Clenergy PV-ezRack SolarRoof User manual

PV-ezRack SolarRoof Code-Compliant Planning and Installation Guide (AU) V1.6 Page 1 of 18
18/20 Duerdin St Tel: [phone]
Clayton VIC 3168, Australia Fax: [phone]
www.clenergy.com.au Email: [e-mail]
Clenergy PV-ezRack SolarRoof
Code-Compliant Planning and Installation
With Australia AS/NZS1170
The Clenergy PV-ezRack™has been developed as a universal system for roof-
mounting on pitched 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 your SolarRoof™system.
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 for SolarRoof™.
SolarRoof™products, when installed in accordance with this guide, will be
structurally adequate and will meet the AS/NZS1170 standards. During
installation, and especially when working on the roof, be sure to observe the
appropriate safety regulations and please pay attention to the relevant
regulations of your local region. Please check that you are using the current
version of the installation manual by contacting Clenergy Australia by email on
[e-mail], or your local representative in Australia.

PV-ezRack SolarRoof Code-Compliant Planning and Installation Guide (AU) V1.6 Page 2 of 18
18/20 Duerdin St Tel: [phone]
Clayton VIC 3168, Australia Fax: [phone]
www.clenergy.com.au Email: [e-mail]
The installer is solely responsible for:
Complying with all applicable local or national building codes, including
any that may superseded this manual;
Ensuring that PV-ezRack and other products 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 PV-ezRack parts and installer-supplied parts as specified by
PV-ezRack (substitution of parts may void the warranty and invalidate the
letter of certification on page 2);
Ensuring that lag screws have adequate pullout 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.
Installation tools
6 mm Allen key;
Cordless drill;
Open-end spanner set 9, 10, 17, 19 mm (required only for mounting with
hanger bolts);
Torx-30 (AW 30) bit;
Angle grinder with stone disk;
Power Cord;
If necessary, timber to shim the roof hooks.

PV-ezRack SolarRoof Code-Compliant Planning and Installation Guide (AU) V1.6 Page 3 of 18
18/20 Duerdin St Tel: [phone]
Clayton VIC 3168, Australia Fax: [phone]
www.clenergy.com.au Email: [e-mail]
1. Code-Compliant Planning
This document is designed to support for installations using SolarRoof™ PV
Module Mounting System, manufactured by Clenergy Co. Ltd. Follow the six
steps below and the installation instructions section to install SolarRoof™in
compliance with the AS/NZS1170.
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 SolarRoof™will be installed must have the capacity
to resist the combined Design Dead Load and Live Load per footing.
To determine the part you need you can used our PV-ezRack SolarRoof
Calculator.
1. Determine the installation area on the roof
Clenergy PV-ezRack SolarRoof may be installed anywhere on a roof but fixing
centres are required to be reduced at ridges and edges. The diagram below
shows the area of higher wind loadings within 0.2a and 0.2b of a roof edge or
ridge (where a and b are the plan dimension of the building).
Roof area 1 Roof area 2
The following table will help you determine the maximum rail support spacing
for your project.
Also note that if the roof slope is less than 10 degree the reduction on spacing
does not apply.

PV-ezRack SolarRoof Code-Compliant Planning and Installation Guide (AU) V1.6 Page 4 of 18
18/20 Duerdin St Tel: [phone]
Clayton VIC 3168, Australia Fax: [phone]
www.clenergy.com.au Email: [e-mail]
2. Determine the wind region of your installation site
Region Definition:
Wind regions are pre defined for all of Australia by Australian Standard 1170.
The Wind Region has nothing to do with surrounding topography or buildings.
Most of Australia is designated Region A which indicates a Regional
Ultimate Basic Wind Velocity of 45msec.
Some areas are designated Region B (57msec). Local authorities will
advise if this applies in your area.
Region C areas (66msec) are generally refered to as Cyclonic and are
generally limited to northern coastal areas. Most Region C zones end
100km inland.
Region D (80msec) Australia's worst Cyclonic Region between Carnarvon
and Pardoo in Western Australia.
3. Determine the height of your installation site
This document provides sufficient information for SolarRoof™ system installation
height less than 20 meters. If your installation site is more than 20 meters in
height, please contact Clenergy to obtain engineering data to support your
installation.

