Clenergy PV-ezRack SolarRoof User manual

Code-Compliant Planning and Installation Guide V 6.0
Complying with AS/NZS 1170.2:2021
Penetrative Tilt Legs
Last Updated - Nov. 2022

Installation Guide / SolarRoof Tilt Legs
1Code-Compliant Planning and Installation Guide V 6.0 - Complying with AS/NZS 1170.2:2021
Introduction
Complying with all applicable local or national
building codes, including any updates that may
supersede this manual;
Ensuring that PVezRack®and other products are
appropriate for the particular installation and the
installation environment;
Using only PVezRack® parts and installer-supplied
parts as specified by PVezRack® 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 PVezRack® SolarRoof components
as required in AS/NZS 5033: 2021;
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: 2021;
Veryfying atmospheric corrosivity zone of installation
site by referring to AS 4312-2008 or consulting local
construction business to determine appropriate
products and installations.
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The installer is solely responsible for:
List of contents
Introduction
Planning
Tools & Components
System Overview
Installation Instruction
Certification
01
02 - 13
14
15 - 18
19 -22
23 - 42
The Clenergy PVezRack® 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
PVezRack® SolarRoof Tilt Legs.
This manual provides:
1) Supporting documentation for building permit
applications relating to PVezRack® SolarRoof Tilt Legs
Universall PV Module Mounting System,
2) Planning and installation instructions.
- Introduction -
The PVezRack® SolarRoof Tilt Legs parts, when installed
in accordance with this guide, will be structurally sound
and will meet the AS/NZS 1170.2:2021 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.
Product Warranty:
Please refer PVezRack® Product Warranty on our
website.

Installation Guide / SolarRoof Tilt Legs
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Code-Compliant Planning and Installation Guide V 6.0 - Complying with AS/NZS 1170.2:2021
- Planning -
Planning
Determine the wind region of your installation site
Central Australia is now classified as Wind Region A0
and Terrain Classification 2 instead of Wind Region
A4.
Region A1, previously most of the South coast of
Australia, now is divided into Regions A1 and A5.
Tasmania is now Region A4.
Region B has been divided into regions B1 and B2.
This will affect installations in Northern NSW, Gold
Coast, Brisbane, Sunshine Coast, and Gladstone.
Region B1 was increased to include more inland cities
around Brisbane. This will likely mean extra structural
requirements such as extra rail for installs.
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Wind regions are pre-defined for the whole of Australia by the Australian Standard 1170.2:2021. Comparing to
1170.2:2011, 2021 version has a lot of changes in wind regions.
Wind Regions – Australia

Installation Guide / SolarRoof Tilt Legs
3Code-Compliant Planning and Installation Guide V 6.0 - Complying with AS/NZS 1170.2:2021
Determine the Terrain Category
It requires to determine the right terrain category to ensure the installation meets the maximum interface spacing
specified in the engineering certificate.
In 1170.2-2021, Terrain category 1.5 was removed and Terrain category 2.5 was added. See the definitions below.
Terrain Category 1 (TC1) – Very exposed open terrain with very few or no obstructions,
and all water surfaces (e.g. flat, treeless, poorly grassed plains; open ocean, rivers, canals,
bays and lakes).
Terrain Category 2 (TC2) – Open terrain, including grassland, with well-scattered obstructions
having heights generally from 1.5 m to 5 m, 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 some trees or isolated obstructions, terrain in developing outer urban areas
with scattered houses, or larger acreage developments with more than two and less then 10 buildings per hectare.
Terrain Category 3 (TC3) – Terrain with numerous closely spaced obstructions having
heights generally from 3 m to 10 m. The minimum density of obstructions shall be at least the
equivalent of 10 house-size obstructions per hectare (e.g. suburban housing, light industrial
estates or dense forests).
Terrain Category 4 (TC4) – Terrain with numerous large, high (10 m to 30 m tall) and closely spaced constructions, such
as large city centres 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.
Verify Atmospheric Corrosivity Zone of Installation Site
Please refer to “AS 4312-2008 Atmospheric Corrosivity Zones in Australia “or consult local construction business to
verify corrosivity category of installation site to determine appropriate products and interface spacing. When standard
products are installed in high corrosivity zones, like C4/C5, interface spacing reduction factor need to be applied.
Please refer to the generic notes of Certification Letter for the details.
Determine the Height of the Installation Site
This document provides sufficient information for the PVezRack®SolarRoof system installation up to 30 meters
building height (average roof height of structure above the ground, see the diagram below). If your building is more
than 30 meters high, please contact Clenergy to obtain project specific engineering certificate to support your
installation.
Determine Roof slope and Tilt Leg Angle
The PV-ezRack® SolarRoof Tilt Legs system is suitable for roof slope up to 22° for rails running perpendicular to the roof
slope (including standard and reverse tilt), and up to 10° for rails running parallel to the roof slope. See the diagrams of
3 different scenarios below.
Please always keep back leg tilt within 30° - 90° from roof plane or horizontal depending on certain scenario.
- Planning -

Installation Guide / SolarRoof Tilt Legs
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Code-Compliant Planning and Installation Guide V 6.0 - Complying with AS/NZS 1170.2:2021
- Planning -
Standard Tilt – Rails perpendicular to Roof Slope
Reverse Tilt – Rails perpendicular to Roof Slope
Standard Tilt – Rails parallel to Roof Slope

