iFIX OW Smart Substructure Instruction Manual

iFIX OW Smart Substructure

Product Information: Photovoltaic Flat Roof Installation System for East-

West Orientation

The iFIX OW East-West Version 2021 (Version 2022)* is a smart substructure for photovoltaic installations. It is designed for flat roofs with an east-west orientation. The system is suitable for use in accordance with EN 1991-1-3 snow loads (Eurocode 1) and EN 1991-1-4 wind loads (Eurocode 1) standards. The iFIX OW installation unit has special features, including compatibility with steel sheets on gravel roofs and the absence of the need for a protection mat.

Product Usage Instructions

Important Planning Information

• Prior to installing the PV system, ensure that the roof is waterproofed according to DIN 18531 standards.
• Check the compatibility of the roof surface with iFIX OW to avoid long-term damage.
• Adhere to national and local construction regulations, standards, and environmental regulations.

General Installation and Safety Guidelines

• PV systems should only be installed and commissioned by persons with professional competence or experience to guarantee proper installation.
• At least one copy of the installation instructions must be present at the construction site and referred to during the entire installation period.
• The latest version of the installation instructions should always be referred to as steps in the installation process may change.
• Comply with occupational safety and accident prevention regulations, as well as relevant standards and regulations of the employers’ liability insurance association.

Statics
The assembly and layout of the substructure must meet EN 1991-1-3 snow loads (Eurocode 1) and EN 1991-1-4 wind loads (Eurocode 1) standards. Calculations must be undertaken according to current structural engineering practice.

Installation Steps
The system is installed by following the installation steps in the manual. The installation steps may change, so it is recommended to refer to the most recent version of the installation instructions. The latest documents are available at www.voestalpine.com/iFIX.

Maintenance
Regular maintenance is required to ensure the optimal performance of the PV system. Refer to the maintenance section of the manual for more information.

Warranty
Refer to the warranty section of the manual for information on the product warranty.

The Company
Refer to the company section of the manual for information on the manufacturer. Grounding/Equipotential Bonding

Connect the PV system with the building’s equipotential bonding prior to commissioning. The module clamps are linked so that all the components within a row of modules are conductively connected. One connection per row (up to 40 modules) is sufficient. Depending  on the situation on the roof, parts of the system may need to be connected with the external lightning arrester.

iFIX OW INSTALLATION UNIT

SPECIAL FEATURES OF THE iFIX OW

• Unique one click connection removes need for tools to connect the rows
• Fixation points to lay concealed cabling beneath the PV modules
• Uniform middle clamp and appropriate end clamps with pre-fixed Allen screws for all PV module frame heights
• Suitable building protection mat can be attached to the steel sheet
• No thermal separation between the rows necessary
• Large contact area permits use even on soft roof insulation material

IMPORTANT PLANNING INFORMATION

• iFIX OW can currently be used for buildings with closed facades. Other buildings must be examined on an individual basis.

• iFIX OW is suitable for installation on all standard flat roofs with a roof pitch of 0 to 3° and which are free of standing water. Up to 5° with special dimensions.

• Permissible roofing material: Bitumen, plastic sheeting, gravel, green roofs (metal sheets and others where individually inspected)

• Building heights of up to 25 m

• Fields of application: Snow loads up to 3.8 kN/m²

  • Wind load zones 1 to 3 (at least 3 km from the coast) Max. peak velocity pressure 1,400 N/m²

• Minimum distance between main iFIX OW steel sheet and roof edge 0.50 m.

• The PV modules should be installed on the roof in blocks of 4 units, i.e., 2 double rows, each with 2 PV modules. Where roof structures disrupt the layout, it is also permissible to occasionally have fewer PV modules side by side.

• Calculating the necessary number of iFIX OW in-stallation units per row: number of PV modules +1

• Calculating the row length (east-west): Calculating the row length (largest PV module length + 20 mm) x number of PV modules in the row + 380 mm

• Calculating the length of the array (north-south): 1,185 mm (1,210 mm)* x number of rows + 20 mm

• Separation due to linear thermal expansion:

  • A gap is necessary after max. 7 PV modules in the row (north-south orientation), with the ends of the PV modules separated by a distance of min. 0.5 m and max. 1.3 m. For larger distances, separate fields must be assumed when calculating ballast loads.
  • No gap is necessary between rows (east-west orientation).

