Clenergy PV-ezRack PostMount 4-A User manual

PostMount 4-A for XL Panels
Installation Guide V1.0
Code-Compliant Planning and Installation Guide V1.0
Complying with AS/NZS1170.2：2011 ADMT 4-2016

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Introduction
1. Introduction
Clenergy PV-ezRack PostMount 4-A for XL
Panels (up to 2100 x 1100 mm) is a ground
mounting system suitable for large scale
commercial and utility scale installations. PV-
ezRack PostMount 4-A for XL Panels has
been developed to fit any PV module in the
outdoors and uneven ground areas. PV-
ezRack PostMount 4-A for XL Panels have
good compatibility for the different region via
the angle adjustment (10°~60°). Using high
quality engineered components PostMount 4-A
for XL Panels saves developers and installers,
time and money when delivering large scale
projects.
Please review this manual thoroughly before
installing PostMount 4-A for XL Panels. This
manual provides the following contents:
(1) Installation planning;
(2) Installation instructions.
The PV-ezRack PostMount 4-A for XL Panels
parts, when installed in accordance with this
guide, will be structurally adequate and meet
the AS/NZS1170.2:2011 Admt 4-2016 standard.
During installation, and espe-cially when working
on the ground, please comply with the appropriate
occupational health and safety regulations. Please
also pay attention to other relevant regulations in
your local region. Please check that you are using
the latest version of the installation manual by
contacting Clenergy via email on www.clenergy.
com.cn.or contacting your local distributor.
The installer is solely responsible for:
• Complying with all applicable local or national
building codes, including any updates that may
supersede this manual;
• Ensuring that PV-ezRack and other products
are appropriate for the particular installation and
the installation environment;
• Using only PV-ezRack parts and installer
supplied parts as specified by PV-ezRack
project plan (substitution of parts may void the
warranty and invalidate the letter of certification);
• Recycling: Recycle: according to the local
relative statute;
• Ensuring that there are no less than two
professionals working on panel installation;
• Ensuring the installation of related electrical
equipment is performed by licenced
electricians;
• Ensuring safe installation of all electrical aspects
of the PV array, including providing adequate
earth bonding of the PV array and PV-ezRack®
PostMount components as required in AS/NZS
5033-2014 ADMT 2 2-2018.
Introduction
Tools & Components
System Overview
Installation Instruction
Warranty
Certification Letter
01
02
03
06
12
13
List of Contents

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2.2 Components
C-U/30/46-G
Universal Clamp
ER-R-ECO/2100
ECO Rail, length 2100mm
ER-P-152/3000
Pipe
Components
SC-PM2/3/4/A
Steel Cap
ER-RT-100
Adjustable Tube
ER-RT-100
Rectangular Tube-
Master
AB-75/45/550-LP
Angle Bracket
Tools & Components
2. Tools & Components
2.1 Tools
Tools
EZ-GL-ST
Grounding Lug
Allen Key 6 mm Spanner 5m TapeTorque Wrench

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System Overview
3. System Overview
3.1 Overview of PV-ezRack
①Universal Clamp
②ECO Rail
③Pipe
④Steel Cap Assembly
⑤Adjustable Tube
⑥Rectangular Tube-Master
⑦Angle Bracket
①
②
③
⑤
⑦
④
⑥
Side view drawing of PV-ezRack PostMount 4-A for XL Panels is shown below. The panels tilt
angle and embedment depth below are for reference only. Please refer to Certificate Letter to
obatin the certified max panels tilt angle and min embedment depth for different wind regions
and different soil types.

