Installation Manual
Contents
1. cCLENERGY PV ezRack SolarRoof Code Compliant Planning and Installation Complying with AS NZS1170 2 2011 ADMT 2 2012 CONTENT ee Installation Guide_PV ezRack_SolarRoof_AU_ V2 3 18 20 Duerdin St Clayton VIC 3168 Australia www clenergy com au nege aS EnS Ue A EE E eau tence ees inte sa ga stay emda E EEE E E E 2 PANIN ee E E E EA J Oe i 812 9 9 es EIS iaee r E E S E E E E 8 Aray PANN ea S E ener 9 Step Dy step installaatio 6 eee me no i 10 e a E E ee ee ere 18 Page 1 of 18 Tel 61 3 9017 6688 Fax 61 3 9017 6668 Email sales clenergy com au CLENERG Y Introduction The Clenergy PV ezRack SolarRoof has been developed as a universal PV mounting system for roof mounting on pitched and flat roofs The use of patented aluminium base rails the Z Module technology and the telescopic mounting technology eliminates custom cutting and enables particularly fast installation Please review this manual thoroughly before installing PV ezRack SolarRoof This manual provides 1 Supporting documentation for building permit applications relating to PV ezRack SolarRoof Universal PV Module Mounting System and 2 planning and installation instructions The PV ezRack SolarRoof parts when installed in accordance with this guide will be structurally adequate and will meet the AS NZS1170 2 2011 Admt 2 2012 standard During installation and especially when working on the roof pl2. Region B S AE ae a f TEON Cocos Islands Darwin _ amp a Region C fg 11 t ih ke McDonnell Creek S ie er Moreton Region C Wyndham Ic RS Mareeba Adelaide River Region C FN wCairns f Kununurra West Moreland A a P Ivanhoe l gt Burketown Port er Renna _ scr Croydon fo Karratha OYN N 20 gt lt j Rockhampton Millstream SS ae Biloela _ AN Bundaberg Region D lt e AO d Region C O 4 25 Carnarvon Z Y Region B 25 Si Gascoyne Junction Region A4 Toowoomba A Brisbane AN Yy Callytharra Z NY LS H yoge j Corindi Norfolk Islands 3 iF aa Mullewa Dae f Region Bourke 73 30 Region B ni Morawa pim PA Region A1 Woomera Lord Howe Island we Kalgoorlie Region A 30 Green Sunviat Head Perth Sydney Region A2 Esperance pie ane 35S Albany Mount Gambier _ 50 km Regions are marked with the letters Region A5 __ i L t A A 10am ae D within 70 km aa a y border oastal Region boundaries are of Melbourne G P O oat Pat smooth lines set in from a smoothed Geelong 2 TA 40 coastline by 50 100 150 and 200 km Jo islands within 50 km of the coast Region A3 are the same Region as the adjacent coast Hobart Region Definition Wind regions are pre defined for al
3. 61 3 9017 6668 www clenergy com au Email sales clenergy com au cCLENERGY 9 1 In case you need to install on corrugated tin roof cladding the Tin Interface L Feet is to be used Drill through the roof cladding at the planned location and use the supplied wood screws to fix the L Feet to the wooden purlin If you need to fix to metal purlin please use suitable metal screws 14TPI or Buildex RoofZips with the same 6mm diameter 9 2 Place the supplied EPDM rubber under the L Feet in the way that the screw goes through the hole in the EPDM rubber pad When fastening the screw make it sure that you don t deform the corrugation of the roof cladding This can happen if you penetrate too deep with the screw when fastening Installation Guide_PV ezRack_SolarRoof_AU_V2 3 Page 13 of 18 18 20 Duerdin St Tel 61 3 9017 6688 Clayton VIC 3168 Australia Fax 61 3 9017 6668 www clenergy com au Email sales clenergy com au CLENERG Y 13 Before installing the modules add anti slip protection to the lowest row of modules horizontal rail installation only To do this fasten M6 x 20 mm bolts with the shank downwards to the lower mounting holes of the module frame using M6 nuts When installing large modules M8 x 20mm bolts must be used 14 Place the first module of the bottom row so that the anti slip protection sits in the rail channel of the lowest row of rails 15 Slide the m
