Clenergy PV-ezRack SolarRoof Technical manual

PV-ezRack®SolarRoof™
Adjustable Tilt Legs
Code-Compliant Planning and Installation Guide
Complying with AS/NZS1170.2:2011 ADMT 2-2012
Image: ER-TL15/30 installed by Todae Solar
CONTENT
1. Introduction…………………………………………………………………………………………………………2
2. Planning………………………………………………………………………………………………………………3
3. Components List………………………………………………………………………………………………10
4. Array Planning.…………………………………………………………………………………………………12
5. Step by Step Installation ………………………………………………………………………………13
6. MT-Rail Application Tilt Leg and Tin Interface Installations with MT-Rails ……21
Service………………………………………..………………………………………………………………………….22
Installation Guide_PV-ezRack_SolarRoof_Adjustable Tilt Legs_AU_V3.3
Page 1 of 22
1/10 Duerdin St
Tel: +61
3 9017 6688
Clayton VIC 3168, Australia
Fax: +61
3 9017 6668
www.clenergy.com.au
Email: [e-mail]

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
please 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
[e-mail], or contacting your local distributor in Australia.
Installation Guide_PV-ezRack_SolarRoof_Adjustable Tilt Legs_AU_V3.3
Page 2 of 22
1/10 Duerdin St
Tel: +61
3 9017 6688
Clayton VIC 3168, Australia
Fax: +61
3 9017 6668
www.clenergy.com.au
Email: [e-mail]

Planning
The installer is solely responsible for:
Complying with all applicable local or national building codes and Clean
Energy Council guidelines including any that may superseded this manual;
Ensuring that PV-ezRack®SolarRoof™ and other products you use are
appropriate for the particular installation and the installation environment;

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);

Using only genuine PV-ezRack®parts (substitution of parts may void the
warranty and invalidate the letter of certification);

Ensuring that lag screws have adequate pull-out strength and shear
capacities as installed;

Maintaining the waterproof integrity of the roof, including selection of
appropriate flashing; and
Ensuring safe installation of all electrical aspects of the PV array, including
providing adequate earth bonding of the PV array and PV-ezRack®
SolarRoof™ components as required in AS/NZS 5033-2014 ADMT 2 2-
2018.
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 six 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:
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.

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.
To determine the parts (Bill of material) you need you can use our PV-ezRack®
SolarRoof™ Calculator.
Installation Guide_PV-ezRack_SolarRoof_Adjustable Tilt Legs_AU_V3.3
Page 3 of 22
1/10 Duerdin St
Tel: +61
3 9017 6688
Clayton VIC 3168, Australia
Fax: +61
3 9017 6668
www.clenergy.com.au
Email: [e-mail]

1. Determine the wind region of your installation site
Region Definition:
Wind regions are pre-defined for all 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
Ultimate Basic Wind Velocity of 45m/s.

Some areas are designated Region B (57m/s). Local authorities will advise
if this applies in your area.

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.

Region D (80m/s) Australia's worst Cyclonic Region between Carnarvon
and Pardoo in Western Australia.
Installation Guide_PV-ezRack_SolarRoof_Adjustable Tilt Legs_AU_V3.3
Page 4 of 22
1/10 Duerdin St
Tel: +61
3 9017 6688
Clayton VIC 3168, Australia
Fax: +61
3 9017 6668
www.clenergy.com.au
Email: [e-mail]

2. Determine the Terrain Category
You will need to determine the terrain category that is most applicable to the
installation.
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 unenclosed bays on seas and oceans;
lakes; and enclosed bays extending greater than 10km in the wind
direction.

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.