• Suitable PV module sizes:

  • Minimum: 1,640 x 990 mm
    Maximum: max. 2,100 x 1,135 mm (x 1,145 mm)* Frame height: Frame 30 – 40 mm
    The PV module dimensions may not exceed a sur face area of 2.17 m² and a width of 1,145 mm.

• The compatibility of the roofing material and the iFIX OW steel sheet should be examined to ensure the long-term protection of the roof (see installa-tion guidelines). Building protection mats can also be fixed to the underside of the iFIX OW steel sheet.

• During planning, it should be determined whether the roof insulation material can bear the addi-tional pressure resulting from the weight of the PV installation, the ballast, and pressure loads. A contact area of 0.28 m² should be calculated for each PV module and iFIX OW steel sheet.

• From Version 10/2022* onwards, iFIX OW steel sheets will also be available with pre-mounted building protection mats (contact area 0.084 m²).

• System weight for 5 PV modules (length 1,770 mm) per row, without PV and ballast, incl. building protection mat, 1.40 kg/m²

• Installation over a roof ridge is only permissible where the knuckle line coincides with the area in which the steel sheets interlock.

• The system must be secured against lifting and shifting, respective of building location, wind and snow loads, and building height. Weights to hold the installation in place must be positioned in areas determined in the ballast plan drawn up by a system provider for that installation.

• iFIX OW steel sheets are currently delivered in packing units of 200 pieces.

• Further accessories can be supplied as required.

GENERAL INSTALLATION AND SAFETY GUIDELINES

STATICS
Prior to installation, the customer must check whether the building and roof are able to withstand the additional static requirements of the iFIX OW systems with respect to horizontal and vertical loads. The requirements for the Eurocode 3 (DIN EN 1993) standard must be observed. The ballast for placement on the roof is specified in the ballast plan drawn up by the system provider. The ballast plan may only be drawn up by trained personnel. A program is available for calculating the ballast and is based on a wind load certificate and the system statics provided by a government-approved struc- tural engineer.
Where the substructure for a PV installation has been planned by the customer themselves, the as-sembly and layout as well as the structural stability must meet the following standards:

• EN 1991-1-3 snow loads (Eurocode 1)
• EN 1991-1-4 wind loads (Eurocode 1)
  The calculations must be undertaken according to the standards of current structural engineering practice.
  Adherence to national and local construction regu-lations, standards and environmental regulations must be guaranteed.

SAFETY
Occupational safety and accident prevention r egulations, as well as the relevant standards and regulations of the employers’ liability insurance association, must be complied with.

These are:

• BGV A1: General accident prevention regulations
• BGV A3: Electrical systems and equipment
• BGV C22 Accident prevention regulations – construction work
• DIN 18338 Roofing work
• DIN 18451 Scaffolding work

The following should be noted in particular:

• Safety clothing must be worn (in particular a pro-tective helmet, safety boots, and gloves)
• Regulations on working on roofs must be observed during roof work (e.g., the use of: fall protection, equipment with fall arresting device for eaves at heights of over 3 m, etc.)
• Two persons must be present during the entire process of installation to ensure that help can be provided quickly in the event of an accident.
• Any necessary work to the roof itself must be undertaken by a roofing contractor.
• AC/DC cabling must be laid by an electrician. Here the following must be taken into account: DIN VDE 0100 Part 712 – Installation of low volt age systems.