4. Vertical spacing of the roof hooks approx 1 2 to 3 4 of module height 5 Distance between the modules 17 mm 6 Always check the installation manual of the PV Module you use in order to determine the allowed fixing points on the Module frame Installation Guide_PV ezRack_SolarRoof_AU_V2 3 Page 10 of 18 18 20 Duerdin St Tel 61 3 9017 6688 Clayton VIC 3168 Australia Fax 61 3 9017 6668 www clenergy com au Email sales clenergy com au CLENERGY Step by Step Installation 1 Determine the positions of the roof hooks according to your plans Remove the roof tiles at the marked positions or if possible simply push them up slightly 2 Fix the roof hooks to the rafter using two 6 x 80mm wood screws Use ONLY stainless steel sockets using normal steel socket can result surface rust on the wood screw 3 The roof hook must not Correct press against the roof tile If necessary shim the roof hook with wood 4 If necessary use an angle grinder or hammer to cut a recess in the tile that covers the roof hook at the point where the roof hook comes through so that the tile lies flat on the surface If grooved tiles are used it will also be necessary to cut a recess in the lower tile For high profile Spanish tiles a Roof Hook Extender can be used Installation Guide_PV ezRack_SolarRoof_AU_ V2 3 Page 11 of 18 18 20 Duerdin St Tel 61 3 9017 6688 Clayton VIC 3168 Australia Fax 61 3 9017 6668 www clen
5. terrain category 3 if it is outside of this please refer to the accreditation letter Installation Guide_PV ezRack_SolarRoof_AU_V2 3 Page 5 of 18 18 20 Duerdin St Tel 61 3 9017 6688 Clayton VIC 3168 Australia Fax 61 3 9017 6668 www clenergy com au Email sales clenergy com au CLENERG Y 3 Determine the height of your installation site This document provides sufficient information for the PV ezRack SolarRoof system installation up 20 meter height If your installation site is more than 20 meters please contact Clenergy to obtain additional engineering certificate to Support your installation 4 Determine Roof slope The PV ezRack SolarRoof system can be used for roof slope up to 60 degrees Please verify that the Installation site roof slope is between O and 60 degrees 5 Determine the Maximum Rail Support Spacing a Tile roof Please use the following table to determine the base rail support spacing for tile roof installations mm Max PV panel dimension 2000mm x 1000mm Max panel weight 15 kg m Roof Angle 20 60 Terrain Category 3 for roof pitch 30 60 refer to accreditation letter 10 20 pitch Building Height H m 10 lt H lt 15 15 lt H lt 20 20 30 pitch Wind Building Height H m Region 10 lt H lt 15 15 lt H lt 20 A B C D e Please consult Clenergy for installing PV modules with a greater length than 2000mm or heavier than 15 kg m e In case the wooden
6. unenclosed bays on seas and oceans lakes and enclosed bays extending greater than 10km in the wind direction The terrain height multipliers for this terrain category shall be obtained by the linear interpolation between the values for the TC1 and TC2 in table 4 1 Terrain Category 2 TC2 Open terrain including grassland with well scattered obstructions having heights generally from 1 5m to 5m with no more than two obstructions per hectare e g farmland and cleared subdivisions with isolated trees and uncut grass Terrain Category 2 5 TC2 5 Terrain with a few trees or isolated obstructions This category is intermediate between TC2 and TC3 and represents the terrain in developing outer urban areas scattered houses or larger acreage developments with fewer than ten buildings per hectare The terrain height multipliers for this terrain category shall be obtained by linear interpolation between the values for the TC2 and TC3 in table 4 1 Terrain Category 3 TC3 Terrain with numerous closely spaced obstruction having heights generally from 3m to 10m The minimum density f obstructions shall be at least the equivalent of 10 house sizes obstructions per hectare e g suburban housing or light industrial estates Terrain Category 4 TC4 Terrain with numerous larger high 10m to 30m tall and closely spaced constructions such as large city centres and well developed industrial complexes In this installation manual we have used
7. e modules is identical Continue mounting the PV Modules as described in steps 15 to 20 until all PV modules are installed Installation Guide_PV ezRack_SolarRoof_AU_V2 3 Page 15 of 18 18 20 Duerdin St Tel 61 3 9017 6688 Clayton VIC 3168 Australia Fax 61 3 9017 6668 www clenergy com au Email sales clenergy com au CLENERG Y Accessories 1 Position the Z Module in the rail channel Fix the bracket with bolt Recommended bolt torque 15 20Nm 2 The final installation with the isolator mounted Installation Guide_PV ezRack_SolarRoof_AU_V2 3 Page 16 of 18 18 20 Duerdin St Tel 61 3 9017 6688 Clayton VIC 3168 Australia Fax 61 3 9017 6668 www clenergy com au Email sales clenergy com au cCLENERG Y 1 Hook the top end of clip into the groove on the back of the rail 2 Push the other end of clip in to the rail groove You can use a rubber mallet 3 cable clip installation completed 4 The cable clip can hold up to 6 PV cables Installation Guide_PV ezRack_SolarRoof_AU_V2 3 Page 17 of 18 18 20 Duerdin St Tel 61 3 9017 6688 Clayton VIC 3168 Australia Fax 61 3 9017 6668 www clenergy com au Email sales clenergy com au CLENERG Y Service 10 year limited Product Warranty 5 year limited Finish Warranty Clenergy co Ltd warrants to the original purchaser Purchaser of product s that it manufactures Produc
