iFIX SOUTH Assembly Instructions

One Part – One Click

Features of iFIX S

Tool-free connections between rows through a unique click-locking mechanism.
Wind deflector can be mounted without tools by simply sliding it in.
Fastening points designed for invisible cable routing underneath the PV modules.
Universal centre clamps and matching end clamps with pre-fixed Allen screw for all PV module frame heights.
Matching building protection mats are pre-assembled or can be attached to the sheet metal.
Thermal separation between the rows is not required.
Also suitable for use with soft roof insulation due to large footprint.

Important Planning Notes

iFIX S is suitable for buildings with a closed building front. It can be used on all standard flat roofs with a pitch of 0 to 3°, and up to 5° with special on-site measures, provided there is no permanent standing water. Acceptable substrates include bitumen, plastic film, gravel, and green roof. For sheet metal and other substrates, individual testing is required. The system is approved for building heights up to 25 m and application areas with pressure loads up to 3.8 kN/m² and wind zone 1-3 (gust velocity pressure up to 1,400 N/m²).

Key considerations include:

Minimum distance of iFIX S main sheet to roof edge: 0.50 m. No parapet required.
PV modules must be installed in blocks of at least 2 (e.g., 2 PV modules in a row or next to each other).
Calculation of required iFIX mounting units: Number of PV modules + 1 (for 1x iFIX EW + 1x iFIX S connector per row).
Row length calculation (east-west): (largest PV module length + 20 mm) x number of PV modules in series + 380 mm.
Field length calculation (north-south): 1,620 mm x number of rows + 20 mm (short connector) or 1,810 mm x number of rows + 20 mm (long connector).
Field separations due to thermal length changes are required: maximum 14.5 m in the row (east-west) with a gap of 0.5 to 1.3 m between PV module ends. For larger distances, separate fields must be assumed for ballast calculation. No field separation is required between rows (north-south).
Field separation due to thermal length changes (north-south): maximum 15 m in the row with a gap of 0.5 to 1.3 m between PV module ends.
Field separation between rows (east-west): required after max. 30 m. Regular visual inspections for thermally induced displacements are necessary, especially when using equipotential bonding or lightning protection accessories. Maintenance scope depends on observed displacement.

Note: Insufficient securing or lack of maintenance can lead to damage. voestalpine Automotive Components Schwäbisch Gmünd GmbH & Co. KG accepts no liability for consequential damage.

Applicable PV module sizes: Width: 990-1145 mm, Length: 1650-2100 mm, Frame height: 30-40 mm. Module area must not exceed 2.17 m² with a width of 1,145 mm.

Ensure compatibility between the roof surface and iFIX sheets. Building protection mats are recommended for bituminous roof waterproofing and for plastic foil roofs to prevent the roof cladding from becoming brittle. The film manufacturer must approve the compatibility of the film with the protective mat. Fleece mats are not allowed.

Compensate for height differences in the roof cladding with suitable underlays. Treat cut edges of iFIX sheet metal parts to prevent injury and damage to the roof cladding.

Adhere to the PV module manufacturer's instructions for clamping the modules.

Avoid conductor loops when laying cables under PV modules.

Comply with VDS 2023, DIN 4102, and DIN 1860 standards.

Earthing / Equipotential Bonding: Connect the system to the building's equipotential bonding. All components within a module row are conductively connected. Connection to external lightning protection may be necessary depending on the situation.

Lightning Current Carrying Capacity: Plan lightning protection with a specialist. The support system is not used as an arrester. The lightning protection system should be designed independently of the PV system, with a defined separation distance. In specific cases, connecting the rack system to the lightning protection is permissible, but requires careful consideration of partial lightning currents and low-resistance potential connections.

Standards to be Complied With: DIN EN 62305 (Lightning protection), DIN VDE 0185 Part 1-4 (Lightning protection), DIN VDE 0100 Part 410 (Grounding), DIN VDE 0105 (Operation of electrical systems), DIN VDE 0298 (Electrical wiring).

General Assembly and Safety Instructions

Structural Engineering: Clients must verify that the building and roof meet the static requirements for horizontal and vertical loads according to Eurocode 3 (DIN EN 1993). Ballast information is provided in the system provider's individual weighting plan, which must be drawn up by trained personnel. The iFIX Tool calculation program is available for determining weighting, based on a wind load report and system statics from a structural engineer.

Structural design must comply with EN 1991-1-3 (Snow loads) and EN 1991-1-4 (Wind loads), as well as the latest civil engineering standards. National and site-specific building regulations, standards, and environmental protection regulations must be observed.

Safety: Adhere to work safety and accident prevention regulations, including those from employers' liability insurance associations (e.g., BGV A1, BGV A3, BGV C22) and relevant DIN standards (DIN 18338, DIN 18451).

Wear protective clothing: safety helmet, work shoes, gloves.
For roof works, observe regulations for working on roofs, including fall protection and scaffolding with safety gear if the eaves height is 3 m or more.
Ensure two people are present during the entire installation process for rapid assistance in case of an accident.
Any necessary roof work must be carried out by a roofer.
AC/DC wiring must be carried out by an electrician, following DIN VDE 0100 Part 712 and other applicable regulations.

Mounting: PV systems should only be installed and commissioned by individuals with professional suitability (training or experience) to ensure work is carried out in accordance with regulations. Ensure at least one copy of the assembly instructions is available on site.

iFIX is under constant development; always use the latest version of the installation instructions. Current documents are available at www.voestalpine.com/iFIX.

