IBC SOLAR AeroFix Series, Installation Instructions Manual

Page 1: ...1 Installation instructions IBC AeroFix AeroFlat Version 20 01 Date 20 July 2020...

Page 2: ...ion standards and regulations 4 4 System variants 8 5 Technical data 10 6 System planning 11 7 System design dimensioning 15 8 System installation AeroFix 16 9 System installation AeroFlat 44 10 Syste...

Page 3: ...oFix AeroFlat flat roof system quickly and simply we have enclosed detailed assembly instructions They should help you to quickly become familiar with the assembly of the bracket and the modules Pleas...

Page 4: ...at roof system is for mounting solar modules onto flat roofs and pitched roofs The modules are attached on supports or base rails using clamps The number of parts varies depending on installation size...

Page 5: ...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 guideli...

Page 6: ...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 Pr...

Page 7: ...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...

Page 8: ...System variants 4 1 AeroFix Southern orientation East west orientation Fig 2 AeroFix 15 S AeroFix 15 S Kits Fig 3 AeroFix 10 S Fig 4 AeroFix 10 EW beginning ending with wind plates Fig 5 AeroFix 10 EW...

Page 9: ...9 Version 20 01 20 July 2020 4 2 AeroFlat Parallel to the roof Fig 6 AeroFlat...

Page 10: ...ration 15 x 15 15 x 15 14 x 15 14 x 14 Minimum distance to roof edge m no no no 0 3 Material Aluminium stainless steel Aluminium stainless steel Aluminium stainless steel Aluminium stainless steel Max...

Page 11: ...f covering The AeroFix AeroFlat flat roof system can be built on bitumen foil concrete gravel an green roof Basically the building protection mats of the base rails should lie completely on the roof s...

Page 12: ...e latest after 14 rows 7 V rows and after 15 modules in the row The field beginning and ending with modules is not counted as a row AeroFlat must be separated at the latest after 14 rows and after 14...

Page 13: ...e surface pressure of the AeroFix base rail G2 Eco is higher than that of the AeroFix base rail G2 because of the smaller contact surface Important information The assembly system including the module...

Page 14: ...anning purposes depending on the material combination the following values can be used as an approximation Fleece polyester Building protection mat rubber based Building protection mat aluminium lamin...

Page 15: ...econds afterwards In the next step the force F has to be applied steadily and parallel to the centre of the specimen and measured by the dynamometer To determine the coefficient of friction the decisi...

Page 16: ...V system the roof must be cleared of dirt snow and ice Base rails The assembly of the base rail G2 and G2 Eco is idendical Measure roof and mark out edge and corner areas Install base rails with integ...

Page 17: ...17 Version 20 01 20 July 2020 Fig 15 Installation base rails Fig 16 Installation base rails...

Page 18: ...18 Version 20 01 20 July 2020 Extend base rails Fig 17 Insert base rail connectors up to half way into the base rail Fig 18 Secure each base rail connector with a sheet metal screw...

Page 19: ...19 Version 20 01 20 July 2020 Base rail alignment Fig 19 Join the base rails together and screw in 2 more sheet metal screws Fig 20 Align the base rails so that they are parallel and vertical...

Page 20: ...uneven roofs it can happen that the base rail rests on the roof covering In this case additional protection mats must be placed Building protection mats can be ordered separately Fig 21 Distance betw...

Page 21: ...rmissible surface pressure of the roof insulation a third base rail may be necessary The additional baserail with supports is placed cetrally under the modules Module clamps are not reqired here Fig 2...

Page 22: ...22 Version 20 01 20 July 2020 Supports AeroFix Southern orientation AeroFix 15 S AeroFix 10 S Fig 24 AeroFix 15 S Dimensions Fig 25 AeroFix 15 S Support top and support bottom...

Page 23: ...tion of the supports AeroFix 10 S 15 S Support bottom must be laid out completely on the base rail AeroFix 15 S 1 8m 1 62m 1 98m AeroFix 10 S 1 6m 1 44m 1 76m Fig 26 Mark out support bottom Fig 27 Sta...

Page 24: ...24 Version 20 01 20 July 2020 Fig 28 Screw the support bottom onto the base rail on the marking with screw M8x16 Fig 29 Mounted support bottom...

Page 25: ...960 mm 725 mm 970 mm 736 mm 980 mm 746 mm 990 mm 756 mm 1000 mm 767 mm 1010 mm 777 mm 1020 mm 787 mm 1030 mm 797 mm 1040 mm 807 mm 1050 mm 818 mm Tab 3 AeroFix 15 S Distance between support top and su...