8. ease comply with the appropriate occupational health and safety regulations Please also pay attention to other relevant regulations of your local region Please check that you are using the latest version of the installation manual which you can do by contacting Clenergy Australia via email on sales clenergy com au or contacting your local distributor in Australia Installation Guide_PV ezRack_SolarRoof_AU_V2 3 Page 2 of 18 18 20 Duerdin St Tel 61 3 9017 6688 Clayton VIC 3168 Australia Fax 61 3 9017 6668 www clenergy com au Email sales clenergy com au cCLENERG Y Planning The installer is solely responsible for e Complying with all applicable local or national building codes and Clean Energy Council guidelines including any that may superseded this manual e Ensuring that PV ezRack SolarRoof and other products you use are appropriate for the particular installation and the installation environment e Ensuring that the roof its rafters connections and other structural support members can support the array under building live load conditions this total assembly is hereafter referred to as the roof rafter assembly e Using only genuine PV ezRack parts substitution of parts may void the warranty and invalidate the letter of certification e Ensuring that lag screws have adequate pull out strength and shear Capacities as installed e Maintaining the waterproof integrity of the roof including selection of approp
9. ergy com au Email sales clenergy com au CLENERG Y 5 Caution Do not use fitted roof hooks as a ladder as this extreme point load could damage the tile below 6 Variation for installation on plain tile roofs with plain tile roof cladding a recess must be cut into the tiles around the position of the roof hook 7 General Information for using Z Module connection to ensure easy connection of the roof hooks with the rail using the Z Module you should make sure that the thread of the bolt does not project through the lower side of the Z Module max flush Position the Z Module in the rail channel and fasten it loosely with 2 to 3 turns of the bolt The bolts can be then freely moved in the rail channel Slide the bolts to their final and fasten firmly recommended torque is 15 20Nm 8 Installation of the rails on roof hooks if the PV ezRack rails consist of different lengths always begin with the shortest piece Install the framing for each row of modules loosely on the roof hooks using an M8 x 25 mm Allen bolt washers retaining washers and the Z Module 2 to 3 turns of the screw are adequate for loose installation 9 Adjust to necessary vertical and horizontal position by using the slot hole in the roof hooks and connection of the Z Module or on the rail Installation Guide_PV ezRack_SolarRoof_AU_ V2 3 Page 12 of 18 18 20 Duerdin St Tel 61 3 9017 6688 Clayton VIC 3168 Australia Fax
10. esigned for mounting in to wooden structures 10TPI Clenergy recommend using 12G 14TPI screws or M6 Buildex RoofZips to fix to steel purlins Installation Guide_PV ezRack_SolarRoof_AU_V2 3 Page 7 of 18 18 20 Duerdin St Tel 61 3 9017 6688 Clayton VIC 3168 Australia Fax 61 3 9017 6668 www clenergy com au Email sales clenergy com au CLENERG Y General Notes e Recommended screws Wood purlins and Rafter eran ener aon oan M6 11 TPI RoofZips OR 14g 10 TPI embedment and above gt Screws minimum embedment length into timber 35 mm gt Above Spacing calculated based on 1 9mm steel purlin OR F17 Hardwood e In wind region C and D the spacing on should be reduced as shown below Material Wind Region C Wind Region D 0 55 mm steel Batten 0 75 mm steel Batten lt P VSS Purlins Battens SSS SN gt Sy i aa i E VY Yy Rafters Trusses 6 Verify acceptable Rail End Overhang Rail End Overhang must equal 50 or less of foot spacing Thus if foot spacing is 1200 mm the Rail End Over hang can be up to 600 mm In this case two feet can support a rail of as much as 2400 mm 1200 mm between the feet and 600 mm of overhang at each end Installation Guide_PV ezRack_SolarRoof_AU_V2 3 Page 8 of 18 18 20 Duerdin St Tel 61 3 9017 6688 Clayton VIC 3168 Australia Fax 61 3 9017 6668 www clenergy com au Email sales clenergy com au cCLENERGY Components List Installati
