Clenergy PV-ezRack SolarBase User manual

PV-ezRack SolarBase
Low Ballast Flat Roof System
Installation Guide V1.4
NO.:PZ30-IM01-14
Content
1Introduction…………………………………………….. 1
2Tools & Components ……………………………….. 2
3 System overview…………………………………………. 3
4 Installation Instructions…………………………….. 6

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No. 999-1009, Min’an Avenue, Xiang’an 18/20 Duerdin ,
Xiamen China 361006 Clayton VIC 3168
Tel: [phone] Tel: [phone]
Fax: [phone] Fax: [phone]
Email: [email protected].cn Email: [e-mail]
Website: www.clenergy.com.cn Website: www.clenergy.com.au
1.Introduction
PV-ezRack SolarBase system is a roof mounting system suitable for small
and medium-sized commercial roof installations. Professional structure
design greatly simplifies installation steps, under the premise of
guaranteeing safety, which reduces cost and improves efficiency during
installation.
Please review this manual thoroughly prior to installing PV-ezRack
SolarBase. This manual provides supporting documentation for building
permit applications relating to PV-ezRack SolarBase system.
The PV-ezRack SolarBase parts, when installed in accordance with this
guide, will be structurally adequate. During installation please comply with
the appropriate occupational health and safety regulations. Please also pay
attention to other relevant regulations of your local region. 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], or contacting
your local distributor.

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No. 999-1009, Min’an Avenue, Xiang’an 18/20 Duerdin ,
Xiamen China 361006 Clayton VIC 3168
Tel: [phone] Tel: [phone]
Fax: [phone] Fax: [phone]
Email: [email protected].cn Email: [e-mail]
Website: www.clenergy.com.cn Website: www.clenergy.com.au
2. Tools and Components
2.1 Tools
6mm inside
hexagonal spanner
Electric tool
5m tape
Marking pen
Torque spanner
string
Socket spanner
Note：tools in the figure are only used for rack system（not included in supply scope）;
Consult system installation personnel about electronic part installation tools.
2.2 Components
Component list
ER-S-SB/S10
Support Leg for SolarBase
ER-BB-SB/900
Ballast Bar for SolarBase
EZ-GC-MC40,
Module Clamp 40 mm
ER-WD-SB10/17/A3
Wind Deflector for
SolarBase
EZ-GL-B
Grounding Lug

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No. 999-1009, Min’an Avenue, Xiang’an 18/20 Duerdin ,
Xiamen China 361006 Clayton VIC 3168
Tel: [phone] Tel: [phone]
Fax: [phone] Fax: [phone]
Email: [email protected].cn Email: [e-mail]
Website: www.clenergy.com.cn Website: www.clenergy.com.au
3. System overview
3.1 Overview of PV-ezRack SolarBase
1. Support Leg
2. Ballast Bar
3. Module Clamp 40 mm
4. Wind Deflector
5. Grounding Lug
1
2
3
4
5

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No. 999-1009, Min’an Avenue, Xiang’an 18/20 Duerdin ,
Xiamen China 361006 Clayton VIC 3168
Tel: [phone] Tel: [phone]
Fax: [phone] Fax: [phone]
Email: [email protected].cn Email: [e-mail]
Website: www.clenergy.com.cn Website: www.clenergy.com.au
a) Installation planning
Note: Red circles highlight installation of Module Clamp 40;
Take 1650x990x40 PV module as an example. Installation angle is 10°and
distance between front and rear parts of component is 532mm.

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No. 999-1009, Min’an Avenue, Xiang’an 18/20 Duerdin ,
Xiamen China 361006 Clayton VIC 3168
Tel: [phone] Tel: [phone]
Fax: [phone] Fax: [phone]
Email: [email protected].cn Email: [e-mail]
Website: www.clenergy.com.cn Website: www.clenergy.com.au
3.3 Precautions during Stainless Steel Fastener Installation
Improper operation may lead to deadlock of Bolts and Nut. Follow the steps below to
reduce this risk
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 tightening to avoid
galling or seizing in the threads;
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;
3．Safe Torques
Please refer to safe torques defined in this guide as shown in 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.
M8 Nuts：18-20N·m
M8*35 bolts：10-12N·m
M8 Nuts：8-9N·m
M8*25 bolts：18-20N·m
U bolts M8*58：8-9N·m
M6*14 bolts：8-9N·m

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No. 999-1009, Min’an Avenue, Xiang’an 18/20 Duerdin ,
Xiamen China 361006 Clayton VIC 3168
Tel: [phone] Tel: [phone]
Fax: [phone] Fax: [phone]
Email: [email protected].cn Email: [e-mail]
Website: www.clenergy.com.cn Website: www.clenergy.com.au
3.4 Installation Dimensions
All drawings and dimensions in this installation guide are for a generic reference. The
Clenergy PV-ezRack SolarBase is to be optimized to suit specific conditions for each
project and documented in a construction drawing. As a result, major components of
the Clenergy PV-ezRack SolarBase 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 modifications 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 modification for comment and approval.
4. Installation Instruction
4.1 Install Support Leg team
4.1.1 According to specification of
ballast, adjust distance between two
square neck bolts on Support Leg
and fix square neck bolts, as shown
in Figure 1.
4.1.2 Put rubber protection gasket
into Support Leg and make sure the
hole centre of rubber gasket is
aligned with bolt centre, as shown in
Figure 2.
Figure 1
Figure 2
According to specification of ballast,
adjust distance between both square
neck bolts.

