Clenergy PV-ezRack SolarTerrace Eco User manual

PV-ezRack
SolarTerrace Eco
Installation Guide
Content
1. Production Introduction ............................................................................ 2
2. Tools & Components ............................................................................... 3
3. System Overview ..................................................................................... 6
4. Installation Instructions ............................................................................ 8
Designed
by： Version： V1.0
Checked by： Reviewed
by：
Approved
by：

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1. Production Introduction
Clenergy PV-ezRack®SolarTerrace Eco (hereinafter referred to as ST Eco) is a
pre-assembled ground PV-Module mounting system, which is suitable for large-
scale commercial installation and multi-purpose installation.ST Eco has been
developed as a mounting system for various PV-module. Innovative and unique
Rail with M Module is convenient and helps to improve the installation precision.
Using high quality engineered components SolarTerraceEco more suitable for
areas with higher salinity, and saves developers and installers, time and money
when delivering large scale projects.
Before system installation, please read the installation instruction manual carefully.
The manual provides the following content: (1) simple introduction of installation;
(2) product installation specification;
Please use it according to the installation instruction manual, which complies with
GB50009-2012, JIS 8955-2017, ASCE7-10, ISO 14713 and other building codes.
Please pay attention to safety when installing the product, and construct it
according to local laws and regulations. You can confirm the latest installation
instruction manual on www.clenergy.com.cn if necessary.
Installation personnel shall conform to the following specifications
- Conform to all local or national construction specifications that can replace the
manual;
- Guarantee that Clenergy mounting products are applicable to specific
installation and installation environment;
- Please use Clenergy’s accessories and your installation tools. (Clenergy will
be not liable to other accessories that replace Clenergy’s ones);
- Recycle according to local related laws;
- Disassembly is corresponding to installation steps;
- The number of solar plate installation personnel shall be not less than 2;
- Guarantee that installation of electric equipment is finished by professional
electricians.

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2. Tools & Components
2.1 Tools
Tools
Allen Key 6mm
(M8 Hexagon
Socket Screw)
Socket
Wrench
M8/M12
Torque Wrench Electric Drill
5m Tape Marker String
Total Station or
Equivalent device
Note：The tools in the figure are only used for installation of rack system (not
included in supply scope). Please consult system installation personnel about
installation of electronic parts.
2.2 Components

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Components
EC-W/A
End Clamp
ICII-W/A
Module Inter Clamp II
R-TW
TW Rail
SP-TW
Splice for TW Rail
S-Eco/N
Support
EZ-GCII-ST
Grounding ClipⅡ
EZ-GL-B
Grounding Lug
EZ
-
CC
-
PV/4
Universal Cable for PV
Panels for holding 4
cables
ER-AA
Angle AL
CO-RT
Connector for Rectangular
Tube
2.3 Installation Precautions
Stainless Steel Fastener Installation Precautions

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Improper operation may lead to deadlock of Bolts and Nuts. Follow the steps
below to reduce this risk
- 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 tightening to
avoid galling or seizing in the threads;
- 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,
- Safe Torques
Please refer to safe torques defined in this guide as shown in below figure. 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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3. System Overview
3.1 Composition
1) End Clamp with W Module
2) Module Inter Clamp II
3) TW Rail
4) Splice for TW Rail
5) Support
6) Angle AL
7) Connector for Rectangular Tube

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3.2 Installation Planning
1） PV Module Orientation：Portrait
2） Rail Length per table：L2 according to engineering drawings
3） Distance between the two adjacent supports：L1 according to
engineering drawings
4） Distance between two legs：L3 according to engineering drawings

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4. Installation Instructions
4.1 Concrete Foundation Installation
4.1.1 The distance
between the embedded
bolts on the concrete
foundation is 120mm.
4.1.2 Ensure that the
centerlines of the two
embedded M16 Bolts are
on the same line.
1)Distance between the
two set Pre-assembled
Support：L1 according to
engineering drawings
2)Distance between two
legs：L3 according to
engineeripng drawings
4.1.3When installing the
concrete foundation,
need to pull the wire to
ensure that the concrete
foundation surface is at
the same height. The
deviation should be within
±20mm.l. as shown
Figure2-2.
Figure 1
Figure 2-1
F
igure
2
-
2
20mm
Line

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4.2 Pre-assembled Support Installation
4.2.1 Before installing
Pre-assembled Support,
check centerlines of the
two embedded M16 Bolts
are on the same line and
are all aligned.
4.2.2 Before installation, it
looks as shown Figure3.
Unfold the Rectangular
Tubes as shown in Figure
4.
Unlock the M12*85 Bolts
from Rear leg (③). Insert
the end of 2 free end
Rectangular Tubes into
the Slot U-Shape Joint.
Lightly lock them with
M12*85 Bolts. Here,
please note the
orientation of the 2 sets of
bolt; make sure their head
are in the same side with
other bolts. Rotate the
Corrugated L-anchor
Plates to make them in a
same horizontal level, as
shown in Figure 6.
Figure 3
Figure 4
Figure 5
Figure 6
1
2 3