11. ied Warranty periods the Product shall be reasonably proven to be defective then Clenergy shall repair or replace the defective Product or any part thereof in Clenergy s sole discretion Such repair or replacement shall completely satisfy and discharge all of Clenergy s liability with respect to this limited Warranty Under no circumstances shall Clenergy be liable for special indirect or consequential damages arising out of or related to use by Purchaser of the Product Manufacturers of related items such as PV modules and flashings may provide written warranties of their own Clenergy s limited Warranty covers only its Product and not any related items Installation Guide_PV ezRack_SolarRoof_AU_V2 3 Page 18 of 18 18 20 Duerdin St Tel 61 3 9017 6688 Clayton VIC 3168 Australia Fax 61 3 9017 6668 www clenergy com au Email sales clenergy com au
12. l of Australia by the Australian Standard 1170 2 The Wind Region is an independent factor of surrounding topography or buildings e Most of Australia is designated Region A which indicates a Regional Ultimate Basic Wind Velocity of 45m s e Some areas are designated Region B 57m s Local authorities will advise if this applies in your area e Region C areas 66m s are generally referred to as Cyclonic and are generally limited to northern coastal areas Most Region C zones end 100km inland e Region D 80m s Australia s worst Cyclonic Region between Carnarvon and Pardoo in Western Australia Installation Guide_PV ezRack_SolarRoof_AU_V2 3 Page 4 of 18 18 20 Duerdin St Tel 61 3 9017 6688 Clayton VIC 3168 Australia Fax 61 3 9017 6668 www clenergy com au Email sales clenergy com au CLENERG Y 2 Determine the Terrain Category You will need to determine the terrain category that is most applicable to the installation Note Terrain Category 1 TC1 Very exposed open terrain with few or no obstructions and enclosed limited sized water surfaces at serviceability and ultimate wind speeds in all wind regions e g flat treeless poorly grassed plains rivers canals and lakes and enclosed bays extending less than 10km in the wind direction Terrain Category 1 5 TC1 5 Open Water surfaces subjected to shoaling waves at serviceability and ultimate wind speeds in all win regions e g near shore ocean water larger
13. odule end clamp tightly against the module and fasten tightly using the Allen bolt recommended torque is 15 20Nm 16 Cross section through the module end clamp when installation step 15 has been correctly performed 17 Insert the pre assembled inter module clamp into the rails from above place it firmly against the module and fasten loosely approx 2 3 turns Installation Guide_PV ezRack_SolarRoof_AU_ V2 3 Page 14 of 18 18 20 Duerdin St Tel 61 3 9017 6688 Clayton VIC 3168 Australia Fax 61 3 9017 6668 www clenergy com au Email sales clenergy com au cCLUENERG Y 18 Now slide the next module against the previously installed module Ensure that the vertical side of the module frame is in contact with the vertical surface of the Inter clamp no gap between inter clam and panel Tighten the inter module clamp using the Allen key recommended torque is 15 20Nm Ensure that the anti slip protection sits in the rail channel of the lowest row of rails 19 Place the last PV Module in the row on the rails and fasten the last inter module clamp and the module end clamp using the Allen key torque 15 20Nm 20 Now slide in the first module of the next row from above onto the corresponding PV module of the row beneath A separation from the lower module can be maintained for optical reasons An inter module clamp can be used as a separator so that the vertical and horizontal separation of th
14. on tools 6 mm Allen key Cordless drill Use ONLY stainless steel sockets Open end spanner set 9 10 17 19 mm required only for mounting with hanger bolts Angle grinder with stone disk e Power Cord c PV ezRack Standard Splice End Clamp with Z Module Inter Clamp with Z Module PV ezRack Standard Rail a en Tile interface Wood screw Roof Hook with 6x80mm Z Module r PV ezRack Standard Splice a ia Inter Clamp with Z Module End Clamp with Z Module PV ezRack Standard Rails Tin Interface L Feet with Z Module Wood screw 6x90mm Installation Guide_PV ezRack_SolarRoof_AU_V2 3 Page 9 of 18 18 20 Duerdin St Tel 61 3 9017 6688 Clayton VIC 3168 Australia Fax 61 3 9017 6668 www clenergy com au Email sales clenergy com au CLENERGY Preparation Ju Overview of system Z Vt 7 Se components en Ly VULM bby LILI ELA aD UAE DT i b are E Lip Wey yj c Roof hook Tile Interface Vy AA d Spli 7 Vii pi e End Clamp iii EIT f LT RL Planning the module area 1 Number of modules in the vertical direction x module height please check the installation manual of the Solar module manufacturer 2 Number of modules in horizontal x module width 18mm 32mm 3 Horizontal spacing of the roof hooks up to 2 0 m 4