Page 26: ...960 mm 773 mm 970 mm 783 mm 980 mm 793 mm 990 mm 803 mm 1000 mm 813 mm 1010 mm 823 mm 1020 mm 833 mm 1030 mm 843 mm 1040 mm 854 mm 1050 mm 864 mm Tab 4 AeroFix 10 S Distance between support top and su...

Page 27: ...ail The number and position of the ballast rail is determined by the static calculations for the project See more at chapter 8 4 Fig 32 The ballast rail is attached directly in front of the support to...

Page 28: ...least 1250 mm when using a wind deflector Important information If you end with a wind plate you will need the AeroFix 10 S support top instead the AeroFi 10 EW support top Define the position of the...

Page 29: ...29 Version 20 01 20 July 2020 Fig 38 Screw the support bottom into the base rail on the marking with screw M8x16 Fig 37 Standard grid spacing 2 3 m...

Page 30: ...763 mm 960 mm 773 mm 970 mm 783 mm 980 mm 793 mm 990 mm 803 mm 1000 mm 813 mm 1010 mm 823 mm 1020 mm 833 mm 1030 mm 843 mm 1040 mm 854 mm 1050 mm 864 mm Tab 5 Distance between support top and support...

Page 31: ...position of the ballast rail is determined by the static calculations for the project For more information on ballast please refer to chapter 8 4 Fig 40 The ballast rail is attached directly in front...

Page 32: ...ing ballast to the base rail it is not permitted to completely seal the space between the base rail and the module with ballast stones Fig 41 AeroFix 10 EW ballast with ballast rail and base rail Fig...

Page 33: ...system has to be loaded with more than 42 kg 28 kg per module a ballast rail is necessary The assignment of the ballast track should always be done from the outside inward When using the ballast ston...

Page 34: ...ner clamping The snow load rail is inserted in the mountuing supports and is fixed with clips on the module The clips do not replace the module clamp The installation instructions and maximum allowed...

Page 35: ...iddle clamp G4 and at the end of the row with the EC adapter The clips of the sno load rail do not replace the module clamps The surface pressure on the insolation is increased and must also be checke...

Page 36: ...procedure for installing AeroFix10 S AeroFix 10 EW is identical to that of AeroFix 15 Fig 50 The module must lie flat against the end stop on the support top with wind plate mounting Fig 49 Insert th...

Page 37: ...r panel of the upper support Beginning with the outer clamps tighten the modules to a torque of 15 Nm For this we recommend a torque wrench with Torx bit size TX40 Fig 51 Module on the end stop and cl...

Page 38: ...information Depending on the height of the module frame a different version of the outer clamp G3 will be required The EC adapter for G4 middle clamp covers only the frame sizes 33 35 38 40 45 and 46m...

Page 39: ...o the support or introduced laterally where it is needed The adaptor EC is clamped by the given frame height with the middle clamp G4 and substitutes thus the end clamp Fig 54 Pivoting the middle clam...

Page 40: ...ate Screw both plates onto the base rail The gap between screw and end of the base rail should be at least 3 cm Repeat process with the other wind plates in the row The first and last wind plates in t...

Page 41: ...41 Version 20 01 20 July 2020 Fig 59 Wind plate assembly starting from the left Fig 60 Insert wind plate...

Page 42: ...42 Version 20 01 20 July 2020 Fig 61 Wind plate assembly Fig 62 Fixation wind plate...

Page 43: ...43 Version 20 01 20 July 2020 Cable clip assembly Fig 64 assembly cable clip 90 Fig 63 assembly cable clip 0...

Page 44: ...Flat Before constructing the PV system the roof must be cleared of dirt snow and ice 9 1 Base rail Install base rails with integrated building protection mat Fig 65 Base rail installation Fig 66 Inser...

Page 45: ...45 Version 20 01 20 July 2020 Fig 67 Secure each base rail connector with a sheet metal screw Fig 68 Join the base rails together and screw in 2 more sheet metal screws...

Page 46: ...46 Version 20 01 20 July 2020 9 2 Support rail Fig 69 Fix universal connector AeroFlat with M8x20 socket cap screw Fig 70 Mounted universal connectors AeroFlat...

Page 47: ...rsion 20 01 20 July 2020 Important information The support rail overhang of the TF60 profile must not exceed 400 mm Fig 71 Support rail TF60 mounted at universal connector Fig 72 Maximum allowable ove...

Page 48: ...engaged with the rail so they are completely inserted The support rail pieces must be fastened to at least two support points before a butt connector may be installed Not more than one butt connector...

Page 49: ...allasting potential on the base rail is and corresponds in the above mentioned blocks 56 kg for the AeroFlat Important information It must be ensured by the customer that the ballast does not slip ove...