PV-ezRack SolarRoof Code-Compliant Planning and Installation Guide (AU) V1.6 Page 5 of 18
18/20 Duerdin St Tel: [phone]
Clayton VIC 3168, Australia Fax: [phone]
www.clenergy.com.au Email: [e-mail]
4. 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).
Wind Region A
Wind Region B
Wind Region C
Wind Region D
Roof 1
Roof 2
Roof 1
Roof 2
Roof 1
Roof 2
Roof 1
Roof 2
5 Meters
2130
1500
1690
1200
1380
980
1080
10 Meters
1940
1370
1540
1090
1260
890
990
15 Meters
1840
1230
1460
980
1190
800
940
20 Meters
1740
1380
1130
890
The figures above are based on attaching 200W PV modules (length of
1675 mm, weight of 23 kg) to SolarRoof system. These figures should be
sufficient for installing smaller PV modules. Please consult Clenergy for
installing PV modules greater than length of 1675mm and weight of 23 kg.
The Tile roof hooks should be fixed to the rafter using at least two
12Gx80mm wood screws minimum.
b) Tin roof
Please use the following table to determine the base rail support spacing for
sheet metal roof installations (mm).
Region A & B
Region C
Region D
Roof 1
Roof 2
Roof 1
Roof 2
Roof 1
Roof 2
5 Meters
1320
990
770
550
770
10 Meters
1200
900
700
500
700
15 Meters
1140
810
665
450
665
20 Meters
1080
630
630
The figures above are based on attaching 200W PV modules (length of
1675mm, weight of 23 kg) to SolarRoof system. These figures should be
sufficient for installing smaller PV modules. Please consult Clenergy for
installing PV modules greater than length of 1675mm and weight of 23 kg.
The L Feet should be fixed to the purlins under using 12GX90 screws
through sheet metal roofs with gasket.
The above spacings apply for fixing through thin sheet purlins (greater
than 1mm thickness) or a minimum embedment of 50mm into timber
purlins.
Based on an embedment depth of 35mm (fixing into the battens) the
spacings remain unchanged for region A and B. For region C, the spacings
should be reduced by 10% and for region D, the spacings should be
reduced by 30%.

PV-ezRack SolarRoof Code-Compliant Planning and Installation Guide (AU) V1.6 Page 6 of 18
18/20 Duerdin St Tel: [phone]
Clayton VIC 3168, Australia Fax: [phone]
www.clenergy.com.au Email: [e-mail]
5. Verify acceptable Rail End Overhang
Rail End Overhang must equal 50 percent 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).
6. Determine Roof slope
SolarRoof™ system can be used for roof slope up to 60 degrees. Please verify
the Installation site roof slope should be between 0 degrees and 60 degrees.
2. Solar
3.
4.
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7.
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10.
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18.
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PV-ezRack SolarRoof Code-Compliant Planning and Installation Guide (AU) V1.6 Page 7 of 18
18/20 Duerdin St Tel: [phone]
Clayton VIC 3168, Australia Fax: [phone]
www.clenergy.com.au Email: [e-mail]
22.
23.
24.
25.
26.
Overview of system components for Tile Roof
PV-ezRack Rails
PV-ezRack Splice
Inter Clamp with
Z Module
End Clamp with
Z Module
Tile interface
with Z module
Wood screw
6x80 mm
Overview of system components for Tin Roof
PV-ezRack Rails
PV-ezRack Splice
Inter Clamp with
Z Module
End Clamp with
Z Module
Tin interface with
Z module
Wood screw
6x90 mm

PV-ezRack SolarRoof Code-Compliant Planning and Installation Guide (AU) V1.6 Page 8 of 18
18/20 Duerdin St Tel: [phone]
Clayton VIC 3168, Australia Fax: [phone]
www.clenergy.com.au Email: [e-mail]
27.Installation preparation
Overview of system
components
a PV-ezRack rails
b Inter Clamp
c Roof hook
d Splice
e End Clamp
f Telescopic mounting
(optional)
Planning the module area
1. Number of modules in the vertical direction x module height (please check
also the installation manual of the manufacturer of the solar module)
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

PV-ezRack SolarRoof Code-Compliant Planning and Installation Guide (AU) V1.6 Page 9 of 18
18/20 Duerdin St Tel: [phone]
Clayton VIC 3168, Australia Fax: [phone]
www.clenergy.com.au Email: [e-mail]
Tile Roof Hook 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 lift them up
slightly.
2. Fix the roof
hooks to the rafter
using three 6 x 80
mm wood screws.
3. The roof hook
must not press
against the roof
tile. If necessary,
shim the roof hook
with wood.
Incorrect Correct
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.
5. Caution! Do not
use fitted roof
hooks as a ladder,
as this extreme
point load could
damage the tile
below.

PV-ezRack SolarRoof Code-Compliant Planning and Installation Guide (AU) V1.6 Page 10 of 18
18/20 Duerdin St Tel: [phone]
Clayton VIC 3168, Australia Fax: [phone]
www.clenergy.com.au Email: [e-mail]
Tile Roof Hook Installation
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. A titanium zinc
metal sheet must
be cut to fit on site,
with an overlap of
at least 20 mm
around the recess,
and installed under
the roof hooks.
Caution! Please
take note of Figure
3.
8. For easy use of
the Z module, you
must make sure
that the thread of
the screws 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
screw.
The screws can still
be freely moved in
the rail channel.
Slide the screws to
their final position
in connection with
the inter-module
clamp, module end
clamp or roof
hooks/hanger bolts
and fasten firmly
(recommended
torque is 8 Nm).