15. rafters trusses you wish to mount on are too thin and the screws would be too close to the edge of the rafters please pre drill with a 3 4mm pilot hole in order to avoid the splitting of the timber or use the side mount roof hook ER I 26 Installation Guide_PV ezRack_SolarRoof_AU_V2 3 Page 6 of 18 18 20 Duerdin St Tel 61 3 9017 6688 Clayton VIC 3168 Australia Fax 61 3 9017 6668 www clenergy com au Email sales clenergy com au ier ct amp si peste Y b Tin roof Please use the following table to determine the base rail Support spacing for sheet metal roof installations mm Max PV panel length 2000mm Max panel weight 15 kg m72 Terrain Category 3 Roof Angle lt 10 Building Height H m Region A B D Roof Angle 10 20 Building Height H m Region A B D Roof Angle 20 30 Building Height H m SD TEROR 10 lt H lt 15 15 lt H lt 20 A B C D Roof Angle 30 60 H lt 10 1529 7 14386 1404 43590 Bu O 1272 D 124 ee 1170 1137 e Please consult Clenergy for installing PV modules with a greater length than 2000mm or heavier than 15 kg m e The L Feet ER I 05 should be fixed to the purlins under using one 12g 6mm screw through sheet metal roofs with gasket e The above spacing applies for fixing through thin sheet purlins thickness gt 0 55mm or a minimum embedment of 35mm into timber purlins e Please note that the screws provided with our products are d
16. riate flashing and e Ensuring safe installation of all electrical aspects of the PV array This document is designed to support for installations using PV ezRack SolarRoof PV Module Mounting System manufactured by Clenergy Xiamen Technology Co Ltd Follow the steps below and the installation instructions section to install this product in compliance with the AS NZS1170 2 2011 ADMT 2 2012 Before proceeding note the following e This document addresses only wind loads on the assumption that wind produces the maximum load factor affecting an installation Verify that other local factors such as snow loads and earth quake effects do not exceed the wind loads Give precedence to any factor that does Wind loads are considered to act on the entire projected area or may be perpendicular to any surface e The roof on which the PV ezRack SolarRoof will be installed must have the capacity to resist the combined Design Dead Load and Live Load per footing e To determine the parts Bill of material you need you can use our PV ezRack SolarRoof Calculator Installation Guide_PV ezRack_SolarRoof_AU_V2 3 Page 3 of 18 18 20 Duerdin St Tel 61 3 9017 6688 Clayton VIC 3168 Australia Fax 61 3 9017 6668 www clenergy com au Email sales clenergy com au CLENERGY o t 1 Determine the wind region of your installation site 142 Region B Christmas Island _ Region B A Region C Australian Territory only
17. t at the original installation site that the Product shall be free from defects in material and workmanship for a period of ten 10 years except for the anodised finish which finish shall be free from visible peeling or cracking or chalking under normal atmospheric conditions for a period of five 5 years from the earlier of 1 the date the installation of the Product is completed or 2 30 days after the purchase of the Product by the original Purchaser Finish Warranty The Finish Warranty does not apply to any foreign residue deposited on the finish All installations in corrosive atmospheric conditions are excluded The Finish Warranty is VOID if the practices specified by AAMA 609 amp 610 02 Cleaning and Maintenance for Architecturally Finished Aluminum www aamanet org are not followed by Purchaser This Warranty does not cover damage to the Product that occurs during its shipment storage or installation This Warranty shall be VOID if installation of the Product is not performed in accordance with Clenergy s written installation instructions or if the Product has been modified repaired or reworked in a manner not previously authorized by Clenergy IN WRITING or if the Product is installed in an environment for which it was not designed Clenergy shall not be liable for consequential contingent or incidental damages arising out of the use of the Product by Purchaser under any circumstances If within the specif
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