Clenergy PV-ezRack ezShade Series Technical manual

PV-ezRack®ezShade™
Code-Compliant Planning and Installation V2.0
Complying with AS/NZS1170.2:2011 AMDT 2-2012

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Introduction
Clenergy PV-ezRack®ezShade™ is a pre-
assembled ground mount system suitable
for large scale commercial and utility scale
installations. PV-ezRack®ezShade™ has
been developed to fit any PV module. The
innovative and patented T-Rails simplify and
improve the accuracy of the installation. Using
high quality engineered components PV-
ezRack®ezShade™ saves developers and
installers, time and money when delivering
large scale projects.
Please review this manual thoroughly before
installing your PV-ezRack®ezShade™system.
This manual provides
1) Simple introduction of the installation relating
to PV-ezRack®ezShade™ Mounting systems.
2) Planning and installation instructions for PV-
ezRack®ezShade™.
PV-ezRack®ezShade™parts, when installed in
accordance with this guide, will be structurally
sound and meet the AS/ NZS 1170.2:2011
(R2016) standards. During installation and
especially when working on the roof, please
comply with the appropriate safety regulations,
and please also comply with 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 tech@ clenergy.
com.au, or your local representative.
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;
• 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);
• Recycling: Recycle according to the local
relative statute.
• Removal: Reverse installation process.
• Ensure that there are no less than two
professionals working on panel installation.
• Ensure the installation of all electrical
equipment is performed by licensed
electricians.
• Ensuring safe installation of all electrical
aspects of the PV array. This includes providing
adequate earth bonding of the PV array and
PV-ezRack®ezShade™ components as
required in AS/NZS 5033-2014 AMDT 2 2-20 .
Introduction
Planning
Tools &Components
System Overview
Installation Instruction
01
02
05
07
10
List of Contents
1. Introduction

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2. Planning
- Side View
Below are the side view drawings of support for 60 cell panels (up to 1700 x 1050 mm) and 72 cell panels (up
to 2108 x 1050 mm) at 5° tilt angle.
Planning
Location Plan of Anchors

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Planning
- Front View
Below are the front view drawings of support for 60 cell panels (up to 1700 x 1050 mm) and 72 cell panels (up
to 2108 x 1050 mm)
Front view drawings of single bay for 60 cell panels
(up to 1700x1050 mm)
Front view drawings of double bay for 60 cell panels
(up to 1700x1050 mm)

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Planning
Front view drawings of single bay for 72 cell panels
(up to 2108x1050 mm)
Front view drawings of double bay for 72 cell panels
(up to 2108x1050 mm)
NOTE: 20 mm gaps between panels are for dry bars. If not using dry bars, it is not necessary to leave 20
mm gaps. .

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3.1 Installation Tools
3. Tools and Components
Tools & Components
String
Rubber hammer
Mark Pen
Scissor
Wrench
Caulking Gun
Socket Wrench
M8/M12
Total Station or
Equivalent Instrument
Torque WrenchTapeAllen Key 6mm
(M8
Hexagon
Socket
Screw)
Electric Drill
(ST4.8x16
self-tapping
screw & M8
Hexagon
Socket
Screw)

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Tools & Components
3.2 Components
ER-R-T150
T-Rail 150
ER-SP-B150
Splice for Main
Support Beam
ER-B-L/A
Dry Bar-Landscape
ER-B-T6/L
T bolt kit M6*L
ER-RC-T/G
Rail Clamp for T Rail
with Grounding
ER-B-L
Dry Bar-Landscape
(with Bushing)
ER-CAP-B/P
End Cap for Portrait
Dry Bar
RT-100/90
Rectangular Tube
ER-CAP-B/L
Top Cover for
Landscape Dry Bar
ER-CAP-B/L
End Cap for
landscape Dry Bar
U-AP/TR
Trapezoidal U-anchor
Plate 300/380
ER-CC-B/L
Cross Connection for
Dry Bar-Landscape
ER-CAP-T150/PA
Cap for T-150 Rail
ER-SP-T150
Splice for T-150
Rail
ER-B-150
Main Support
Beam
ER-MC-40
Module Clamp
40 mm
ER-B-P
Dry Bar-Portrait
ER-CAP-B150/PA
Cap for Composite
Beam

