piece of string.
Reinsert roofing tile.
Important!
Do not use fitted roof hooks as a step ladder, as the pantile below could be damaged by the extreme
concentrated load!
Figure 6: Roof hook on the rafter Figure 7: Fitted roof hook
Figure 8: Fitted roof hook Figure 9: Alignment with piece of string
Figure 5: Roof hook

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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.
Important!
The leg of the roof hook lies in the depression in the pantile and must have a clearance of 5mm from the
surface of the tile. If necessary an underlay of suitable material should be installed in the space between
the rafter and the roof hook’s base plate as per Figure 10.
The roofing must not be damaged by loads arising from the fitted roof hooks! If there is a risk of this
occurring, additionally install suitable supports to distribute the load. Especially with older tiles, plain tiles
and slate roofs and where the installation site is in a high snow load zone, the use of sheet metal supports
or tin tiles is recommended. The guidelines of the roofing manufacturer must be observed.
The securing screws in the rafters and the rafters themselves are extremely important for the overall
system stress. Chipboard screws are not suitable owing to their smaller head diameter. 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.
Figure 10: Roof hook load distribution

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4.3 Roof hook types
Important!
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.
4.3.1 "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 1.4301 S460
yield strength
fy,k = 460 N/mm²
Dimensions base plate (length / width / height)
135/ 70/ 4 mm
Dimensions hook (width / height)
30/ 6 mm
Drilling holes baseplate
∅ 9 mm
Drilling holes hook
slot ∅ 11 mm, L=30 mm
Hook distancefrom the base plate
45 mm
weight
0,830 kg
General construction approval
Z-14.4.-661
Maximum ch. load / roof hook [kN]
not specified
not specified
not specified
Accessories
flat head screw 6x100-A2 TX25
flat head screw 8x100-A2 TX40
flat head screw 8x140-A2 TX40
flat head screw ASD 8x240-A2 TX40
countersunk screw 8x280 TX40
flat head screw ASD 8x300-A2 TX40
countersunk screw 8x340 TX40
connection piece for roof hook profile M10
Figure 12: Parameters roof hook Standard S+
Figure 11: "Standard S+" roof hook

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4.3.2"Standard S+ 35 mm" roof hooks
parameters
value
Material
Stainless steel 1.4301 S460
yield strength
fy,k = 460 N/mm²
Dimensions base plate (length / width / height)
135/ 70/ 4 mm
Dimensions hook (width / height)
30/ 6 mm
Drilling holes baseplate
∅ 9 mm
Drilling holes hook
slot ∅ 11 mm, L=30 mm
Hook distancefrom the base plate
35 mm
weight
0,820 kg
General construction approval
Z-14.4.-661
Maximum ch. load / roof hook [kN]
not specified
not specified
not specified
Accessories
flat head screw 6x100-A2 TX25
flat head screw 8x100-A2 TX40
flat head screw 8x140-A2 TX40
flat head screw ASD 8x240-A2 TX40
countersunk screw 8x280 TX40
flat head screw ASD 8x300-A2 TX40
countersunk screw 8x340 TX40
connection piece for roof hook profile M10
Figure 14: parameters roof hook “Standard S+ 35 mm“
Figure 13: roof hook “Standard S+ 35 mm“

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4.3.3 "Mammut S+" roof hooks
"Mammut S+" roof hooks are used to ensure the safety of the structure under high
snow loads. This roof hook provides improved static characteristics compared with
the "Standard S+" roof hook. In certain conditions (e.g. low snow load zone), it may
be possible to install "Mammut S+" roof hooks only on every second rafter and
consequently reduce the number of roof hooks.
parameters
value
Material
Stainless steel 1.4301 S460
yield strength
fy,k = 460 N/mm²
Dimensions base plate (length / width / height)
135/ 70/ 5 mm
Dimensions hook (width / height)
35/ 6 mm
Drilling holes baseplate
∅ 9 mm
Drilling holes hook
slot ∅ 11 mm, L=30 mm
Hook distancefrom the base plate
45 mm
weight
0,985 kg
General construction approval
Z-14.4.-661
Maximum ch. load / roof hook [kN]
not specified
not specified
not specified
Accessories
flat head screw 6x100-A2 TX25
flat head screw 8x100-A2 TX40
flat head screw 8x140-A2 TX40
flat head screw ASD 8x240-A2 TX40
countersunk screw 8x280 TX40
flat head screw ASD 8x300-A2 TX40
countersunk screw 8x340 TX40
connection piece for roof hook profile M10
Figure 16: parameters roof hook “Mammut S+”
Figure 15: "Mammut S+" roof hook

