Clenergy PV-ezRack User manual

PV-ezRack®SolarTripod
Single/Adjustable and Double
Code-Compliant Planning and Installation Guide V3.0
Complying with AS/NZS1170.2-2011 AMDT 2-2016

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01page of 15
Introduction
1. Introduction
Clenergy PV-ezRack SolarTripod is suitable
for home, commercial, flat roof and even for
large scale solar installations. SolarTripod
divides 2 solutions, single row and double
rows in portrait of modules. The advantage of
SolarTripod is the pre-assembly fixed angle
brackets; it reduces the time and labour in
installation.
Please review this manual thoroughly before
installing PV-ezRack®SolarTripod ™. This
manual provides
1) Supporting documentation for building
permit applications relating to PV-ezRack®
SolarTripod ™ Universal PV Module Mounting
System;
2) Planning and installation instructions.
The PV-ezRack®SolarTripod ™ 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 that may
supersede 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/purlins,
connections, and other structural support
members can support the array under building
live load conditions;
• Use only PV-ezRack parts as specified in this
document (substitution of any PV-ezRack part
may void the warranty and invalidate the letter
of certification);
•Recycling: Recycle: according to the local
relative statute;
•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
Warranty
Certification Letter
01
02
05
06
09
14
15
List of Contents

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02page of 15
2. Planning
2.1 Determine the wind region of your installation site
Planning
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.

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Planning
This certification document provides sufficient information for the PV-ezRack®SolarTripod™ 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
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

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Planning
PV-ezRack®SolarTripod ™ system is certified to use for roof slopes up to 10°. If your installation site
is more than 10°, please contact Clenergy to obtain project specific engineering certificate to support
your installation.
2.4 Determine Roof slope
On pitched roof, there are four different roof zones for installation. See the steps below to determine
area of each zone.
2.5 Determine the Installation Area of Roof
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.
Please refer to the Certification Letter and Spacing Table. If a project specific Certification Letter has been
provided, please refer to the support spacing in this letter.
Rail end overhang should be not over 40% of the Tripod spacing. For example, if the Tripod spacing is
1500mm, the Rail end overhang can be up to 600mm only.
2.6 Determine the Maximum Rail Support Spacing
2.7 Verify Maximum Rail End Overhang
In the figure above h= height, b =width and d= length of the building.

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3.2 Components
ER-EC-ST
End Clamp
ER-SP-T50
Splice for T-50 Rail
ER-RC-T/G
Rail Clamp for T-Rail
ER-S-TRI30-D3000
Tripod Double Support
ER-IC-ST
Inter Clamp
ER-S-TRI/S15-30
ER-S-TRI/S30-AU
Tripod Support
(single or adjustable)
ER-R-T50
T-Rail 50mm
ER-AP-TRI/01
Screws and EPDM
rubber Accessory
package
Component list
Tools and Components
3. Tools and Components
3.1 Tools
6mm Allen Key
5m Tape
14mm Open Spanner
String & Marker Pen
Tools
Screw Driver (maximum
torque≥34N·m)

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System Overview
4. System Overview
4.1 Overview of PV-ezRack®SolarTripod Single/Adjustable and Double
1
2
3
4
5
6
①Inter Clamp ②End Clamp ③T-Rail 50mm ④Splice for T-50 Rail ⑤Tripod Support
⑥Rail Clamp for T-Rail
As the drawing above, mounting details are as follow:
(1) Module orientation: portrait.
(2) Length of rail in the same row: L1= Number of modules per row x (module width + 18mm) + 32mm.
(3) Distance between the two rows: L2 must be determine based on the location to avoid shading.
(4) Distance between the two support Tripod: L3 (refer to the Certification Letter).

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-Single Tripod
System Overview
Improper operation may lead to the deadlock of bolts and nuts. Follow the steps below to reduce this
risk:
4.2 Precautionary Measures for Stainless-Steel Fastener Installation
4.2.1 Reduce the friction coefficient
(1) Ensure that the thread surface is clean (no dirt or contaminant).
(2) Apply lubricant (grease or 40# engine oil) to fasteners prior to tightening to avoid galling or seizing in the
threads.
4.2.2 General installation instructions
(1) Apply force to fasteners in the direction of thread.
(2) Apply force uniformly to maintain required torque.
(3) Professional tools and tool belts are recommended.
(4) Avoid using electric tools for final tightening.
(5) Avoid working at high temperatures.
4.2.3 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.