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.
Note: In this installation manual we have used terrain category 3, if it is outside
of this please refer to the accreditation letter.
Installation Guide_PV-ezRack_SolarRoof_Adjustable Tilt Legs_AU_V3.3
Page 5 of 22
1/10 Duerdin St
Tel: +61
3 9017 6688
Clayton VIC 3168, Australia
Fax: +61
3 9017 6668
www.clenergy.com.au
Email: [e-mail]

3. Determine the height of the 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 installation slope
The PV-ezRack®SolarRoof™ Adjustable Tilt Leg system can be used for North
facing roof as well as south and east-west facing roof.
5. Determine the installation area on the roof
Installation Guide_PV-ezRack_SolarRoof_Adjustable Tilt Legs_AU_V3.3
Page 6 of 22
1/10 Duerdin St
Tel: +61
3 9017 6688
Clayton VIC 3168, Australia
Fax: +61
3 9017 6668
www.clenergy.com.au
Email: [e-mail]

6. Determine the Maximum Rail Support Spacing
North and East/West Facing Roof
Please use the following table to determine the base rail support spacing
for sheet metal roof installations.
Max PV panel length: 2000mm.
Roof Angle: ≤10˚. Terrain Category 3.
a) 10 to 15˚
b) 15 to 30˚
c) 30 to 60˚
Installation Guide_PV-ezRack_SolarRoof_Adjustable Tilt Legs_AU_V3.3
Page 7 of 22
1/10 Duerdin St
Tel: +61
3 9017 6688
Clayton VIC 3168, Australia
Fax: +61
3 9017 6668
www.clenergy.com.au
Email: [e-mail]

South Facing roof (Reverse Tilt)
In case of installation on south facing roof with a slope less than 30° please
use the following tables to determine the base rail support spacing for sheet
metal roof installations.
Max PV panel length: 2000mm. Type of Interface: 30˚-60˚ Adjustable Tilt Leg
Terrain Category 3.
Roof Angle (Φ) ≤10°
Roof Angle (Φ) ≤20°
Roof Angle (Φ) ≤30°
Please consult Clenergy for installing PV modules with a greater length
than 2000mm.
Each Foot should be fixed to the purlins using at least two screws through
sheet metal roofs. Please consult Clenergy if using a single screw.

Installation Guide_PV-ezRack_SolarRoof_Adjustable Tilt Legs_AU_V3.3
Page 8 of 22
1/10 Duerdin St
Tel: +61
3 9017 6688
Clayton VIC 3168, Australia
Fax: +61
3 9017 6668
www.clenergy.com.au
Email: [e-mail]

General Notes
Recommended screws
Metal Purlins/Battens
Fasteners to use
0.55 mm –1.5 mm
M6-11
TPI RoofZips
1.9 mm
M6-11
TPI RoofZips OR 12g-14 TPI Teks screws
2.4 mm and Above
12g-24 TPI Teks screws
Wood purlins and Rafter
Fasteners to use
Pine and Hardwood (35mm
M6 (12g) with 10 TPI
embedment and above)
Screws minimum embedment length into timber 35 mm

For the adjustable tilt legs:
oMaximum back leg angle to horizontal - 90°
o Minimum Back leg angle to horizontal - 30°
For PV panels with length of 1700 mm, increase the spacing of 15%.
7. Verify acceptable Rail End Overhang
Rail End Overhang must equal 40% or less of foot spacing. Thus, if foot spacing
is 1500mm, the Rail End Over hang can be up to 600mm. In this case, two feet
can support a rail of as much as 2700mm (1500mm between the feet and
600mm of overhang at each end).
Installation Guide_PV-ezRack_SolarRoof_Adjustable Tilt Legs_AU_V3.3
Page 9 of 22
1/10 Duerdin St
Tel: +61
3 9017 6688
Clayton VIC 3168, Australia
Fax: +61
3 9017 6668
www.clenergy.com.au
Email: [e-mail]

Component list
Overview of system components
Part name
Picture
Part name
Picture
PV-ezRack®
Front Foot
ECO Rail
PV-ezRack®
ECO rail Back Legs
Splice
Inter Clamp
End Clamp
Hex head bolt
M8*25 M8*55
Hex head bolt
Pan-head 5/8"
Set Screw
Wood Screw
M10*10
6*90
Installation tools
6 mm and 4mm Allen key

