Clenergy PV-ezRack SolarRoof DC User manual

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Created by Clenergy
Mounting system instruction manual
1. Document Summary
Rev
Date
Description
Written by
1.0
May.12.2022
First Generation
Mao
1.1
August.28.2022
Delete the vertical spacing of the Roof Hooks and chapter 5
Mao
1.2
Oct.12.2022
Change the name of the roof hook
Wright

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PV-ezRack® SolarRoof™DC for ER-I-
DC/02A/CS(PV-ezRack SolarRoof Pro,
Adjustable Tile Interface, with carbon steel
main body)
Code-Compliant Planning and Installation Guide
Complying with Eurocodes 0-9 and VDI 6012

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1. Introduction
The Clenergy PV-ezRack® SolarRoof™DC has
been developed as a universal PV-mounting
system for roof-mounting on pitched and flat
roofs. The use of patented aluminium base rails,
M-Module technology and telescopic mounting
technology eliminates custom cutting and
enables fast installation.
Please review this manual thoroughly before
installing PV-ezRack® SolarRoof™DC. This
manual provides:
1) Supporting documentation for building permit
applications relating to PV-ezRack®
SolarRoof™DC Universal PV Module Mounting
System,
2) Planning and installation instructions.
The PV-ezRack® SolarRoof™DC parts, when
installed in accordance with this guide, will be
structurally sound and will meet the Eurocodes
and VDI 6012 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 via email on
[email protected].
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 the PV-ezRack
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.
•Ensure that there are no less than two
professionals working on panel installation.
•Ensure the installation of related electrical
equipment is performed by licenced
electricians.
•Ensuring safe installation of all electrical
aspects of the PV array.
• 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;
List of contents
Introduction 1
Tools & Component list 3
System Overview 4
Installation Instruction 6
Care 12

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The mounting rack is applicable for
following conditions.
•Tile roofs from 15deg to 60deg tilt
•Building height <=12m
•Installations in Wind zone 1 to Wind zone 4
•Installations in Snow zone 1 to Snow Zone 3
•All wood fasteners need to follow the local
building regulations, e.g. DIN 1052
•Max altitude: according to the calculation
report
•Max Span width: according to the calculation
report
•Only approved and certified wood screws are
to be used for roof hook installations
•Min distance for wood screws from wood
egdes according to EN 1995-1-1
•The hooks can only be mounting on the roof
rafters but not on the roof lath (the horizontal
wood beams that hold the tiles)
Design Standards:
•BS EN 1990:2002 Basis of Structural Design
•DIN EN 1991-1-4. Eurocode 1: Actions on
structures - Part 1-4: General actions - Wind
actions
•DIN EN 1991-1-3 : 2004 EUROCODE 1:
ACTIONS ON STRUCTURES - PART 1-3:
GENERAL ACTIONS - SNOW LOADS
•VDI 6012 Blatt 1.4 Integration of
decentralised and regenerative energy systems
in buildings
•EN 1995-1-1: Eurocode 5: Design of timber
structures

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2. Tools and Components
2.1 Tools
−Angle Grinder with Stone Disk
−Screw Driver (for M8 Torx Screw and bolt)
−Torque Spanner
−Torx L-key or the equivalent
−5m Tape
−String & Marker Pen
2.2 Components
Component list
ER-EC-DC/30/35B
End Clamp for DC
Rail L50
IC-DC30/35/SRP/G/B
SRP Inter Clamp
30&35mm L50
ER-R-DC50/2500
DC Rail 50, L2500m
ER-SP-DC50/200
Splice for DC Rail
50, L200mm
ER-I-DC/02A/CS
PV-ezRack
SolarRoof Pro,
Adjustable Tile
Interface，with
carbon steel main
body
EZ-CAP-DC50
Cap for DC Rail 50
EZ-GL-DC/S
Grounding Lug for
DC Rail, side
mount
GC-DT
Grounding Clip
EZ-CC-DC
Cable Clip
ER-CC-DC50/2
Cross Connector for
DC Rail 50, version
2.0
ER-RC-DC50/G/2
Grounding Rail
Clamp for DC Rail

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E: [email protected] | W: www.clenergy.com.cn
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3. System Overview
3.1 Overview of PV-ezRack SolarRoof DC
- Single layer (mounting rails), mounting solar panels in portrait
1) End Clamp 2) Inter Clamp 3) DC Rail 50 4) Tile interface 5) Splice for DC Rail 50
- Double layer (mounting rails), mounting solar panels in landscape
1) End Clamp 2) Inter Clamp 3) DC Rail 50 4) Tile interface 5) Splice for DC Rail 50
6) Cross Connector 2.0 7) Grounding Clamp 2.0
Installation Scenarios:
For the static calculation and span distance detail, please refer to below calculation tool.
•“01-MR calculation tool - V1.0 for ER-I-DC/02A/CS(PV-ezRack SolarRoof Pro,
Adjustable Tile Interface, with carbon steel main body)”.
1
2
3
4
5
1
2
3
3
4
5
6
7

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4. Installation Instruction
−The min. distance from the mounting rack to the roof edges is 3cm.
−Assess the horizontal spacing of the Roof Hooks.
−Check the allowed max. spacing as provided by the Calculation Tool “01-MR-
calculation tool - V1.0 for ER-I-DC/02A/CS(PV-ezRack SolarRoof Pro, Adjustable Tile
Interface, with carbon steel main body)”.
−Always check the installation manual of the PV-Module you use in order to determine
the allowed fixing points on the module frame.