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3.2 Precautionary Measures for Stainless-Steel Fastener Installation
Improper operation may lead to the deadlock of bolts and nuts. Follow the steps below to reduce this
risk.
3.2.1 Reduce the friction coefficient
(1) Ensure that the thread surface is clean (no dirt or contaminant).
(2) Apply lubricant (grease or 40# engine oil) to fasteners prior to tightening to avoid galling or
seizing in the threads.
System Overview

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System Overview
3.2.2 General installation instructions
(1) Apply force to fasteners in the direction of thread.
(2) Apply force uniformly to maintain required torque.
(3) Professional tools and tool belts are recommended.
(4) Avoid using electric tools for final tightening.
(5) Avoid working at high temperatures.
3.2.3 Safe Torques
Please refer to safe torques defined in this guide as shown in the figure below. If power tools are
required, Clenergy recommends the use of low speed only. High speed and impact drivers increase
the risk of bolt galling (deadlock). If deadlock occurs and you need to cut fasteners, please make sure
that there is no load on the fastener before you cut it. Avoid damaging the anodized or galvanized
surfaces.
3.3 Installation Dimensions
All drawings and dimensions in this installation guide are for generic reference. The PV-ezRack
PostMount 4-A for XL Panels is to be optimized to suit specific conditions for each project and
documented in engineering drawings. As a result, major components of the PV-ezRack PostMount
4-A for XL Panels may be provided in sectional sizes and lengths that vary from those shown in this
guide. The installation operations detailed in this instruction guide remain the same regardless of the
component size. In case you need to do any on-site modifications or alteration of the system in a way
that would be different from engineering drawings, please provide marked up drawings/sketches for
Clenergy’s review prior to modification for comment and approval.

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Installation Instruction
4. Installation Instruction
4.1 Pipe Installation
Dig a hole with the diameter of 300mm.
Place the pipe into the middle of the hole and fill
it with concrete. Maintain the position of the pipe.
The allowed vertical tolerance is ±2°.Keep the axle
of the 2- Ø16 holes parallel to East-West;keep the
vertical angle deviation within ±5°.For more than
one system on one site maintain all the axles of 2-
Ø16 holes aligned.
4.2 Steel Cap Installation
Connect the Pipe to the corrugated washer and Steel Cap Assembly with M20*210 hexagonal bolt,
washer 20, Hexagon nut M20 .
Combine two Steel Caps with M20*210 hexagonal bolt, washer 20, Hexagon nut M20.
Note：
1. Do not fasten the M20 Bolt prior to complete the assembly of PM-A Rectangular Tube-Master.
2. Keep all the Bolt head aligned.

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Installation Instruction
4.3 Rectangular Tube-Master and Adjustable Tube Installation
4.3.1 Fix the Rectangular Tube-Master at Steel Cap
Assembly with M20*160 hex bolt, M20 nut, plain
washer 20, and spring washer 20. See the mark ①.
4.3.2 Fix the Adjustable Tube at Rectangular Tube-
Master with M20*160 hex bolt , plain washer 20, and
spring washer 20 ，M20 nut. See the mark ②.
4.3.3 Fix the Adjustable Tube at Steel Cap Assembly
with M20*160 hex bolt, M20 nut, plain washer 20, and
spring washer 20. See the mark ③.
Realized the angle adjustment by position the bolt in
the differrent holes.
4.3.4 Fasten the Steel Cap Assembly to Pipe with
M20*210, M20*160 Hex Bolt, keep the Rectangular
Tube-Master parallel to the south-north by adjust the
Steel Cap Assembly.
Recommended torque for M20 bolts is 210~220 N·m.
Note:
1. Adjust the angle of the allation, the angle of the Rectangular Tube-Master with 10° (6 holes from up
to bottom corresponds to 10° to 60° tilt angle) in order to make the assembly process run smooth.
2. Using the adjustable washer to avoid the gap between the Rectangular Tube-Master and the
Adjustable Tube.
Unreliable connection is forbidden.

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Installation Instruction
4.4 Angle Bracket Installation
4.4.1 Preassemble the Cross Connection Clamp at the Angle Bracket with 2 pcs M8*28 Hex Bolt, 2
pcs plain washer, 2 pcs Washer 8, 2 pcs Hexagon nut M8 as shown in the figure below.
Note：Do not tighten the nut in order to make ECO Rail well.
4.4.2 Connect the Angle Bracket to Rectangular Tube-Master with 6 pcs U bolts, 12 pcs M10 nuts,
12 pcs spring washer 10, 12 pcs plain washer 10 as shown in the figure below.
Note：Do not tighten the nut until all the Angle Bracket aligned.