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System Overview
4.1 Overview of PV-ezRack ezShade
4. System Overview
①Main Support Beam,150*L
② Splice for Main Support Beam
③T-Rail 150*L
④ Splice for T-150 Rail
⑤Rail Clamp for T Rail
⑥Rectangular Tube 100*90*L
⑦Corrugated U-anchor Plate 300
⑧Corrugated U-anchor Plate 380
⑨Top Cover for Landscape Dry Bar
⑩Dry Bar-Landscape(with Bushing)

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System Overview
⑪End Cap for Portrait Dry Bar
⑫T-bolt kit M6*L
⑬Dry Bar-Portrait
⑭Cross Connection for Dry Bar
⑮Dry Bar-Landscape
⑯End Cap for Dry bar-landscape
⑰Cap for T-150 Rail (PA6)
⑱Cap for Composite Beam (PA6)
⑲Module Clamp 40 mm (in use when Dry bars are not used)
4.2 Precautions during Stainless Steel Fastener Installation
Improper operation may lead to deadlock of Nuts and Bolts. Follow the steps below to reduce this risk.
4.2.1 Reduce the friction coefficient:
① Ensure that the thread surface is clean (no dirt or contaminants)
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 the 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 as shown below. In case 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
4.3 Installation Dimensions
All drawings and dimensions in this installation guide are for a generic reference. PV-ezRack®
ezShade™ is to be optimized to suit specific conditions for each project and documented in a
construction drawing. As a result, major components of PV-ezRack®ezShade™ may be provided in
section sizes and lengths that vary from those shown in this guide. The installation process detailed in
this instruction guide remains the same regardless of the component size. In case you need to do any
on-site modification or alteration of the system in a way that would be different from the construction
drawing please provide marked up drawings/sketches for Clenergy’s review prior to modification for
comment and approval.
4.2.4 These steps should be applied for every stainless steel nut and bolt assembly.

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Installation Instruction
Fig. 1
5.1 Post and Main Beam Installation
5. Installation Instruction
Mark out the positions for bolts and embed
2 pcs of M20 bolt in each position as shown in
Fig 1.
Make sure all M20 bolts are aligned in both
horizontal and vertical direction as shown in
Fig 2. Make sure all M20 bolts are aligned in
both horizontal and vertical direction.
The distance between two bolts for Trapezoidal
U-anchor Plate 300 and 380 is 200mm and 280mm
respectively. All embedded bolts will
be revealed 60mm~80mm above the ground as
shown in Fig 1.
Note: The M20 bolts and matching nuts, washers
and spring washers are provided by installer.
5.1.1 Embed 2 pcs of M20 bolt
5.1.1 Fix the Rectangular Tubes into the Trapezoidal U-anchor Plate
Place the Rectangular Tube into the Trapezoidal U-anchor Plate 300,
align the holes and fix with M16 bolts assembly. Place the other two
Rectangular Tubes into the Trapezoidal U-anchor Plate 380 one by one,
align the holes and fix with M16 bolts assembly as shown in Fig 3.
Please refer to the engineering drawings for the size of the Rectangular
Tube. Recommended Torque: M16: 135~150 N
Fig. 3
Fig. 2

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Installation Instruction
5.1.3 Fix the Main Support Beam
Slide 6 sets of M8 Cup head square neck bolts along the half slot of each Main Support Beam. Fasten each
Splice for Main Support Beam with two sets of M8 bolt assembly slightly by Socket Spanner 13mm. Take the
other Main Support Beam and fix it with Splices by the above steps. Do not fasten the M8 bolts tightly before the
end faces of Main Support Beams aligned as shown in Fig 4.
Fig. 4
5.1.4 Fix the assembled Main Beam into Rectangular Tube
Insert the assembled Main Beam into Rectangular Tube, align the holes and fasten with M16 Bolts
assembly by Socket Spanner 24mm as shown in Fig 5. Double-check all bolts are fastened tightly.
Note: Laying down the Main Beam and Rectangular Tube on ground will be easier to assemble.
Please note that grease must be applied and tool speed must be controlled while fastening the bolts.
Fig. 5
Recommended Torque:
M16: 135~150N·m