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4.3.4“Mammut SV+” roof hooks
For vertical installation of the carrier profile in the 1st layer.
parameters
values
Material
Stainless steel 1.4301 S460
yield strength
fy,k = 460 N/mm²
Dimensions base plate (length / width / height)
157/ 65/ 5 mm
Dimensions hook (width / height)
35/ 6 mm
Drilling holes baseplate
∅ 9 mm
Drilling holes hook
slot ∅ 11 mm, L=30 mm
Hook distancefrom the base plate
45 mm
weight
1,02 kg
General construction approval
Z-14.4.-661
Maximum ch. load / roof hook [kN]
not specified
not specified
not specified
Accessories
flat head screw 6x100-A2 TX25
flat head screw 8x100-A2 TX40
flat head screw 8x140-A2 TX40
flat head screw ASD 8x240-A2 TX40
countersunk screw 8x280 TX40
flat head screw ASD 8x300-A2 TX40
countersunk screw 8x340 TX40
connection piece for roof hook profile M10
Figure 18: parameters roof hook „Mammut SV+“
Figure 17: “Mammut SV+” roof hook

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4.3.5“Vario S+” roof hooks
For horizontal and vertical adjustability at the base plate.
parameters
value
Material
Stainless steel 1.4301 S460
yield strength
fy,k = 460 N/mm²
Dimensions base plate (length / width / height)
155/ 75/ 5 mm
Dimensions hook (width / height)
35/ 6 mm
Drilling holes baseplate
∅ 9 mm
Drilling holes hook
slot ∅ 11 mm, L=30 mm
Hook distancefrom the base plate
42 mm –55 mm
Horizontal adjustment at the base plate
± 55,5 mm
weight
1,355 kg
General construction approval
Z-14.4.-661
Maximum ch. load / roof hook [kN]
not specified
not specified
not specified
Incl. 1x coach bolt M10x25 A2 / 70
Incl. 1x hexagon nut M10 A4 / 70 with locking teeth
Accessories
flat head screw 6x100-A2 TX25
flat head screw 8x100-A2 TX40
flat head screw 8x140-A2 TX40
flat head screw ASD 8x240-A2 TX40
countersunk screw 8x280 TX40
flat head screw ASD 8x300-A2 TX40
countersunk screw 8x340 TX40
connection piece for roof hook profile M10
Figure 20: parameters roof hook “Vario S+”
Figure 19: “Vario S+” roof hook

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4.3.6 “Schiefer S+” roof hooks
Special roof hooks designed for the particular roofing tile shape are used for slate tiles.
parameters
value
Material
Stainless steel 1.4301 S460
yield strength
fy,k = 460 N/mm²
Dimensions base plate (length / width / height)
280/ 30/ 6 mm
Dimensions hook (width / height)
30/ 6 mm
Drilling holes baseplate
∅ 8,5 mm
Drilling holes hook
slot ∅ 11 mm, L=30 mm
Hook distancefrom the base plate
not specified
weight
0,55 kg
General construction approval
Z-14.4.-661
Maximum ch. load / roof hook [kN]
not specified
not specified
not specified
Accessories
countersunk screw 8x100 A2 TX40
connection piece for roof hook profile M10
Figure 22: parameters roof hook “Schiefer S+”
Figure 21: "Schiefer S+" slate tile roof hook