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any that may superseded this manual;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.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.

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).

PV-ezRack SolarRoof Code-Compliant Planning and Installation Guide (AU) V1.6 Page 11 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
9. Installation of
the rails on roof
hooks.
If your set of rails
consists of rails of
different lengths,
always begin with
the shortest piece.
Install the framing
for each row of
modules loosely on
the roof hooks,
using an M8 x 25
mm Allen bolt,
washers, retaining
washers and the Z
Module (2 to 3
turns of the screw
are adequate for
loose installation).
Please take note of
Figure 10.
10. An optimum
adjustment of the
vertical and
horizontal position
can be made by
taking advantage
of the long hole in
the roof hooks and
the still loose
connection of the Z
Module or T-head
bolts in the rail.
Please take note of
Figure 13 below.
Position

PV-ezRack SolarRoof Code-Compliant Planning and Installation Guide (AU) V1.6 Page 12 of 18
18/20 Duerdin St Tel: [phone]
Clayton VIC 3168, Australia Fax: [phone]
www.clenergy.com.au Email: [e-mail]
Tin Roof Hook Installation
11. In the case of
corrugated roof
cladding, hanger
bolts are used
instead of roof
hooks. Drill through
the roof cladding at
the planned
location and screw
the hanger bolts
into the purlins.
Then mount the L-
brackets.
12.Cross-section
of a hanger bolt
installation. Take
special care that
the nut tightly
fastens the sealing
washer without
damaging the roof
cladding. When
performing the
installation, take
care that the
thread of the
hanger bolt does
not cover the long
hole in the L-
bracket.
Base Rail Installation
13. Position the
first frame rails for
each row and
fasten them
temporarily to the
roof cladding using
a cord. Tighten the
Allen bolts or the
nuts on the T-head
bolts that are used
to fasten the roof
hooks/hanger bolts
(recommended
torque is 8 Nm).
Please also pay
attention to Figure
10.

PV-ezRack SolarRoof Code-Compliant Planning and Installation Guide (AU) V1.6 Page 13 of 18
18/20 Duerdin St Tel: [phone]
Clayton VIC 3168, Australia Fax: [phone]
www.clenergy.com.au Email: [e-mail]
Base Rail Installation
14. 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.
15. Tighten the
second M8 Allen
bolt using the Allen
key. The
connection is
finished. An
expansion gap at
the rail joints is
recommended. For
this purpose, leave
a gap about the
same width as a
finger between the
rail joints and then
loosely tighten the
M8 allen bolt.
16. When planning
a system using a
telescopic
mounting, please
mount a telescopic
mounting at the
end of every row of
rails.
To do this, you
insert the end of
the telescopic
mounting into the
rail. The mountings
can be adjusted to
their correct
positions later.
For this reason,
you should not yet
fasten the M8 Allen
bolt to the rear of
the telescopic
mounting.

PV-ezRack SolarRoof Code-Compliant Planning and Installation Guide (AU) V1.6 Page 14 of 18
18/20 Duerdin St Tel: [phone]
Clayton VIC 3168, Australia Fax: [phone]
www.clenergy.com.au Email: [e-mail]
Base Rail Installation
17. Fasten any
remaining roof
hooks to the
movable rail
element of the
telescopic
mounting. Please
repeat steps 14 to
16 until all base rail
rows in your
system are
installed.
PV Module Installation
18. Before
installing the
modules, add anti-
slip protection to
the lowest row of
modules (horizontal
rail installation
only). To do this,
fasten M6 x 20 mm
bolts (with the
shank downwards)
to the lower
mounting holes of
the module frame
using M6 nuts.
When installing
large modules (e.g.
ASE250) M8 x 20
mm bolts must be
used.
19. Place the first
module of the
bottom row so that
the anti-slip
protection sits in
the rail channel of
the lowest row of
rails.

PV-ezRack SolarRoof Code-Compliant Planning and Installation Guide (AU) V1.6 Page 15 of 18
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Clayton VIC 3168, Australia Fax: [phone]
www.clenergy.com.au Email: [e-mail]
PV Module Installation
20. Slide the
module end clamp
tightly against the
module and fasten
tightly using the
Allen bolt
(recommended
torque is 8 Nm).
Please take note of
Figure 10.
21. Cross-section
through the module
end clamp when
installation step 20
has been correctly
performed.
22. Slide the pre-
assembled inter-
module clamp into
the rails from
above, place it
firmly against the
module and fasten
loosely (approx. 2 -
3 turns). Please
also take note of
Figure 10.
23. Now slide the
next module
against the
previously installed
module and tighten
the inter-module
clamp using the
Allen key
(recommended
torque is 8 Nm).
Take care that the
anti-slip protection
sits in the rail
channel of the
lowest row of rails.
Please also take
note of Figure 10.

PV-ezRack SolarRoof Code-Compliant Planning and Installation Guide (AU) V1.6 Page 16 of 18
18/20 Duerdin St Tel: [phone]
Clayton VIC 3168, Australia Fax: [phone]
www.clenergy.com.au Email: [e-mail]
PV Module Installation
24. If your system
does not use a
telescopic
mounting, position
the last module of
the row in the base
rail and fasten the
module using the
module end clamp
(recommended
torque is 8 Nm).
For systems with
telescopic
mountings, please
take note of
Figure 25 below.
25. Installation
using telescopic
mounting Position
the telescopic
mounting, which
was loosely
mounted in step
16, so that there is
sufficient room for
the last module,
the last inter-
module clamp and
the end clamp
(calculation:
module width or
length in mm + 43
mm). Now tighten
the telescopic
mounting using the
Allen key.
26. Place the last
module in the row
on the rails (with
the first row of
modules, take care
that the anti-slip
protection sits
properly in the rail
channel) and fasten
the last inter-
module clamp and
the module end
clamp using the
Allen key (torque
8 Nm).

PV-ezRack SolarRoof Code-Compliant Planning and Installation Guide (AU) V1.6 Page 17 of 18
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Clayton VIC 3168, Australia Fax: [phone]
www.clenergy.com.au Email: [e-mail]
PV Module Installation
27. Now slide in
the first module of
the next row from
above onto the
corresponding
module of the row
beneath. A
separation from the
lower module can
be maintained for
optical reasons. An
inter-module clamp
can be used as a
separator, so that
the vertical and
horizontal
separation of the
modules is
identical. Continue
mounting the
modules as
described in steps
20 to 26 until all
modules are
installed. The
installation is
finished.

PV-ezRack SolarRoof Code-Compliant Planning and Installation Guide (AU) V1.6 Page 18 of 18
18/20 Duerdin St Tel: [phone]
Clayton VIC 3168, Australia Fax: [phone]
www.clenergy.com.au Email: [e-mail]
10 year limited Product Warranty, 5 year limited Finish Warranty
Clenergy 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, in 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.