Clenergy PV-ezRack SolarRoof ER-TL-10/15 User manual

PV-ezRack®SolarRoofTM Tilt Legs
Installation Guide
Code-Compliant Planning and Installation Guide V5.0
Complying with AS/NZS1170.2-2011 AMDT 2-2016

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Introduction
1. Introduction
The Clenergy PV-ezRack®SolarRoof™ Tilt
Legs has been developed as a universal
PV-mounting system for roof-mounting on
pitched and flat roofs. The use of patented
aluminium base rails, Z-Module technology
and telescopic mounting technology eliminates
custom cutting and enables fast installation.
Please review this manual thoroughly before
installing PV-ezRack®SolarRoof™ Tilt Legs.
This manual provides
1) Supporting documentation for building
permit applications relating to PV-ezRack®
SolarRoof™ Tilt Legs Universall PV Module
Mounting System,
2) Planning and installation instructions.
The PV-ezRack®SolarRoof™ Tilt Legs parts,
when installed in accordance with this guide,
will be structurally sound and will meet the
AS/NZS1170.2:2011 Amdt 2- 2016 standard.
During installation, and especially when
working on the roof, please comply with the
appropriate Occupational Health and Safety
regulations. Please also pay attention to any
other relevant State or Federal regulations.
Please check that you are using the latest
version of the Installation Manual, which you
can do by contacting Clenergy Australia via
email on [e-mail], or contacting
your local distributor in Australia.
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;
• Removal: Reverse installation process;
• 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, This includes adequate
earth bonding of the PV array and PV-ezRack®
SolarRoof™ components as required in AS/
NZS 5033-2014 AMDT 2 2-2018;
• Ensuring that the roof, its rafters/purlins,
connections, and other structural support
members can support the array under building
live load conditions;
• Ensuring that screws to fix interfaces have
adequate pullout strength and shear capacities
as installed;
• Maintaining the waterproof integrity of the roof,
including selection of appropriate flashing;
•Verifying the compatibility of the installation
considering preventing electrochemical
corrosion between dissimilar metals. This
may occur between structures and the building
and also between structures, fasteners and PV
modules, as detailed in AS/NZS 5033: 2014.
Introduction
Planning
Tools & Components
System Overview
Installation Instruction
Certification Letter and Tilt Legs
Spacing Table
01
02
14
15
19
28
List of Contents

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Region Definition:
Wind regions are pre-defined for the whole of
Australia by the Australian Standard 1170.2.
The Wind Region is an independent factor of
surrounding topography or buildings.
• Most of Australia is designated Region A which
indicates a Regional Wind Velocity of 43 m/s with
wind average recurrence of 200 years.
• Some areas are designated Region B (52 m/s).
Local authorities will advise if this applies in your
area.
• Region C areas (64 m/s) are generally referred to
as Cyclonic and are generally limited to northern
coastal areas. Most Region C zones end 100km
inland.
• Region D (79 m/s) is Australia's most extreme
Cyclonic Region, located between the town of
Carnarvon and Pardoo Station in Western
Australia.
2. Planning
2.1 Determine the wind region of your installation site
Planning

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Planning
You will need to determine the terrain category to ensure the installation meets the required standard.
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 wind regions, e.g. near-shore ocean water; larger 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.
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 with
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.
Terrain Category 3 (TC3) – Terrain with numerous closely spaced obstructions having heights generally
from 3m to 10m. The minimum density of obstructions shall be at least the equivalent of 10 house sized
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
buildings, such as large city centers and well-developed industrial complexes.
If your installation site is not at TC 2, 2.5 or 3, please contact Clenergy to obtain a project specific
engineering certificate to support your installation.
2.2 Determine the Terrain Category
This document provides sufficient information for the PV-ezRack®SolarRoof™ Tilt Legs system installation
up to heights of 20 meters. If your installation site is more than 20 meters high please contact Clenergy to
obtain project specific engineering certificate to support your installation.
2.3 Determine the Height of the Installation Site

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Planning
The PV-ezRack®SolarRoof™ Tilt Legs system can be used for roof slopes up to 30°. Please verify that
the Installation site roof slope is between 0° and 30°.
2.4 Determine Roof slope
On the north facing roof, the angle of rear leg is between 30° and 90° with the roof plane.
On the south facing roof to make the panels facing the north (reverse tilt), the angle of rear leg should be
no more than 90° with the horizontal.
30-60° adjutable tilt legs is certified for reverse tilt installation on the south facing roof. Please refer to
Certification Letter and Tilt Legs Spacing Table.

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Planning
On pitched roof, there are four different roof zones for installation. See the diagrams and steps below
to determine area of each zone.
2.5 Determine the Installation Area of Roof
In the front figure h= height, b =width and d= length of the
building.
Step 1: Determine building height, width and length.
Step 2: Multiply the width of the building by 0.2
Step 3: Multiply the length of the building by 0.2
Step 4: Determine lowest value between: (height of the building)
and 0.2 × length of the building and 0.2 × width of the building
Step 5: The lowest value in step 4, equates to a.