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Installation Instruction
4.5 ECO Rail Installation
4.6 PV Module Installation
Uplift the Cross Connection Clamp in the certain angle. Click the Clamp into the ECO Rail. Position the
Rail in the middle of the Rectangular Tube-Master, and then fasten the M8*28 bolt.
Recommended torque for M8 bolts is 18~20 N·m.
Adjust the Rectangular Tube- Landscapes until the dimension D1=D2;D3=D4;D5=D6;D7=D8;D9=D10.
Fasten the U bolt.
Recommended torque for M10 bolts is 35~40 N·m
Note:ECO Rail of 2100mm is a standard length in this system, which can be suitable for up to 1002
mm wide panel. If the panels are over 1002 mm (less than 1100 mm) wide, the required minimum
rail length is:
(panel width-1002)*2+2100 (mm).
For example, panels are 1050 mm wide. The required minimum rail length is (1050-1002)*2+2100 =
2196 mm. For convenience, the rail length is rounded up to 2200mm (multiple of 50 mm).
4.6.1 Fix the PV panel to ECO Rail, via Universal Inter Clamps and End Clamps step by step until all the
panels complete.
Recommended torque for M8 bolts is 18~20 N·m

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Installation Instruction
Note: The Universal Clamp can be used both as a End Clamp and a Inter Clamp, and the height
can be adjusted from 30 to 46 mm.
When the side of the Universal Clamp close the narrow side of the Universal Clamp Buckle, it can be
used as End Clamp, and when the side of the Universal Clamp close the wide side of the Universal
Clamp Buckle, it can be used as Inter Clamp, as shown in the figure on the right. The Universal
Clamp can be directly rotated to the position of required End or Inter Clamp.
Recommended torque for M8 bolts when it is Inter Clamp is 18~20 N·m
Recommended torque for M8 bolts when it is End Clamp is 13~14 N·m
Inter clamp
90°
End clamp
4.6.2 Apply one pre-assembled Grounding Lug per Rail. Click the Grounding Lug into to the rail
channel and insert the Copper Wire. (the maximum size is 4 mm2or similar) Fasten the bolt M6*14 with
5~6 N·m and the bolt M8*25 with 16~20 N.m .Copper Pipe will be supplied for the case that using
small size Copper Wire.

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There are three solutions for Grounding Lug
installation.
-Solution 1 Fix the Grounding Lug at the end of Rail
as shown in the figure on the right.
-Solution 2 Fix the Grounding Lug at the Rail where
just under the PV Module as shown in the figure on
the right.
-Solution 3 Fix the Grounding Lug at the side
channel of Rail as shown in the figure on the right.
Installation Instruction

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10 year limited Product Warranty, 5 year limited Finish Warranty
Clenergy (Xiamen) Technology co. Ltd warrants to the original purchaser ("Purchaser") of product(s)
that it manufactures ("Product") 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 & 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 specified Warranty periods the Product shall be reasonably proven to be defective,
then Clenergy shall repair or replace the defective Product, or any part thereof, at 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.
5. Warranty
Warranty

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Certification Letter

REF: CL-10129-S
Internal REF: 00142


18
th
April 2019
Clenergy Australia
1/10 Duerdin Street
Clayton, VIC 3168
Array Frame Engineering Certificate
Postmount PM4-A/2100 Installation
MW Engineering Melbourne Pty Ltd, being Structural Engineers within the meaning of Australian and
NZ Building Regulations, have carried out a structural design check of the PV-ezRack Postmount PM4-
A/2100 within Australia. The design check has been based on the information in the PV-ezRack PM4-
A/2100 Planning and Installation Guide and schematic drawings of the system components, provided by
Clenergy Australia.
Part number Descri
p
tion
ER-R-ECO/2100 PV-ezRack ECO Rail 2100mm
ER-RT-100
/
3400
PV-ezRack PM4，Rectangular Tube-Master
100*100*3400*T5
ER-RT-100/576
PV-ezRack (PM6-A,PM8-A), Adjustable Tube
100*50*576
ER-P-152/3000 PV-ezRack, Pi
p
e ø152*3000*T6
ER-SC-PM6/PM8
PV-ezRack PM6-A,PM8-A, Steel Cap
Assembl
y
C-U/30/46-G
PV-ezRack, Universal Clamp for Frame
Height 30-46mm with Grounding Clip
We find the Postmount PM4-A/2100 to be structurally sufficient for Australian and New Zealand use,
based on the following conditions:
 Wind Loads to AS/NZ1170.2:2011, Amendment 4-2016:
o Wind Terrain Category: 2;
o Wind average recurrence interval of 100 years- For ultimate state, 25 years- service-
ability;
o Wind region A, B, C & D;
 Max Solar Panel Length 2.1m, width 1.1m;
 Yield Strength:

REF: CL-10129-S
Internal REF: 00142


 Steel 300 MPa,
 Aluminium 240 MPa;
 Maximum tilt angle options: refer to tables;
 Dimension as shown here on the picture;

REF: CL-10129-S
Internal REF: 00142



REF: CL-10129-S
Internal REF: 00142


Maximum Tilt Angle Options
Wind Region
Region
A
Region
B
Region
C
Region
D
Wind speed (m/s) 41 48 - -
Maximum tilt angle (◦) 30 20 - -
Soil Type
Post Embedded in concrete pier:
300 mm diameter concrete piers
minimum depth (m)
Hard class soil
1.15 1.07 - -
[Gravels; dr
y
(
hard
)
cla
y
s]
Very Firm class soil
1.22 1.13 - -
[Dry (Stiff) clays; clayey sands; coarse
sands; compact sands]
Firm class soil
- 1.25 - -
[Dam
p
cla
y
s; sand
y
cla
y
s; dam
p
sands]
Soft class soil
- 1.60 - -
[wet clays; silty loams; wet loose sands]
Notes:
1. Terrain Category 2 (TC2) refers to open terrain, including grassland, with well-scattered
obstructions having heights generally from 1.5m to 5m, with no more than two obstructions
per hectare. This certificate will only cover Postmount PM4-A/2100 installed on TC2.
2. Panel weight calculated: 28kg
3. Solar Panels structural check by others.
4. Other piers dimensions are possible, contact Clenergy, if required.
5. For concrete pier foundations, use 25Mpa strength concrete (minimum).
6. The scope of this certification is for projects located at a maximum altitude of 100m above
sea level. No snow loads have been assessed.
7. If depth of footing is less than length of post below ground (embedment depth of post) the
post must be cut to suit the new level.

REF: CL-10129-S
Internal REF: 00142


8. Footing depths are for reference only. The characteristics of the soil must be checked on site
by a technical expert. A soil report assessment is always recommended and Clenergy must be
informed on the outcome of the soil report.
Construction is to be carried out strictly on accordance with the instruction manual. This work was
designed in accordance with the provisions of Australian Building Regulations and in accordance with
sound, widely accepted engineering principles.
Should you have any queries, do not hesitate to contact us.
Best Regards,
Alberto Escobar
Civil/Structural Engineer
BEng MIEAust NER
BRP EC 46542
RPEQ 18759
[e-mail]

Clenergy Australia
1/10 Duerdin Street, Clayton VIC 3168 Australia
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Xiang’an District 361101, Xiamen, Fujian, China
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Esplanade 41, 20354 Hamburg, Germany
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E-mail: [e-mail]
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Nittochi Yamashita Building 5th Floor
23 Yamashita-cho, Yokohama, 231-0023 Japan
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E-mail: [e-mail] www.clenergy.jp
Clenergy Philippines
145 Yakal St., San Antonio village, Makati City, Philippines
Tel: [phone]
E-mail: [e-mail] www.clenergy.ph
Clenergy Thailand
9/2, 5th Floor, Vorasin Building, Soi Yasoob 2, Viphavadee-Rungsit
Road, Chomphon Sub-district, Chatuchak District, Bangkok 10900
Tel: [phone]
E-mail: [e-mail],[e-mail]
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24 Raffles Place #28-01 Clifford Centre Singapore 048621
Tel: [phone]
E-mail: [e-mail]
Clenergy Vietnam
Tel: [phone]
E-mail: [e-mail];
[e-mail];
[e-mail]
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Clenergy PostMount 4-A for XL Panels Installation Guide V1.0 201911
Warranty