Cordless drill

Use ONLY stainless steel sockets

Open-end spanner set 9, 10, 17, 19 mm (required only for mounting
with Nut)
Installation Guide_PV-ezRack_SolarRoof_Adjustable Tilt Legs_AU_V3.3
Page 10 of 22
1/10 Duerdin St
Tel: +61
3 9017 6688
Clayton VIC 3168, Australia
Fax: +61
3 9017 6668
www.clenergy.com.au
Email: [e-mail]

Installation preparation
Overview of system components
1. PV-ezRack®Rail
2. Front Foot
3. Splice
4. Back Legs
5. Inter Clamp
6. End Clamp
Installation Guide_PV-ezRack_SolarRoof_Adjustable Tilt Legs_AU_V3.3
Page 11 of 22
1/10 Duerdin St
Tel: +61
3 9017 6688
Clayton VIC 3168, Australia
Fax: +61
3 9017 6668
www.clenergy.com.au
Email: [e-mail]

Array Planning
Number of modules in the vertical direction x module height (please check
installation manual of the Solar module manufacturer)
the
2. Number of modules in horizontal x (module width + 18mm) + 32mm
3. Horizontal spacing of the roof hooks up to 2.0 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. Distance between 2 strings needs to be calculated based on the location
7. Always check the installation manual of the PV-Module you use in order to
determine the allowed fixing points on the Module frame
*Caution: Installations that are exposed to the wind or are located on the edge or
corners of the roof may make it necessary to leave smaller spaces between
interfaces.
Installation Guide_PV-ezRack_SolarRoof_Adjustable Tilt Legs_AU_V3.3
Page 12 of 22
1/10 Duerdin St
Tel: +61
3 9017 6688
Clayton VIC 3168, Australia
Fax: +61
3 9017 6668
www.clenergy.com.au
Email: [e-mail]

Step by step installation
1. Determine the
position of the Front
Foot according to
your plans. Shim the
Front Foot with
rubber, Fix the Front
Foot to the rafter
using two 6 mm
wood screws or in
case of a metal purlin
the recommended
metal screws (Page 6)
2. Fix the remaining
of the Front Foot to
the rafters according
to your plans.
3. The U Bracket
comes pre-assembled
with the Front foot. It
is recommended not
to tighten the M8 bolt
at this stage, so it
can be adjusted.
4. For the PV-
ezRack®rail
installation, position
the first rail to each
row and inset the Z-
Module in the
channel on the side
of the rail. Tighten
the Allen bolts on the
Z-Modules
(recommended
torque is 15-20Nm).
Installation Guide_PV-ezRack_SolarRoof_Adjustable Tilt Legs_AU_V3.3
Page 13 of 22
1/10 Duerdin St
Tel: +61
3 9017 6688
Clayton VIC 3168, Australia
Fax: +61
3 9017 6668
www.clenergy.com.au
Email: [e-mail]

5. Install the back
legs behind the front
legs. Check the
installation
requirements (fixing
points) of the PV-
Module
6. Adjust the length
using a 4mm Allen
key. Tighten
M8*10mm pressure
bolt with 17Nm
torque at the
desirable height.
7. Fix the L-shape
bracket with the Leg
tubebyusing
M8X55mm bolt
provided.
Maximum back
leg angle to
horizontal - 90°

Minimum Back
leg angle to
horizontal - 30°

8. Insert the Z-
Module on the L-
shape bracket in to
the channel on the
side of the PV-
ezRack®rail
(recommended
torque is 15-20Nm).
Installation Guide_PV-ezRack_SolarRoof_Adjustable Tilt Legs_AU_V3.3
Page 14 of 22
1/10 Duerdin St
Tel: +61
3 9017 6688
Clayton VIC 3168, Australia
Fax: +61
3 9017 6668
www.clenergy.com.au
Email: [e-mail]