INSTALLATION
PV systems may only be installed and commis-sioned by persons whose professional competence (e.g., training or work) or experience guarantees that the installation will be carried out properly.
At least one copy of the installation instructions must be present at the construction site and re-ferred to during the entire installation period.
iFIX OW is being constantly developed. Conse-quently, steps in the installation process may change. Therefore please refer to the most recent version of the installation instructions.
The latest documents are available at www.voestalpine.com/iFIX
Prior to installing the PV system, it should be con-firmed that the roof is waterproofed according to DIN 18531 standards. The compatibility of the roof surface with iFIX OW must be checked in order to avoid long-term damage. No protection mat is needed under iFIX OW steel sheets on gravel roofs where the iFIX OW steel sheet is installed directly on  the gravel. iFIX OW steel sheets fitted with building protection mats should be used on roofs water-proofed with bitumen. iFIX OW steel sheets with alu-minium-laminated protection mats must be used on roofs covered with plastic sheeting to prevent embrittlement of the roofing material. The sheeting manufacturer must confirm that the sheeting is compatible with the protection mat. Fleece matting may not be used as underlay and constitutes a danger! Localized depressions in the roofing mate-rial which lead to puddle formation must be leveled by laying material compatible with the roofing ma-terial in order to create a flat surface.
Where iFIX OW steel sheets are freshly cut at the in-stallation site, care must be taken that this does not impair their stability, and that sharp corners and edges on the cut edges cannot injure persons or the roofing material.
The PV module manufacturer’s installation instruc-tions must be adhered to, so that the PV module clamps are only applied in the areas authorized by the PV module manufacturer.
Cables must be laid to so that no cable loops are formed under the PV modules.
The following standards must also be complied with:

• VDS 2023 Electrical systems in building structures with predominantly combustible materi – als – guidelines on damage prevention DIN 4102 Fire behavior of building materials and parts
• DIN 1860 Drainage systems for buildings and  property

voestalpine Automotive Components Schwäbisch Gmünd GmbH & Co. KG is exempt from liability where our installation instructions and safety guide-lines have been ignored, or where parts made by competitors have been added or installed. The system is de-installed by following the installa-tion steps in the reverse order.

GROUNDING / EQUIPOTENTIAL BONDING
The PV system must be connected with the build-ing’s equipotential bonding prior to commissioning. The module clamps are linked so that all the com- ponents within a row of modules are conductively connected. One connection per row (up to 40 mod-ules) is sufficient. Depending on the situation on the roof, parts of the system may need to be connected with the external lightning arrester.

LIGHTNING CURRENT CARRYING CAPACITY
A lightning protection specialist must plan the PV system’s lightning current carrying capacity and that of the underlying building. The term “lightning current carrying capacity” is used for connections, clamps, etc. which must actively conduct lightning current as part of the lightning protection system. Each of these components must be subject to sep-arate testing and certification. The lightning current carrying capacity of a supporting system is gener-ally not relevant as the substructure is not used as a conductor or lightning rod as part of the external lightning protection system. Normally, the lightning protection system is planned completely inde-pendently of the PV system. As a rule, the PV system and the lightning protection system must be sepa-rated by a specified distance.
In some cases, it is permissible for the substructure to be connected to the lightning protection system, although here the partial lightning currents will be prevented from entering the electrical equipment. In this case the internal equipotential bonding of the substructure is correspondingly low-resistance and connected with a sufficiently large cross sec-tion. See separate “Information on equipotential bonding and lightning protection”.

The relevant standards for planning and installing lightning protection, grounding, and equipotential bonding:

• DIN EN 62305 Lightning protection DIN VDE 0185 Part 1–4 Lightning protection (in particular Part 3 Supplement 5)
• DIN VDE 0100 Part 410 Grounding
• DIN VDE 0105 Operation of electrical installations
• DIN VDE 0298 Electrical wiring

Please read all the instruction steps prior to installa-tion to ensure safe and proper installation of the system. The necessary material is listed for each step.

NECESSARY COMPONENTS

iFIX OW sheet with pre-fixed Allen screw

• Dimensions: 1,218 x 376 x 227 mm Weight: 3.236 kg
• Material: corrosion-resistant
• zinc-magnesium coated steel plate

Central clamp
2 per PV module

End clamp with pre-fixed Allen screw suitable for height of the PV module frame
2 per row end

Building protection mat with aluminium lamination
Optional: 1 piece per iFIX OW steel sheet

REQUIRED TOOLS\

(NOT INCLUDED)