Installation Guide / SolarRoof Tilt Legs
5Code-Compliant Planning and Installation Guide V 6.0 - Complying with AS/NZS 1170.2:2021
Determine the Installation Area of Roof
There are 4 different roof zones for tilt leg installation: Internal Zone, Intermediate Zone, Edge Zone and Corner Zone.
Please see diagrams and steps below to define area of each zone.
Step 1. Determine building height (h), width (b) and length (d)
Step 2. Check ratio of height to length/width (h/b and h/d)
If both h/b and h/d < 0.2, then a = 2h
Step 3. If h/b and h/d > 0.2 then a = the lowest value between 0.2b and 0.2d
- Planning -
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） × ×
Roof zone definition
Roof Pitch < 10°
Flat/Mono – Slope Roof > 10°
Flat/Mono – Slope Roof < 10°
Flat/Mono – Slope Roof > 10°

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Code-Compliant Planning and Installation Guide V 6.0 - Complying with AS/NZS 1170.2:2021
Determine Two Screws or One Screw Installations of Tilt Legs
There are options of using two screws or one screw for installations of adjustable and fixed tilt legs, depending on the
project scenario, such as required interface spacing, purlin spacing, rib spacing of roof sheet and so on. Please find a
note of engineering letter for details.
Determine the Maximum Rail Support Spacing
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.
Verify Maximum Rail End Overhang
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.
The application of Adjustable Tilt Legs
Following the tilt angle rules of 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.
- Planning -
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.
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） × ×
Verify Purlin Properties of Building
Please verify purlin properties of building, which could affect the interface spacing. Tilt legs spacing on in the
certification letter is based on steel purlin G450 1.5 mm thick or 35 mm Timber F7 (Pine). For example, if the steel purlin
is less than 1.5 mm thick, the corresponding reduction factor of interface spacing could be applied. Please refer to
generic note of engineering letter for details.

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(1)
(2)
(3)

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Code-Compliant Planning and Installation Guide V 6.0 - Complying with AS/NZS 1170.2:2021
- Planning -
(5)
(4)

Installation Guide / SolarRoof Tilt Legs
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(6)
(8)
(7)

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Code-Compliant Planning and Installation Guide V 6.0 - Complying with AS/NZS 1170.2:2021
- Planning -
(9)
(10)

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(11)
(12)

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Code-Compliant Planning and Installation Guide V 6.0 - Complying with AS/NZS 1170.2:2021
- Planning -
(13)
(14)

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(15)

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Code-Compliant Planning and Installation Guide V 6.0 - Complying with AS/NZS 1170.2:2021
Tools and Components
Tools
Screw Driver
(maximum
torque≥34N·m)
String & Marker PenTorque Spanner Socket Wrench M8 5m Tape
- Tools and Components -
Components
ER-R-ECO
ECO-Rail
ER-EC-ST
End Clamp
ER-IC-ST
Inter Clamp
C-U/30/46
Universal Clamp
C-U/30/46-G
Universal Clamp
ER-TL-10/15
ER-TL-15/30
ER-TL-30/60
Adjustable Tilt legs,
non-preassembly
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

Installation Guide / SolarRoof Tilt Legs
15 Code-Compliant Planning and Installation Guide V 6.0 - Complying with AS/NZS 1170.2:2021
System Overview
Adjustable Tilt Legs
Adjustable Tilt Legs with L-feet
1. End Clamp 2. Inter Clamp 3. Grounding Clip 4. ECO-Rail 5. Grounding Lug 6. Adjustable Tilt Legs
1. End Clamp 2. Inter Clamp 3. Grounding Clip 4. ECO-Rail 5. Grounding Lug 6. Adjustable Tilt Legs with L-feet
Overview of PV-ezRack® SolarRoof Adjustable Tilt Legs
- System Overview -
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Code-Compliant Planning and Installation Guide V 6.0 - Complying with AS/NZS 1170.2:2021
Fixed Tilt Legs
1. End Clamp 2. Inter Clamp 3. Grounding Clip 4. ECO-Rail 5. Grounding Lug 6. Fixed Tilt Legs
- System Overview -
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Precautions during Stainless Steel Fastener Installation
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.
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.

Installation Guide / SolarRoof Tilt Legs
17 Code-Compliant Planning and Installation Guide V 6.0 - Complying with AS/NZS 1170.2:2021 - System Overview -
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.
1) Adjustable 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.

Installation Guide / SolarRoof Tilt Legs
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Code-Compliant Planning and Installation Guide V 6.0 - Complying with AS/NZS 1170.2:2021
- System Overview -
2) Adjustable 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.
3) Fixed Tilt Legs
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.

Installation Guide / SolarRoof Tilt Legs
19 Code-Compliant Planning and Installation Guide V 6.0 - Complying with AS/NZS 1170.2:2021
Installation Instructions
Front Leg Installation
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.
- Installation Instructions -
Front & Rear Leg Installation
Figure 2
(Front Leg Installation with Single Screw)
Figure 3
(Tin Foot Front Leg Installation)
Figure 1
(Front Leg Installation with Two Screws)
Please follow Buildex screws installation guide below:
- Use a 3/8" Hex Socket.
- Use a mains powered or cordless screw driver with a drive speed of 3,000 RPM maximum.
- Fit the driver bit into the screw and place at the fastening position.
- Apply consistently firm pressure (end load) to the screw driver until the screw is fastened.
- Screws with bonded washers should be tightened only until the washer is gripped firmly enough to provide a
watertight seal. The screws should be neither under tightened nor over tightened to lead to water penetration.
Take particular care to ensure the screw is driven perpendicular to the interface to avoid deformation of the washer.
Under Tightened Correctly Tightened Over Tightened
Notes:
1. Two screws shall be installed through two side holes of
front leg (as shown in Figure 1);
2. Single screw shall be installed through central hole only
of front leg (as shown in Figure 2).