9. To connect
multiple rails
together, slide the
splices on the rear
side of the pre-
assembled rails
halfway to the side.
Fasten the first M8
Allen bolt firmly using
the Allen key. Now
slide the next rail
segment into the
splice.
10. Tighten the
second M8 Allen bolt
using the Allen key.
An expansion gap at
the rail joints is
recommended, leave
a gap about the
same width as a
finger between the
rail joints and then
loosely tighten the
M8 Allen bolt.
11. 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).
12. Slide the module
end clamp tightly
against the module
and fasten tightly
using the Allen bolt
(recommended
torque is 15-20Nm).
Installation Guide_PV-ezRack_SolarRoof_Adjustable Tilt Legs_AU_V3.3
Page 15 of 22
1/10 Duerdin St
Tel: +61
3 9017 6688
Clayton VIC 3168, Australia
Fax: +61
3 9017 6668
www.clenergy.com.au
Email: [e-mail]

13. Cross-section of
the end clamp when
installation step 12
has been performed
correctly.
14. 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).
15. Now slide the
next module against
thepreviously
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).
10 to 15 degree
Installation Guide_PV-ezRack_SolarRoof_Adjustable Tilt Legs_AU_V3.3
Page 16 of 22
1/10 Duerdin St
Tel: +61
3 9017 6688
Clayton VIC 3168, Australia
Fax: +61
3 9017 6668
www.clenergy.com.au
Email: [e-mail]

15 to 30 degree
30 to 60 degree
Installation Guide_PV-ezRack_SolarRoof_Adjustable Tilt Legs_AU_V3.3
Page 17 of 22
1/10 Duerdin St
Tel: +61
3 9017 6688
Clayton VIC 3168, Australia
Fax: +61
3 9017 6668
www.clenergy.com.au
Email: [e-mail]

Accessories
Isolator Bracket Installation
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_Adjustable Tilt Legs_AU_V3.3
Page 18 of 22
1/10 Duerdin St
Tel: +61
3 9017 6688
Clayton VIC 3168, Australia
Fax: +61
3 9017 6668
www.clenergy.com.au
Email: [e-mail]

Cable Clip Installation
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_Adjustable Tilt Legs_AU_V3.3
Page 19 of 22
1/10 Duerdin St
Tel: +61
3 9017 6688
Clayton VIC 3168, Australia
Fax: +61
3 9017 6668
www.clenergy.com.au
Email: [e-mail]

MT-Rail Application Note
Tilt Leg and Tin Interface Installations with MT-Rails
(base-rail)
This application note is to be used with the “SolarRoof Adjustable Tilt Legs -
Installation Guide V3.0”, or eventually with “PV-ezRack SolarRoof Fixed 30 degree
Tilt Legs - Installation Guide” depending on the interface you use.
This document is designed for installations using the PV-ezRack®SolarRoof™ MT-
Rails manufactured by Clenergy. MT-Rails are mostly used on metal roofs if the
roof doesn’t have suitable mounting points to mount the Clenergy PV-ezRack®
SolarRoof™ interfaces such as tilt legs (adjustable and fixed 30°) or the tin
interface (L-feet). In these cases the MT-Rails are used as a supporting base rail.
Component list
Overview of system components
Part name
Picture
Function
ezRack MT-Rail
Base rail to mount
directly on to the roof
Pan-head universal
Connenction/mounting
between roof and MT-
Screw 6*90
Rail
Diamond module and
Connenction/mounting
between MT-Rail and
bolt
interface
To be mounted on top of
Interface
Tilt leg or Tin L-Feet
the MT-Rail with
Diamond modules and
bolts
Installation Guide_PV-ezRack_SolarRoof_Adjustable Tilt Legs_AU_V3.3
Page 20 of 22
1/10 Duerdin St
Tel: +61
3 9017 6688
Clayton VIC 3168, Australia
Fax: +61
3 9017 6668
www.clenergy.com.au
Email: [e-mail]