INSTALLATION STEPS

1. STEP 1
   First row of iFIX OW steel sheets
   Start at the preset distance from the southern and western edges of the roof. Start by placing the steel sheets but without connecting them!
   Material : measuring tape, snap line, iFIX OW steel sheet

2. STEP 2
   Second and subsequent rows of iFIX OW steel sheets
   Place parallel to the first row.
   Sheet edge to sheet edge:
   L1 = PV module length
   Material : measuring tape, snap line, iFIX OW steel sheet

3. STEP 3
   Attach building protection mat, connect iFIX OW steel sheets, and adjust rows
   Place one building protection mat next to each iFIX OW steel sheet. Connect each building protection mat to the corresponding iFIX OW steel sheet with 4 clips.
   Material : Building protection mat

4. STEP 4
   Laying cables
   The supply and return cables needed for each row of modules can be laid prior to installation of the PV modules themselves and attached to the provided C-clips with cable binders. Tip: Pull the cable binders tight! Additional material such as cable trays and housing (UV resistant!) can also be laid.
   Material : Cable binders (UV-resistant), etc.

5. STEP 5
   Place ballast
   Position next to the first row.
   Sheet edge to sheet edge:
   L1 = PV module length
   Material : measuring tape, snap line, iFIX OW steel sheet

6. STEP 6
   Mounting the first row of PV modules
   Place PV module on upper positioning aid A, attach cable, use cable binder to fix cable to the C-shaped cutout provided on the steel sheet, and lay the PV module on the substructure.

7. STEP 7
   Place ballast on substructure
   Place ballast only on first iFIX OW steel sheet in a row.
   A and B are positioning aids for distancing the PV modules.

8. STEP 8
   Attach clamps
   Always attach clamps immediately after placing each individual PV module on the substructure using the torque controlled screwdriver (14 Nm tightening torque), and then make necessary minor adjustments to the orientation of the iFIX OW steel sheet rows
   Material : PV module, end clamp, middle clamps

9. STEP 9
   Ballast under the first row of PV modules
   Only now should the ballast blocks be positioned on the iFIX OW steel sheets under the PV modules

10. STEP 10
    Ballast under the second row of PV modules
    For every second row (completing a “double row”), the ballast blocks must be laid immediately after laying each individual module as they can no longer be positioned once all PV modules in the row are in place.
    Repeat steps 7 and 8 for all other rows of PV modules

MAINTENANCE

The mechanical safety of the PV installation must be examined annually by means of an on-site inspection. The PV modules must be lifted by hand to check that they remain firmly attached to the substructure. Loose PV modules should be immedi-ately secured. Any dirt which has collected should be removed and soiled areas washed down with water to maintain the corrosion resistance of the substructure. The specifications of the PV module manufacturer and the electrician must be observed during maintenance of the PV modules and the electrical cabling.

WARRANTY

The “General Warranty Conditions for iFIX” and the terms of sale of voestalpine Automotive Compo-nents Schwäbisch Gmünd GmbH & Co. KG as issued at the time of sale apply, both of which are available separately.

THE COMPANY

Based on competence
For decades, Automotive Components Schwäbisch Gmünd GmbH & Co. KG has been recognized for quality and service in pressing technology. As a supplier to the automotive industry, we have devel-oped powerful technical innovations which we now apply in the solar industry.

Working together
We bringing together existing operations to create new value: four sites in Germany and the Netherlands. And above all, the experience of our more than 1,500 employees. When our design, technology, development,and production experts pool their know-how, this gives rise to pioneering solutions for our customers.

With system
We develop system solutions for photovoltaics in-corporating a broad range of products which are perfectly coordinated, seamlessly integrated, and can be adapted to meet various requirements. iFIX OW is a perfect example of one such patented system solution.

All information specified in this brochure is according to the current status of our knowledge and experience. As printed materials cannot be updated, please refer to our website for the most recent version. Subject to technical changes, printing, and typesetting errors.

Find out more about the iFIX OW EAST-WESTand go to www.voestalpine.com/iFIX

voestalpine Automotive Components Schwäbisch Gmünd www.voestalpine.com/iFIX

References

• iFIX ist die smarte Unterkonstruktion für Photovoltaikm

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