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Installation Instruction
5.1.5 Fix the assembled Main Beam & Rectangular Tube onto Ground/Concrete
Insert the assembled Rectangular Tubes with Main Beams into embedded bolts. Adjust the Trapezoidal U-anchor
Plate to make the lower end faces of all Main Beams aligned in one array as shown in Fig 6, 7and 8. Now fasten
the Trapezoidal U-anchor Plate with M20 Bolts assembly tightly.
Please note that grease must be
applied and tool speed must be
controlled while fastening the bolts.
Recommended Torque:
M20: 200~220 Nm
The up-down adjustable range of
the Front/Rear leg is ±24mm.The
north-south adjustable range of the
Front/Rear leg is ±8mm.
±24mm
±8mm
Fig. 6
Fig. 7
Fig. 8

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Installation Instruction
5.2.1 Fix the Rail splice into T Rail
In order to form a longer section, Splices may be used to join two T Rails. Insert Splice halfway into end of first
T Rail, apply Corrugated Shim on outside and fasten using self-drilling screws. Slide second T Rail over splice,
apply Corrugated Shim on outside and fasten using self-drilling screws as shown in Fig 9.
Note: Make sure the Corrugated Shim can match well with the corrugated face of T Rail.
5.2 Rail Installation
Fig. 9
5.2.2 Fix the T Rail onto Main Beam
Place the T Rail on the assembled Main Beam as shown in Fig 10. Apply Rail Clamp to fix the T Rail on the
assembled Main Beam and fasten Rail Clamps by Allen Key 6mm as shown in Fig 11.
Fig. 10

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Installation Instruction
Fig. 11
Recommended Torque:
M8 Bolts: 18~20 N.m
According to engineering drawings, repeat
the above operations to install other T-Rails
as shown in Fig12. Ensure the end faces of
the Rails are aligned, and all Rails are at
same height. Now fasten all the bolts
tightly.
Two Rail Clamps
Four Rail
Clamps in total
Fig. 12
Note: the installation positions of T-Rail as shown in Fig 13.
Fig. 13
Note:
Apply two Rail Clamps for T-Rail on
each side of Rail.
Control the tool speed.

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Installation Instruction
5.2.1 PV Module Installation
Place the first row of PV Module on the
T-rail as shown in Fig 14.
Make sure that the long side of the PV
Module is parallel to the T-rail. Install the
next module which aligns to the first one.
Repeat this step until the last panel is
finished and make sure the end face of
PV modules are aligned as shown in Fig
15.
Fig. 14
Fig. 15

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Installation Instruction
5.2.2 Fix the Dry Bar-Landscape
After PV Module installation, place the Dry Bar-Landscape & Dry Bar-Landscape (with Bushing) into
T-rail as shown in Fig16.
Fig. 16
Note: Cut off the extra Rubber for Dry Bar by scissor.
The Dry Bar-Landscape with Bushing should be placed on the first and last row as shown in Fig 16.
Click the Dry Bar-Landscape or Dry Bar-Landscape (with Bushing) into the U slot of T-rail.
Make sure the T head bolt slide into the groove of T-rail as shown in Fig 17.
Fig. 17

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Maintain 6mm gap between the PV Module and Dry Bar-Landscape/ Dry Bar-Landscape (with Bushing)
as shown in Fig 18.
Turn the T head bolt clockwise with Straight-slot Screwdriver until the T head bolt can’t move anymore
as shown in Fig 19.
Fasten M6 Nuts and T head bolts with Socket Spanner 10mm tightly.
Recommended Torque:
M6 Bolts: 7~8 N.m
Fig.18
Note: Please note that grease must be applied and tool speed must be controlled while fastening the
bolts.
Installation Instruction
Panel Frame

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Fig.19(the middle row)
Fig 19(the first and last row)
Installation Instruction
Repeat the above operations
to install the second row of
PV Modules as shown in
Fig 20.
Note:
Maintain 20mm gap between the first
row and the second row. And ensure
the end faces of PV Modules are
aligned.

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Repeat the above operations to fix the Dry Bar-Landscape or Dry Bar-Landscape (with Bushing) as
shown in Fig 21.
Fig.21
Fig.22
Note:
Maintain 6mm gap between the PV Module and Dry Bar-Landscape/ Dry Bar-Landscape (with Bushing).
Maintain 32mm gap between two Dry Bar-Landscape as shown in Fig 21.
Installation Instruction
5.2.3 Fix the Cross Connection for Dry Bar
Place the Cross Connection for Dry Bar between the two adjacent Dry Bar-Landscape as shown in
Fig 22.