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4.2.3 Connect the Pre-
assembled Support and
Concrete Base by using
embedded M16 Bolts.
The up-down adjustable
range of Front/Rear leg is
±20mm. The north-south
adjustable range of
Front/Rear leg is ±30mm.
as shown in Figure 7
4.2.4 Fasten all bolts
according to the torque.
Check all bolts and
ensure they are fastened
within recommended
torque.
Recommended Torque:
M8: 18~20 N•m
M16: 40~45N•m
4.2.5 According to
engineering drawings,
repeat the above
operations to install other
Pre-assembled Supports.
Ensure all the Two-
Groove Square Girders of
Pre-assembled Support
are aligned and all Pre-
assembled Support are
parallel to each other.
Unlock M12 bolts to
adjust the position, if
necessary, as shown in
Figure 8.
Figure 7
Figure 8
±30mm
±20mm

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4.3 Rail Installation
4.3.1 Before fix TW Rails
on the Support, splice
them to the required
length with Splice for TW
Rail.
Insert half of Splice into
TW Rail and fasten with
two sets of Self-tapping
screws ST6.3*22 in each
side of TW Rail, and then
insert the other Splice
into TW Rail and fasten
with Self-tapping screws
as shwon in Figure 9.
NOTE: Please fasten the
Self-tapping screws until
its rubber washer attach
the TW Rail tightly.
Figure 9
4.3.2 According to your
plan, place TW Rail on
the girder, make the lower
part of Rail press against
pre-assembled Rail
Clamp II as shown in
Figure 10.
Note: if the project
doesn’t have pre-
assembled Rail Clamp II,
please fix Rail Clamp II
on each side of Rail on
site.
4.3.3 Place the rails one
by one on the planned
position.
Figur 10
50
50
50
50
The lower part of Rail press
against the Rail Clamp

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4.3.4 Repeat the above
steps to install other rails.
Make sure the rails in the
same line aligned over
same horizontal level.
Ensure the distances of
rails between two
adjacent rows conforming
to the engineering
drawings and the end
faces of all rails aligned.
Recommended Torque:
M8: 18~20 N•m
Figure 11

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4.4 Angle AL Installation
4.4.1 According engineer
plan, lightly lock
Connector for
Rectangular Tube on the
rear leg of Support as
shown in Figure12. Insert
M8*30 through the hole
on Angel AL.
Lightly lock another
Connector for
Rectangular Tube on the
next span rear leg and
adjust its position to lock
the Angel AL and make it
be in tension status. Use
Self-tapping screw
ST6.3*22 to fix Connector
for Rectangular Tube and
fasten all bolts as shown
in Figure 13.
Every 3 spans, the next
span needs to add Angle
AL and the Angle ALs
need to be installed
symmetrically, as shown
in Figure 14.
Note:
The quantity, position and
tilt direction need to
comply with the
requirement on engineer
drawings.
Recommend torque:
M 8 bolt 18~20N.m
Figure 12
Figure 13
Figure 14

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4.5 PV Modules Installation
4.5.1 Tilt the Inter Clamps
with W-module into the
channel of the Rail as
shown in Figure 15.
4.5.2 It is suggested to
install PV-Module from
the left side, and use the
End Clamp and Inter
Clamp to fix it. Stretch a
String as a reference to
align PV-Module. Adjust
the PV-Modules to make
their outside faces are in
a line in both portrait and
landscape orientation.
Recommended Torque:
M8: 13~14N•m
Figure 15
Figure 16
Ensure the PV modules aligned in both horizontal
and vertical directions

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4.5.3 Fix the rest of PV-
Module according to the
sequence: from low to up,
from left to right. Make
the side faces of PV-
Module tightly against
Clamps as shown in
Figure 18. Any adjacent
side face of PV-Module
keep the distance of
20mm, as shown in
Figure 17.
Note:
Put an Inter Clamp at
each side of PV-Module
to keep the distance of
20mm and take them
away after the PV-Module
being fixed.
4.5.4 Now the installation
of a single array is
completed as shown in
Figure 18.
Please recheck all bolts,
and fasten them tightly.
Figure 17
Figure 18

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4.6 Grounding System Installation
4.6.1 For the number of PV
Moduleis EVEN in each row.
The position with X shall be
the installation position of
Grounding Clip.
Installation number of
Grounding Clip = number of
PV Module =4
Figure 18
4.6.2 For the number of PV
Module in each row is odd.
The position with X shall be
the installation position of
Grounding Clip.
Installation number of
Grounding Clip = number of
number of PV Module
+1=5+1=6
Figure 19
Figure 20

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4.6.3 Insert the Grounding
Clip under the Inter Clamp as
shown in Figure 21 after you
finished 4.5.1. Then install
the PV modules following the
steps 4.5.2 and 4.5.3.
Note: ensure that the frame
of PV modules could press
against the Groundling Clip
as shown in Figure 21-⑤.
THE GROUNDING CLIP CAN
BE USED ONCE ONLY, DO
NOT FASTEN THE INTER
CLAMP TIGHTLY BEFORE
PV MODULES ARE
INSTALLED PROPERLY.
① ② ③
④ ⑤
4.6.4 Apply one Grounding
Lug at the end of each Rail;
fix the Grounding Lug on the
lower part of Rail. Once the
Grounding Lugs are fixed on
Rails properly in the same
array, fasten the bolt on the
top of Grounding Lug slightly
and then insert the Copper
Wire or Copper Rod into the
slot hole of Grounding Lug
andfastenallboltsof
Grounding Lug slightly
within 5N.m as shown in
Figure 22.
Figure 21
Rail
F
igure
22

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4.6.5 Component clamp
a. Snap the universal
component frame line with
the serrated part into the
component frame. as shown
in Figure 23.
b. After the wire clamp is
assembled, take a cable and
snap it into the cable clamp
slot. One clamp can clamp 4
wires.
P
anel
Figure 23