Page 50: ...the system has to be loaded with more than 56 kg on the base rail the ballast is placed on L angles between the base rails The ballast on the L angles should always be from the outside to the inside F...

Page 51: ...51 Version 20 01 20 July 2020 9 4 Module assembly Fig 77 Place the module on the base rail and fasten with clamps Fig 78 Place the second module next to it and fix ist with clamps...

Page 52: ...52 Version 20 01 20 July 2020 Fig 79 After two modules keep a distance of 250 mm Fig 80 Mounted module field...

Page 53: ...53 Version 20 01 20 July 2020 Fig 81 Schematic system dimensions...

Page 54: ...information Depending on the height of the module frame a different version of the outer clamp G3 will be required The EC adapter for G4 middle clamp covers only the frame sizes 33 35 38 40 45 and 46m...

Page 55: ...o the support or introduced laterally where it is needed The adaptor EC is clamped by the given frame height with the middle clamp G4 and substitutes thus the end clamp Fig 83 Pivoting the middle clam...

Page 56: ...anti slip syftey device can be attached at the building The fastening to the building must be planned and statically tested by the customer The anti slip safety device is then attached every second t...

Page 57: ...57 Version 20 01 20 July 2020 Fig 89 Longitudinally mounted anti slip saftey device AeroFlat Fig 88 AeroFlat anti slip saftey device...

Page 58: ...l with a M8x16 socket head screw The perforated tape is connected to the base rail with at least two M8x16 socket head screws Important information Additional safety measures may be required for large...

Page 59: ...1 Final inspection After completing the PV system inspect the screw and clamp connections Check the entire structure for strength and stability and check the roof cladding for damage It is advisable t...

Page 60: ...se rail with integrated building protection mat foil laminated ak 6101100066 Base Rail ak G2 800mm 6101100067 Base Rail ak G2 1500mm 6101100068 Base Rail ak G2 2200mm 6101100069 Base Rail ak G2 3100mm...

Page 61: ...128 End clamp G3 31 mm black 6700400165 End clamp G3 32mm 6700400166 End clamp G3 32mm black 6700400129 End clamp G3 33 mm 6700400169 End clamp G3 33 mm black 6700400130 End clamp G3 35mm 6700400131 E...

Page 62: ...lamp G4 33 46mm 6700400145 Middle clamp G4 33 46mm black 6700400161 EC adapter 33 46mm 6700400162 EC adapter 33 46mm black 6900600010 Self drilling screw 4 8x19 SW8 6900100012 Socket Cap Screw M8x16 A...

Page 63: ...T head screws 2x DIN 6923 M10 A4 locking nuts 6101100057 Universal connector AeroFlat Including 1x M10x35 A2 T head screw 1x M10 A4 locking nut completely pre assembled 6802100009 Alu L profile 50x30x...

Page 64: ...bottom Also used in AeroFix 10 EW with module beginning and ending 6101100016 Wind plate Also used in AeroFix 10 EW with wind plate beginning and ending AeroFix 10 EW 6101100044 Support top Without wi...

Page 65: ...101100058 Building protection mat 500x172x15 mm 6101100059 Building protection mat ak foil laminated 500x172x15 mm 6101100076 Building protection mat Eco 500x129x15 mm 6101100077 Building protection m...

Page 66: ...bonding 6101100023 Assembling jig for ground rail distance support distance 6101100024 Static friction measuring device to determine the static friction coefficients incl case dynamometer 6101100048 S...

Page 67: ...scribed for the entire PV system it must be carried out an annual and event dependent heavy storm hail etc inspections of the mounting system into account the points of the maintenance log In the main...

Page 68: ...68 Version 20 01 20 July 2020...

Page 69: ...st specimen using the tension spring and then measured using the spring scale It is important that the force be applied evenly The maximum force that can be applied before the test specimen begins to...

Page 70: ...e Temperature Dry Wet Test No Test specimen weight Measured force Test specimen weight Measured force G kg F kg F G G kg F kg F G 1 2 3 4 5 Evaluation based on lowest measured value Appendix Roof layo...

Page 71: ...71 Version 20 01 20 July 2020 13 4 Checklist IBC AeroFix...

Page 72: ...72 Version 20 01 20 July 2020...

Page 73: ...73 Version 20 01 20 July 2020 14 Notes...

Page 74: ...74 Version 20 01 20 July 2020 IBC SOLAR AG Am Hochgericht 10 96231 Bad Staffelstein Phone 49 0 9573 92 24 0 Fax 49 0 9573 92 24 111 info ibc solar de www ibc solar com...