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No. 999-1009, Min’an Avenue, Xiang’an 18/20 Duerdin ,
Xiamen China 361006 Clayton VIC 3168
Tel: [phone] Tel: [phone]
Fax: [phone] Fax: [phone]
Email: [email protected].cn Email: [e-mail]
Website: www.clenergy.com.cn Website: www.clenergy.com.au
4.1.3 According to installation
specification, use tools such as tape,
string and marker pen to make out
position and then place Support Leg,
as shown in Figure 3.
Figure 3
4.2．Install Wind Deflector and ballast (optional parts)
4.2.1 Fix Wind Deflector on the
pre-assembled bolts of Support Leg
team and make it press against
Support Leg, and make sure the
position of Support Leg team
unchanged as shown in Figure 4.
4.2.2 Fix Ballast Bar into the bolts of
Support Leg team, and add M8 plain
washer, washer and nut and fasten
tightly as shown in Figure 4 and 5.
Recommended torque：
8-9 N·m for M8 Bolts
Attention ：Wind Deflectors are
installed on Support Legs of the last
row. Two adjacent Wind Deflectors
will be overlapped as shown in
Figure 6.
Figure 4 Figure 5
Figure 6

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No. 999-1009, Min’an Avenue, Xiang’an 18/20 Duerdin ,
Xiamen China 361006 Clayton VIC 3168
Tel: [phone] Tel: [phone]
Fax: [phone] Fax: [phone]
Email: [email protected].cn Email: [e-mail]
Website: www.clenergy.com.cn Website: www.clenergy.com.au
4.2.3 Use U-bolt M8*58 to lock Wind
Deflector tightly as shown in Figures
7 and 8.
Recommended torque：
8-9 N·m for U-bolt M8*58
4.2.4 After Wind Deflector and
Ballast bar are installed, load ballast
orderly. Ballast height should be no
more than 145mm as shown in
Figure 9.
（If Wind Deflector is not required,
please ignore Step 4.2.1 to 4. 2.3）
Figure 7 Figure 8
Figure 9
4.3．Install PV modules and Module Clamp 40
4.3.1 Rotate the right part of Support
Leg to the required position as
shown in Figure 10.
Figure 10
1. Nut
2. Washer
3. Plain washer
4. Fixing plate

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No. 999-1009, Min’an Avenue, Xiang’an 18/20 Duerdin ,
Xiamen China 361006 Clayton VIC 3168
Tel: [phone] Tel: [phone]
Fax: [phone] Fax: [phone]
Email: [email protected].cn Email: [e-mail]
Website: www.clenergy.com.cn Website: www.clenergy.com.au
4.3.2 Place PV module smoothly on
Support Leg. According to
installation planning, adjust left and
right positions of PV module and
guarantee frame of PV module
attach to the rotating part of Support
Leg. Pay attention to installation
direction of PV module as shown in
Figure 11.
4.3.3 Fasten the frame of PV module
and Support Leg with Module Clamp
40 as shown in Figure 12.
4.3.4 Adjust Module Clamp 40 to
ensure that it’s located in the middle
of preassembled parts of Support
Leg and fasten tightly. While fasten
the Bolts M8*25, hold the Module
Clamp 40 to ensure it unmovable, as
shown in Figure 13 and 14.
Recommended torque:
18-20N.m for Bolts M8*25
Figure 11
Figure 12 Figure 13
Figure 14
Correct direction
Wrong direction

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No. 999-1009, Min’an Avenue, Xiang’an 18/20 Duerdin ,
Xiamen China 361006 Clayton VIC 3168
Tel: [phone] Tel: [phone]
Fax: [phone] Fax: [phone]
Email: [email protected].cn Email: [e-mail]
Website: www.clenergy.com.cn Website: www.clenergy.com.au
4.3.5 After fasten the Module Clamp
40, lay PV Module slightly down on
the preassembled part of Support
Leg in the rear row as shown in
Figure15.
4.3.6 Adjust Module Frame Back
Mounting Clip along fore-aft
direction; ensure the frame of PV
module will be held by Mounting Clip
as shown in Figure 16 and 17.
4.3.7 Fasten Bolts M8*35 and
Square Neck Bolts M8*45 tightly in
order.
Recommended torque：
10-12N·m for Bolts M8*35
Recommended torque：
18-20N·m for Square Neck Bolts M8
4.3.8 Repeat above operations to
install the rest PV modules as shown
in Figure18.
Figure 15
Figure 16 Figure 17
Figure 18

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No. 999-1009, Min’an Avenue, Xiang’an 18/20 Duerdin ,
Xiamen China 361006 Clayton VIC 3168
Tel: [phone] Tel: [phone]
Fax: [phone] Fax: [phone]
Email: [email protected].cn Email: [e-mail]
Website: www.clenergy.com.cn Website: www.clenergy.com.au
4.4．Install Grounding Lug
4.4.1 Fix the Grounding Lug on
Ballast Bar of the longest row along
vertical direction as shown in Figure
19, install one Grounding Lug per
row and fasten tightly.
Notes: the Grounding Lug should
not be installed on Ballast Bar of the
first row as shown in Figure 20.
4.4.2 Fix the Copper Wire on the
Grounding Lug and fasten tightly as
shown in Figure 20.
Recommended torque:
8-9N·m for Bolts M6*14
Figure19
Figure20