Clenergy PV-ezRack SolarFloating I User manual

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PV-ezRack SolarFloating I
Installation Guide V1.0

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Clenergy China Telephone [phone]
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Xiang'an District 361101, Xiamen, Fujian, China [email protected]
1. Introduction
The Clenergy PV-ezRack SolarFloating System is a surface floating
platform suitable for large-scale civil and commercial installations. The Floater
is made of high-density polyethylene (HDPE). This material is insoluble in
organic solvents and resistant to corrosion by acids, alkalis and salts. The
system has the advantages of simple and convenient installation, stable
structure and long service life.
Please review this manual thoroughly before installing SolarFloating. This
manual provides the following contents: (1) Installation planning; (2)
Installation instructions;
Please install SolarFloating System according to this installation guide. It
meets the GB50009-2012、ASCE7-10 ISO 14713 standards. When installing
please comply with the appropriate local safety regulations, and pay attention
to other relevant regulations in your local region. The latest version of the
installation manual is available on our website www.clenergy.com.cn.
The installer shall comply with the following requirements:
Complying with all building codes according to any applicable place or
country 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
Clenergy (substitution of parts may void the warranty and invalidate the
letter of certification).
Recycling: according to local related statutes.
Disassembly: reverse installation process.
Ensuring that there are no less than two professionals working on panel
installation at the one time.
Ensuring that related electrical equipment is installed by a professional
electrician.
Construction process safety statement:
1. Water construction workers must wear life jackets and wear safety helmets.
2. In case of severe weather such as strong winds, waves and dense fog, no
water work is allowed.

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3. During the construction process, the construction personnel must have
sufficient safety awareness, establish the idea of safety first, have a strong
sense of responsibility, and find timely handling and reporting of safety
hazards to ensure smooth construction.
2. Tools and Components
2.1 Tools
Tools
Power Drill (Adapt to
ST6.3*22 self-drilling
screws and M8 hex
bolts)
Socket wrench（M8）
Torque wrench
(M8)
Front and Rear Support
Leg installation tools
Bolt and nut installation
tools
HDPE Bolt installation
tools
Traction boat
Life jacket and lifebuoy
Temporary fixed rope

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2.2 Components
Components
ER-SFI-MF
Main Floater
ER-SFI-AF-D
Aisle Floater (Double)
ER-SFI-RS
Rear Support Leg
ER-SFI-FS
Front Support Leg
ER-SFI-CB
Connect Bolt
ER-SFI-CN
Connect Nut
R-SFI-B/1
HDPE Bolt 1
ER-SFI-B/2
HDPE Bolt 2
ER-SFI-B/3
HDPE Bolt 3
ER-SFI-W
HDPE Washer,
T15mm
SDS-ST6.3/25/304
Self-drilling screw
ST6.3*25
ER-SFI-RC
Rear Clamp

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3. System Overview
3.1 System Overview
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
①Ensure that the thread surface is clean (no dirt or contaminant)
②Apply lubricant (grease or 40# engine oil) to fasteners prior to tightening to
avoid galling or seizing in the threads;
3.2.2General installation instructions
①
②
③
④
⑤⑥
⑦
⑧
⑨
⑫
⑩
⑪
①Main Floater
②Aisle Floater
③Rear Support Leg
④Front Support Leg
⑤Connect Bolt
⑥Connect Nut
⑦HDPE Bolt 1
⑧HDPE Bolt 2
⑨HDPE Bolt 3
⑩HDPE Washer
⑪Self-drilling screw ST6.3*25
⑫Rear Clamp

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①Apply force to fasteners in the direction of thread;
②Apply force uniformly to maintain required torque;
④Avoid using electrical tools for final tightening;
⑤Avoid working at high temperatures;
3.2.3 Safe Torques
Please refer to safe torques defined in this guide. 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 SolarFloating is to be optimized to suit specific conditions for each project
and documented in engineering drawings. As a result, major components of
the SolarFloating 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
any on-site modifications or alteration of the system are needed, 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.
3.4 Preparation before construction
3.4.1 Temporary storage area for Floater
Stacked in the area closest to the construction platform for convenient
secondary transportation .The size of the temporary stacking area is
considered in accordance with the installation schedule and delivery speed.
Large-scale projects are recommended to have a reserve about 2MW
(according to a stacking height of 3 meters, approximately 1200 square meters
of space is required)
3.4.2 Build the construction platform
According to the red line position, the arrangement of the floating square array
and the actual situation of the water shore, select the location where the