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System Overview
-Double Tripod

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Installation Instruction
5.1 Single Tripod Installation
5.1.1 Unfold the tripod support, and put it on
Tin Roof.
5.1.2 Fix the Tripod on the purlin with Buildex
screw and Rubber Pad. Please refer to the
certification letter for the number of Buildex
screw and Rubber Pad.
System dimensions Double TripodSystem dimensions Single/Adjustable Tripod
5. Installation Instruction

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5.1.3 Fix the back tubes to the upper support
by using hex head bolts M10*65, Spring
Washer, Flat Washer and Hex nuts M10.
5.1.4 Fix the tubes with U Bracket to the base
support by using hex head bolts M10*65,
Spring Washer, Flat Washer and Hex nuts
M10.
5.1.5 Repeat the step above for each support
that you need to install.
Fix the support Tripod to the purlin following
the planning guide.
5.2 Double Tripod Installation
5.2.1 Unfold the Double Support
(Preassembly), and put it on Tin Roof.
5.2.2 Fix the Tripod on the purlin with Buildex
screw and Rubber Pad. Please refer to the
certification letter for the number of Buildex
screw and Rubber Pad.
Fix the AL-tube on Upper Support and fasten
tightly with Bolts M10*65.
Installation Instruction

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Installation Instruction
5.2.2 Repeat the step above for each support
that you need to install.
Fix the support Tripod to the purlin following
the planning guide.
5.3 Adjustable Tripod Installation
5.3.1 Fix the Tripod on the purlin with Buildex
screw and Rubber Pad. Please refer to the
certification letter for the number of Buildex
screw and Rubber Pad.
5.3.2 Fix two freeness al-tubes together by
using hex head bolts M10*65, Spring Washer,
Flat Washer and Hex nuts M10.
5.3.3 Tighten the screws through the leg
strug to go along with the positioning groove
on the leg tube, in order to achieve accurate
positioning purposes.
Every 2 degrees set a positioning groove

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Installation Instruction
5.4 T Rail Installation
5.4.1 Use T-rail clamp to fix the T-rail 50 on
to the upper support, two per rails and per
support.
5.4.2 If the rail is not long enough, please
connect the rails by using the splice for T Rail
50 using 2 self-tapping screws on each side.
5.4.3 Fix all the rails on to the upper support
as the step above.
NOTE: WHEN USING TRIPOD FOR
INSTALLATION WORKS, SCREWS NOT
EXPOSED TO FREQUENT RAIN SHOULD
BE WASHED DOWN WITH FRESH WATER
AT LEAST EVERY 6 MONTHS TO MEET THE
WARRANTY CONDITIONS OF BUILDEX
SCREWS.

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Installation Instruction
5.5 PV Modules Installation
5.5.1 Before installing the PV modules on
horizontal rail installations, add anti-slip
protection to the lowest row of PV modules.
To do this, fasten M6 x 20 mm bolts (with the
shank downwards) to the lower mounting holes
of the PV module frame. When installing large
modules (e.g. ASE250) M8 x 20 mm bolts must
be used.
5.5.2 Use Clenergy patented Inter and End
clamps to fix the panels on to the rails.
5.5.3 Finish installing all the panels.
5.5.4 Apply one pre-assembled Grounding
Lug per Rail. Click the Grounding Lug into to
the rail channel and insert the Copper Wire. (the
maximum size is 4 mm2or similar) Fasten the
bolt M6*14 with 5~6 N·m and the bolt M8*25
with 16~20 N·m.Copper Pipe will be supplied
for the case that using small size Copper Wire.

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Warranty
10 year limited Product Warranty, 5 year limited Finish Warranty
Clenergy (Xiamen) Technology 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, at 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.
6. Warranty

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Certification Letter and
Interface Spacing Table

Gamcorp (Melbourne) Pty Ltd A.C.N 141 076 904 A. .N 73 015 060 240
www.gamcorp.com.au [email protected]m.au
Suite 4, 346 Ferntree Gully Rd, Notting Hill VIC 3168 Tel: [phone] Fax: [phone]
Ref No: Issue 662/K.Z
25 August 2016
Clenergy Australia
11/20 Duerdin Street
Clayton North VIC 3168
PV-ezRack Adjustable SolarTripod Engineering Certificate
Gamcorp (Melbourne) Pty Ltd, being Structural Engineers within the meaning of Austalian Regulations,
have carried out a structural design check of the PV-ezRack SolarTripod for installation within Australia.
The design check has been based on the information provided by Clenergy Australia and schematic
drawings of the system components by Clenergy International.
Component Part No
PV-ezRack T Rail 50 ER-R-T50(2560/3405/4200)
PV-ezRack Solar Single Tripod ER-S-TRI/S15-30
PV-ezRack Solar Double Tripod ER-S-TRI/D15-30
PV-ezRack Splice for T-50 Rail ER-SP-T50
PV-ezRack Rail Clamp for T-Rail ER-RC-T/G
PV-ezRack Inter Clamp, Standard 28-57mm ER-IC-ST(28-57)
PV-ezRack End Clamp, Standard 28-57mm ER-EC-ST(28-57)
We find the PV-ezRack adjustable SolarTripod to be structurally sufficient for Australian use based on the
following conditions:
•Wind Loads to AS/NZS 1170.2:2011 Amdt 3:2013
•Wind Terrain Categories 2 & 3
•Maximum building height of 20 meters
•Maximum roof angle of 10 degree
•Panel size 1.65 x 0.99 meters
•Maximum tilt angle of tripod frame is 30 degree
•Wind average recurrence interval of 500 years
•Wind region A, , C, D.
NOTES
•Refer to attached summary table for interface spacing
•The recommended spacing nominated in this certification is based on the capacity of
the array frame, not the roof structure and fixings. It is the responsibility of the
installer to adopt the most critical spacing
•If any of the above conditions cannot be met, the structural engineer must be notified.
Page 1 of 7
ISO 9001:2008 Registered Firm
Certificate No: AU1222
#662 - ngineering Certification for PV-ezRack SolarTripod