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4.1 Roof Hook Installation
4.1.1
Determine the positions of the roof
hooks according to your plans.
Remove the roof tiles at the marked
positions or, if possible, simply push
them up slightly.
4.1.2
Fix the roof hooks to the rafter using
M8*100 Torx screw as shown in the
figure on the right following screws
installation guide below:
- Use a 3/8" Torx Socket.
- Use a powered or cordless screw
driver.
- 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.
Note:
If the rafter width is less than 5 cm,
6mm wood screw with rosette washer
as shown in the figure on the right is
needed.
Only approved and certified wood
screws are to be used for roof hook
installations. A predrill 5mm dia. Hole
is needed and the distance between
the screw to rafter edge is 3xd (screw
dia.)
The hook can only be mounted on the
roof rafter, cannot be mounted on tile
lath.
The wood connections are to
be made according to EN 1995-1-
1:2004+A1:2008

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4.1.3
Use buffer plates to lift the tile bracket
so that the base does not rest on the
tile, as shown in Figure
4.1.4
If necessary, use an angle grinder to
cut a recess in the upper tile covering
the roof hook at the point where the
roof rook extends so that the tiles can
be placed properly.
4.1.5
Caution! Do not use fitted roof hooks
as a ladder, as this extreme point load
could damage the tile below.
INCORRECT
CORRECT

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4.2 Rail Installation
4.2.1
Insert the w module into the channel of
the rail, and fasten the M8 Torx screw
loosely with Torx L-key or the
equivalent.
Please refer to the figures on the right
for height adjustment.
The roof hook should not protrude over
the rail after the adjustment.
4.2.2
In the cases that double layer (cross
rail) is required for the installation,
please use cross connector and
grounding clamp to fix the top and the
bottom rails.
Place the rails on the bottom rails and
fix two rails together.
.
When using the cross connector 2.0
ER-CC-DC50/2, Click the M-module
into the top channel of DC rail 50 at
any given point, move the cross
connector 2.0 close to the rail and
fasten the M8 Torx screw loosely as
shown on the right figures.
When using the grounding clamp 2.0
ER-RC-DC50/G/2, click the M-module
into the top channel of DC rail 50 at
any given point, move the grounding
clamp 2.0 towards to the opening
Incline
Click in
Press down

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channel of the rail, and make sure the
grounding clamp 2.0 close to the rail
edge, and fasten it with M8 Torx
screws loosely.
Now adjust the top rails properly, and
fasten all M8 Torx screws tightly.
The recommended torque is 14N·m.
4.2.3
Now the rails installation are
completed as shown on the right
figures.
Rails are perpendicular to the rafter
Double layer (cross rail)

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4.3 PV Modules installation
Place PV Modules on rails, fix with
end clamps and inter clamps. Click
the M-module of the clamps into the
top channel of rail as shown on the
right figures.
Step 1 Place the first PV Module on
Rails according to your plan and apply
the End Clamps to fix it and then
fasten lightly using Torx L-key or the
equivalent as shown on the right
Figure.
Note: The distance L from end clamp
to the end of the rail shall be greater
than 10mm
Step 2 Slightly lift the PV Module and
slide Inter Clamps and Grounding
Clips into position. The teeth on
Grounding Clip will automatically align
when the Inter Clamp is properly
installed as shown on the right
Figures.
Step 3 loosely place the next framed
PV Module into the other side of the
Inter Clamp and Grounding Clip as
shown on the right Figure.
Important Notes:
-To fix the Grounding Clip
properly, ensure the frames of
PV Modules are completely
pressed against the Inter Clamp
and Grounding Clip. Visually
check that Grounding Clips are
positioned properly.
Incline
Click in
Press down
L

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-Grounding Clips are intended
for SINGLE USE ONLY! Only
fasten the bolts down when the
position of PV Module is
finalized. (Only slightly tighten
bolts to keep PV Modules in
place prior to the final check)
Step 4 Maintain 20mm vertical gap
and 20mm horizontal gap between the
two adjacent rows of PV Modules.
You can use two Inter Clamps to
separate two PV Modules, and
remove after installation as shown on
the right Figure.
Double check if all PV Modules are
fixed properly.
Fasten all the M8 Torx screw tightly.
The recommended torque is 14N·m.
Now the PV modules installation is
completed as shown on the right.
4.4 Accessory installation
4.4.1
Cable clip installation
Click the cable clip into the rail. Insert
the cables into the holes of cable clips
as shown on the right figures.

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4.4.2
Grounding Lug installation
Put the w module into the side
channel of rail, and fasten the M8
Torx screw tightly within 14N.m.
Insert the copper wire into the
grounding lug and fasten the M8 Torx
screw tightly with 8N.m. as shown on
the right figures.