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Please refer to the Certification Letter and Tilt Legs Spacing Table. If a project specific Certification
Letter has been provided, please refer to the support spacing in this letter.
2.7 Determine the Maximum Rail Support Spacing
There are options of using two screws or one screw for installations of adjustable and fixed tilt legs,
depending on the project details, like required support spacing, purlin spacing, rib spacing of roof
sheet and so on. Please find both two screws and one screw engineering certificates at the end of
installation guides for max support spacing.
2.6 Determine Two Screws or One Screw Installations of Tilt Legs
Application of Adjustable Tilt Legs
Purlin spacing 1200 mm 1400 mm 1700 mm
Product 10° 15° 30° 45° 60° 10° 15° 30° 45° 60° 10° 15° 30° 45° 60°
1650 mm panel
in portrait
ER-TL-10/15 √
（1）
√
（2） × × × √ （6） ×××××××××
ER-TL-15/30 ×××××× √
（8） × × × × × × × ×
ER-TL-30/60 × × √
（3）
√
（4） × × × √ （10）
√
（12） × × × √ （14） × ×
1960 mm panel
in portrait
ER-TL-10/15 ××××× √
（7） ×××××××××
ER-TL-15/30 ×××××× √
（9） × × × × × × × ×
ER-TL-30/60 ××× √
（5） × × × √ （11）
√
（13） × × × √ （15） × ×
Note: √indicates applicable; ×indicates not applicable
The table above is based on:
1. The panels are clamped within one quarter of panel length;
2. Rear leg adjustable range: ER-TL-10/15: 260-375 mm; ER-TL-15/30: 390-635 mm; ER-TL-30/60: 675-1205
mm;
3. If the info. is different from the table and diagram, it could have different results. Please contact the
Clenergy to confirm its applicability.
Following the tilt angle rules of 2.4 on the north or south facing roof, the actual panel tilt angles using the
adjustable tilt legs installed at the different purlin spacing could be applicable or not. Please see the table and
side view diagrams below.
2.9 The application of AdjustableTilt Legs
Rail end overhang should not be over 40% of the Tilt Legs spacing. For example, if the Tilt Legs
spacing is 1500mm, the Rail end overhang can be up to 600mm only.
2.8 Verify Maximum Rail End Overhang
Planning

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Planning
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Planning
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Planning
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Planning
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Planning
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Planning
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3.2 Components
ER-EC-ST
End Clamp
ER-TL-10/15 ER-TL-15/30
ER-TL-30/60
Adjustable Tilt legs,
non-preassembly
Component list
ER-R-ECO
ECO Rail
ER-SP-ECO
Splice for ECO Rail
ER-TL-10/15/PS
ER-TL-15/30/PS
Adjustable Tilt legs,
preassembly
TL-10/15/L/PS
TL-15/30/L/PS
Adjustable Tilt Legs with L-feet,
preassembly
ER-TL-5/PS
ER-TL-10/PS
Fixed Tilt Legs,
preassembly
Tools and Components
3. Tools and Components
3.1 Tools
Screw Driver
(maximum torque≥34N·m)
5m Tape
Torque Spanner Socket Wrench M8
String & Marker Pen
Tools
EZ-GL-ST
Grounding Lug
EZ-GC-ST
Grounding Clip
ER-IC-ST
Inter Clamp
C-U/30/46
Universal Clamp
C-U/30/46-G
Universal Clamp

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System Overview
4. System Overview
4.1 Overview of PV-ezRack®SolarRoofTM Adjustable Tilt Legs
4.1.1 Adjustable Tilt Legs
4.1.2 Adjustable Tilt Legs with L-feet
①End Clamp ②Inter Clamp ③Grounding Clip ④ECO Rail ⑤Grounding Lug
⑥Adjustable Tilt Legs
①End Clamp ②Inter Clamp ③Grounding Clip ④ECO Rail ⑤Grounding Lug
⑥Adjustable Tilt Legs with L-feet
①
②
③
④
⑤
⑥
①
②
③④
⑤
⑥

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System Overview
4.1.3 Fixed Tilt Legs
①End Clamp ②Inter Clamp ③Grounding Clip ④ECO Rail ⑤Grounding Lug
⑥Fixed Tilt Legs
①
②
③
④
⑤
⑥
Improper operation may lead to deadlock of Nuts and Bolts. The steps below should be applied to
stainless steel nut and bolt assembly to reduce this risk.
4.2 Precautions during Stainless Steel Fastener Installation
4.2.1 General installation instructions:
(1) Apply force to fasteners in the direction of thread
(2) Apply force uniformly, to maintain the required torque
(3) Professional tools and tool belts are recommended
(4) In some cases, fasteners could be seized over time. As an option, if want to avoid galling or seizing of thread,
apply lubricant (grease or 40# engine oil) to fasteners prior to tightening.

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System Overview
4.2.2 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.
①Adjustable Tilt Legs
Note：Grounding Z Module, External Teeth Lock Washers, Spring washer and corrugated shim
(with pins) on the diagram above are to create the electrical continuity between rail and rear
leg tubes.

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System Overview
②Adjustable Tilt Legs with L-feet
Note：Grounding Z Module, External Teeth Lock Washers, Spring washer and corrugated shim (with
pins) on the diagram above are to create the electrical continuity between rail and rear leg tubes.
Note：Grounding Z Module,External Teeth Lock Washer and Spring washer on the diagram above are to
create the electrical continuity between rail and rear leg tubes.
③ Fixed Tilt Legs

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5. Installation Instruction
5.1 Front & Rear Leg Installation
5.1.1 Front Leg Installation:
Installation Instruction
According to the installation plan, determine
the mounting position and direction of the
front legs. Either two screws or single screw
(Buildex 14-11 x 70 Hex Head Zips screw) is
required depending on the installation spacing
requirement. See two screws and single screw
options in Figures 1 and 2. Tin foot front leg
installation is in Figure 3.
Figure 2 Front Leg Installation with Single Screw
Figure 3 Tin Foot Front Leg Installation
Figure 4
5.1.2 Rear Leg Installation:
According to the installation plan, after
confirming the length L of the Rear Leg, fasten
two M8*12 bolts as shown in Figure 4.
Recommended torque for M8*12 bolts is
18~20 N·m
Figure 1 Front Leg Installation with Two Screws