Client: Issue:
Project: Date:
Address:
Designed:
Checked: M.A
PV-ezRack Adjustable Single SolarTripod Spacing Table
Type of Rail ER-R-T50 (2560/3405/4200)
Type of Interface ER-S-TRI/S15-30
Solar Panel Dimension 1.65mx0.99m
Terrain category 2
Tilt Angle 15°-20°
Roof Angle (Φ) – ≤10°
Corner Edge Interm
ediate Internal Corner Edge Interm ediate Internal Corner Edge Interm ediate Internal Corner Edge Interm ediate Internal
A1473 1641 1775 1991 1402 1560 1685 1886 1366 1520 1641 1835 1290 1498 1617 1806
B1129 1617 1749 1961 932 1409 1661 1858 844 1275 1618 1808 797 1204 1594 1780
C759 1146 1539 1734 627 946 1268 1648 568 856 1148 1605 536 809 1084 1581
D468 705 944 1429 387 582 779 1178 351 528 706 1066 331 499 667 1007
Tilt Angle 21°-25°
Roof Angle (Φ) – ≤10°
Corner Edge Interm
ediate Internal Corner Edge Interm ediate Internal Corner Edge Interm ediate Internal Corner Edge Interm ediate Internal
A1004 1404 1515 1688 829 1253 1441 1604 751 1134 1405 1563 709 1070 1385 1540
B621 937 1257 1664 514 774 1037 1571 465 701 939 1421 440 662 887 1341
C419 631 844 1276 346 521 697 1053 314 472 632 953 297 446 597 900
D259 389 520 784 214 322 430 648 194 292 390 587 184 276 368 555
Tilt Angle 26°-30°
Roof Angle (Φ) – ≤10°
Corner Edge Interm
ediate Internal Corner Edge Interm ediate Internal Corner Edge Interm ediate Internal Corner Edge Interm ediate Internal
A819 1237 1437 1599 676 1021 1368 1521 613 924 1239 1482 579 873 1170 1461
B507 765 1024 1551 419 632 845 1278 380 572 766 1157 359 541 723 1092
C342 515 689 1040 283 426 569 858 257 386 516 777 243 365 487 734
D212 318 425 640 175 263 352 529 159 239 319 479 150 226 301 453
Wind
Region
Building Height – H (m)
H≤5 5<H≤10 10<H≤15 15<H≤20
Wind
Region
Building Height – H (m)
H≤5 5<H≤10 10<H≤15 15<H≤20
Wind
Region
Building Height – H (m)
H≤5 5<H≤10 10<H≤15 15<H≤20
Within Australia
Clenergy 662
PV-ezRack Adjustable Single SolarTripod Spacing Table May-16
K.Z
ISO 9001:2008 Registered Firm
Certificate No: AU1222 Page 2 of 7