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construction platform is built. The construction platform shall make a slope of 5
degrees (the recommended optimum slope) along the waterfront junction
according to the selected suitable location, and deal with the ground (or dam)
part accordingly. According to the actual situation, the scaffolding type is
adopted, and then laying wooden boards or laying the board directly after the
shore is flat (requires a certain roughness but no sharp protrusion).
Construction platform size: 50 m * 20 m (facing the water surface), built
according to less than 12 components (east-west direction) or 8 components
(north-south direction). This construction can be divided into two groups. The
20 meters width of the construction platform need to be adjusted according to
the site conditions, which is only affects the installation progress. And make 4
temporary fixed piles at the waterfront junction for temporary fixed use after
the floating system is launched.

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4. Installation Instruction
4.1 Front and Rear Support Leg Installation
4.1.1 Place the Main
Floater flat on the
ground, as shown in
Figure 1.
4.1.2 Insert the Front
and Rear Support Leg
into the hexagonal
mounting hole of the
Main Floater, as shown
in Figure 2.
4.1.3 According to the
method of Fig. 3, use
tools to rotate the four
support legs clockwise
by 45 degrees in order,
make sure the support
legs are locked into the
holes of Main Floater.
After completion, as
shown in Figure 4.
Figure 1
Figure 2
Figure 3

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Figure4
4.2 Rear Clamp Installation
4.2.1 Lock the Rear
Clamp on the support
leg, and do not lock the
bolt and nut temporarily,
for the Modules
installation, the opening
directions are
respectively outward, as
shown in Figure 5 and
Figure 6.
Figure 5

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Figure 6
4.3 Connect Two Main Floaters
4.3.1 Use one Aisle
Floater to connect the
two Main Floaters
together, and lock them
with bolts and nuts. Pay
attention to the
orientation of the
blowing port of the
floater and the stacking
order of the ear plates,
as shown in Figure 7.

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4.3.2 Use professional
tools to lock the bolts
and nuts, and then use
the electric drill to drill
the Self-drilling screw
ST6.3*25 through the
bolts and nuts, and
connect the two
together, as shown in
Figure 8.
Figure 7
Figure 8
4.4 Peripheral Aisle Floater Installation
4.4.1 Assemble the
Aisle Floater as shown
in Figure 9. Pay
attention to the stacking
order of the ear plates
when assembling it to
avoid warping of the
system.
4.4.2 Install the bolt and
nut, HDPE Bolt 1,
HDPE Bolt 2, and
HDPE Bolt 3 to the
Figure 9

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corresponding positions
in Figure 10. The gap of
ear plate needs HDPE
Washer. Use a
professional tool to
rotate the HDPE Bolt
45°to lock it.
4.4.3 For each bolt and
nut connection point,
use professional tools
to lock the bolts and
nuts first, and then use
the electric drill to drill
the Self-drilling screw
ST6.3*25 through the
bolts and nuts, and
connect the two
together, as shown in
Figure 11.
Figure 10
Figure 11
4.5 PV Modules Installation
4.5.1 Place the PV
Module frame into the
open slot of the Rear
Clamp, as shown in
Figure 12. Adjust the
position of the PV
Module to ensure that
the left and right
dimensions are the
same, and then lock the
M8 bolt and nut .The
Figure 12

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torque of the M8 bolt
should not be too large,
and it is better to lock
the plastic parts slightly
deformed.
4.5.2 Repeat the above
method to install the
remaining PV Modules.
Figure 13 is the
installation effect of a
1*2 unit.
Figure 13
4.6 Connect the Floating System and Anchor System
4.6.1 Push the installed
Floating System into the
water as shown in
Figure 14. Use a motor
boat to pull it to the
designated location and
adjust the north-south
orientation of the
system.
4.6.2 Fixed the Floating
System according to
the anchoring
scheme, as shown in
Fig. 15. Commonly
used anchoring
methods are: pile
anchoring and anchor
block anchoring. The
length of the anchor
rope is determined
Figure 14
Figure 15

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according to the
actual conditions of
the project. After
tightening the anchor
rope, fixed it with a
rope card.
4.6.3 Mark the depth
of the floater in water.