Tool Overview

Protective gloves: EN 388 - Protection class min. 4431.
Measuring tape: About 3.0 m.
Impact cord: About 6.0 m.
Cordless screwdriver: Allen bit: 8 mm.
Torque wrench: Allen bit: 8 mm, TX30 Torx bit. Adjustable from 2 to 14 Nm.
iFIX Spacer
Cable ties: UV-resistant.

Key Components Required

iFIX Base / Protect / Alu-Protect: Dimensions: 1,218 x 376 x 227 mm. Weight: 3.236 kg. Material: corrosion-protected zinc-magnesium-coated sheet steel.
iFIX S Connector Compact: Dimensions: 453 x 376 x 227 mm. Weight: 1.95 kg. Material: corrosion-protected zinc-magnesium-coated sheet steel.
iFIX centre clamp: 2 units per PV module (with pre-fixed screw).
iFIX end clamp: 2 units per row end (with pre-fixed screw to match the PV module frame height).
iFIX S M6 grounding connector: 1 unit per iFIX S Connector.

Assembly Steps

Step 1: Laying out iFIX sheets

Alternately latch the iFIX Base to the S Connector at the markings, forming rows of metal sheets. Define the distance using the spacer. For use of the spacer, see page 16. Material: Measuring tape, impact cord, iFIX Base, iFIX S Connector. Hint: If iFIX Base is used with iFIX Base Protect, fit the building protection mat at the same time (see page 15).

Step 2: Ballasting iFIX sheets

Once the rows have the correct spacing, weigh down the iFIX Base sheets with ballast stones, not the iFIX S Connector. Proceed exactly according to the complaint plan from the project report. Note: Always place the ballast blocks starting at the high area. Material: Ballast stones. Hint: When lightning current carrying connections are required, install them before PV modules are installed.

Step 3: Install PV modules

Position the PV modules on the upper and lower positioning aids (A and B), starting on the south side. Slide the upper frame to the stop (C). Connect the cable and lay the PV module over the entire surface. A and B are positioning aids for the spacing of the PV modules. Material: PV modules.

Step 4: Cable connections

Plug the cable connections between the PV modules together and fasten them. Material: Cable ties. Hint 1: Cables can be fixed to the C-shaped cut-outs in the sheet metal using cable ties. Hint 2: For high snow loads (iFIX Alpin), supports should be installed with the PV modules (see installation instructions for iFIX Alpin).

Step 5: Set clamps

Tighten the clamps immediately after installing the PV modules with a tightening torque of 12 Nm. This ensures fine alignment of the iFIX sheet metal rows. Material: PV modules, iFIX end clamps, iFIX centre clamps, cordless screwdriver, torque spanner with Allen bit: 8 mm.

Step 6: iFIX S Deflector

Slide one end of the iFIX S Deflector into the first upper fastening point (1), then into the lower one (2), and then into the upper one (3). Next, push the iFIX S Deflector through slightly and slide it into the three attachment points at the other end in the same order. Insert the second iFIX S Deflector in the same order, overlapping the first one. Material: iFIX S Deflector.

Move the iFIX S deflectors until they reach the end of the row, 40 to 60 mm from the edge of the iFIX S connector. The iFIX S deflector overlap (X) results from the PV module length and the selected iFIX S deflector length. Hint: iFIX S Deflector 1780 for PV modules up to 1,780 mm in length. iFIX S Deflector 2100 for PV modules up to 2,100 mm in length.

Step 7: Potential equalisation/grounding

Tighten the M6 grounding screw through the slotted hole into the hole of the iFIX S Connector with a maximum of 10 Nm tightening torque. Material: M6 grounding screw, cordless screwdriver, torque wrench with TX30 Torx bit.

Step 8: Ballasting the iFIX connector

Place the ballast on the iFIX S Connector according to the weighting plan from the project report.

Maintenance

Regular checks of the system offset are part of maintenance due to the effect of movements on mechanical stability, roof cladding, and structural connections. The scope of maintenance depends on the observed displacement and is detailed in the relevant chapter. Remove dirt and coarse impurities with water for permanent corrosion protection. Follow the PV module manufacturer's specific specifications and the installer's instructions for electrical components.

Warranty

The "General Terms and Conditions of Warranty for iFIX" and the "General Terms and Conditions of Sale" of voestalpine Automotive Components Schwäbisch Gmünd GmbH & Co. KG apply. These are available separately and are valid at the time of purchase.

Accessories

Fastening the iFIX Base Protect

Place a building protection mat under each iFIX Base sheet. Raise the four tabs over the sheet at the marking on the edge of the sheet. Material: iFIX Base Protect. Hint: Ensure the correct orientation of the mat: a round hole in the low area of the iFIX Base plate. The mat must not cover the water drainage holes.

Protector

Additional protective mat recommended for the last iFIX sheets in the assembly line.

Procedure:

Always slide the protective mat under the iFIX plate on the unconnected side of the last iFIX plate.
Fold the tabs of the mat upwards over the sheet metal. Ensure the mat is positioned in the area of the sheet metal rounding and that it completely underlays the click area.

Important note: The iFIX plate must rest on the roof in the area of the protector. The protector must not hang in the air. It is recommended to move the ballast on the iFIX plate towards the protector.

iFIX Spacer

Spacing gauge for simplified and correct alignment of the iFIX mounting plates.