Client: Issue:
Project: Date:
Address:
Designed:
Checked: M.A
PV-ezRack Adjustable Single SolarTripod Spacing Table
Type of Rail ER-R-T50 (2560/3405/4200)
Type of Interface ER-S-TRI/S15-30
Solar Panel Dimension 1.65mx0.99m
Terrain category 3
Tilt Angle 15°-20°
Roof Angle (Φ) – ≤10°
Corner Edge Interm
ediate Internal Corner Edge Interm ediate Internal Corner Edge Interm ediate Internal Corner Edge Interm ediate Internal
A1546 1725 1869 2104 1546 1725 1869 2104 1490 1661 1797 2018 1448 1612 1743 1954
B1363 1700 1841 2070 1363 1700 1841 2070 1181 1637 1770 1986 1057 1590 1718 1924
C914 1383 1633 1825 914 1383 1633 1825 794 1199 1573 1756 710 1073 1440 1704
D564 850 1139 1661 564 850 1139 1661 489 737 988 1495 438 660 884 1337
Tilt Angle 21°-25°
Roof Angle (Φ) – ≤10°
Corner Edge Interm
ediate Internal Corner Edge Interm ediate Internal Corner Edge Interm ediate Internal Corner Edge Interm ediate Internal
A1211 1474 1590 1776 1211 1474 1590 1776 1050 1421 1532 1709 940 1381 1489 1659
B749 1131 1518 1750 749 1131 1518 1750 650 981 1316 1684 582 878 1177 1635
C504 760 1018 1542 504 760 1018 1542 438 660 883 1336 392 591 790 1194
D312 469 627 946 312 469 627 946 271 407 544 821 243 365 487 735
Tilt Angle 26°-30°
Roof Angle (Φ) – ≤10°
Corner Edge Interm
ediate Internal Corner Edge Interm ediate Internal Corner Edge Interm ediate Internal Corner Edge Interm ediate Internal
A987 1398 1508 1681 987 1398 1508 1681 856 1295 1454 1618 767 1158 1413 1572
B611 922 1236 1657 611 922 1236 1657 531 800 1072 1595 475 716 959 1451
C412 620 830 1255 412 620 830 1255 358 539 720 1088 321 482 645 973
D255 383 512 771 255 383 512 771 221 333 445 670 198 298 398 599
10<H≤15 15<H≤20
Wind
Region
Building Height – H (m)
H≤5
Wind
Region
Building Height – H (m)
H≤5 5<H≤10 10<H≤15 15<H≤20
Wind
Region
Building Height – H (m)
H≤5 5<H≤10 10<H≤15 15<H≤20
5<H≤10
Within Australia
Clenergy 662
PV-ezRack Adjustable Single SolarTripod Spacing Table May-16
K.Z
ISO 9001:2008 Registered Firm
Certificate No: AU1222 Page 3 of 7

Client: Issue:
Project: Date:
Address:
Designed:
Checked: M.A
PV-ezRack Adjustable Double SolarTripod Spacing Table
Type of Rail ER-R-T50 (2560/3405/4200)
Type of Interface ER-S-TRI/D15-30
Solar Panel Dimension 1.65mx0.99m
Terrain category 2
Tilt Angle 15°-20°
Roof Angle (Φ) – ≤10°
Corner Edge Interm
ediate Internal Corner Edge Interm ediate Internal Corner Edge Interm ediate Internal Corner Edge Interm ediate Internal
A1411 1641 1775 1991 1162 1560 1685 1886 1051 1520 1641 1835 992 1498 1617 1806
B869 1317 1749 1961 717 1084 1459 1858 649 981 1319 1808 613 926 1244 1780
C584 882 1184 1734 482 728 976 1481 437 659 883 1339 413 622 834 1263
D360 542 726 1099 298 448 600 906 270 406 543 820 255 384 513 774
Tilt Angle 21°-25°
Roof Angle (Φ) – ≤10°
Corner Edge Interm
ediate Internal Corner Edge Interm ediate Internal Corner Edge Interm ediate Internal Corner Edge Interm ediate Internal
A772 1170 1515 1688 638 964 1295 1604 578 872 1171 1563 546 824 1105 1540
B478 721 967 1468 395 596 798 1208 358 539 722 1093 338 510 682 1032
C322 485 650 982 267 401 536 810 242 363 486 733 228 343 459 692
D199 300 400 604 165 248 331 499 149 225 300 452 141 212 284 427
Tilt Angle 26°-30°
Roof Angle (Φ) – ≤10°
Corner Edge Interm
ediate Internal Corner Edge Interm ediate Internal Corner Edge Interm ediate Internal Corner Edge Interm ediate Internal
A630 952 1279 1599 520 785 1054 1521 471 711 954 1447 445 671 900 1365
B390 588 788 1194 323 486 651 984 293 440 589 890 276 416 556 840
C263 396 530 800 218 328 438 660 197 297 397 598 187 281 375 565
D163 245 327 493 135 203 270 407 122 184 245 369 116 174 232 348
Within Australia
Clenergy 662
PV-ezRack Adjustable Double SolarTripod Spacing Table May-16
K.Z
Wind
Region
Building Height – H (m)
H≤5 5<H≤10 10<H≤15 15<H≤20
Wind
Region
Building Height – H (m)
H≤5 5<H≤10 10<H≤15 15<H≤20
Wind
Region
Building Height – H (m)
H≤5 5<H≤10 10<H≤15 15<H≤20
ISO 9001:2008 Registered Firm
Certificate No: AU1222 Page 4 of 7