Clenergy PV-ezRack SolarRoof Series Technical manual

PV-ezRack®SolarRoof™
Code-Compliant Planning and Installation Guide V3.0
Complying with AS/NZS1170.2-2011 AMDT 2-2016

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Introduction
1. Introduction
The Clenergy PV-ezRack®SolarRoof™ has
been developed as a universal PV-mounting
system for roof-mounting on pitched and flat
roofs. The use of patented aluminium base
rails, Z-Module technology and telescopic
mounting technology eliminates custom cutting
and enables fast installation.
Please review this manual thoroughly before
installing PV-ezRack®SolarRoof™. This manual
provides
1) Supporting documentation for building
permit applications relating to PV-ezRack®
SolarRoof™ Universal PV Module Mounting
System,
2) Planning and installation instructions.
The PV-ezRack®SolarRoof™ 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 updates 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
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;
• Ensuring that there are no less than
two professionals working on panel installation;
• Ensuring the installation of related
electrical equipment is performed by licenced
electricians;
• Ensuring safe installation of all electrical
aspects of the PV array, This includes adequate
earth bonding of the PV array and PV-ezRack®
SolarRoof™ components as required in AS/
NZS 5033-2014 AMDT 2 2-2018;
• 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 &Component list
System Overview
Installation Instruction
Warranty
Certification Letter and
Interface Spacing Table
01
02
05
07
09
24
25
List of Contents

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

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Planning
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
This document provides sufficient information for the PV-ezRack®SolarRoof™ system installation up to
heights of 30 meters. If your installation site is more than 30 meters high please contact Clenergy to obtain
project specific engineering certificate to support your installation.
2.3 Determine the Height of the Installation Site

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Planning
The PV-ezRack®SolarRoof™ system can be used for roof slopes up to 60°. Please verify that the
Installation site roof slope is between 0° and 60°.
2.4 Determine Roof slope
Please refer notes 25-28 of PV-ezRack®SolarRoof Interface Spacing Table in Certification Letter.
2.5 Determine the Installation Area of Roof
Please refer to the Certification Letter and Interface Spacing Table (page 25). If a project specific
Certification Letter has been provided, please refer to the support spacing in this letter.
2.6 Determine the Maximum Rail Support Spacing
Rail end overhang should be not over 40% of the interface spacing. For example, if the interface
spacing is 1500mm, the Rail end overhang can be up to 600mm only.
2.7 Verify Maximum Rail End Overhang

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3.2 Components
ER-EC-ST
End Clamp
ER-IC-ST
Inter Clamp
C-U/30/46-G
Universal Clamp
C-U/30/46
Universal Clamp
Component list
ER-EC-DU35/40
End Clamp, Dual 35 or
40mm
ER-EC-DU40/46
End Clamp, Dual 40 or
46mm
ER-R-ECO
ECO Rail
ER-SP-ECO
Splice for ECO Rail
Tools and Components
3. Tools and Components
3.1 Tools
Angle Grinder with Stone Disk
Spanner
Screw Driver
(for M8 Hexagon Socket Screw)
5m Tape
Torque Spanner
String & Marker Pen
Tools

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Tools and Components
ER-I-01
Tile Interface
ER-I-23
Tile Interface-Landscape
ER-I-01/CS
Tile Interface, Carbon
Steel
ER-I-01/EZC/ECO
Tile Interface with
ezClick connection for
ECO-Rail
ER-I-02
Flat Tile Interface
ER-I-04
Slate Interface
ER-I-05
Tin Interface
Component list
ER-I-05/CM
Tin Interface with Click
Module
EZ-GL-ST
PV-ezRack Grounding Lug
with Copper Pipe
EZ-AD-C43
Adapter (Puck) for
Corrugated Iron Roof
IS-SR265/111
Isolator Shade, non-
assembly (Mill Finish)
ER-I-25
Tin Interface with Curved
Base for Corrugated
Roof
ER-I-26
Tile Interface-Side mount
ER-I-51
Tile Interface, 118mm
horizontal arm
EZ-GC-ST
Grounding clip
AB-SR/IS/260
Angle Bracket
ER-I-05A/EZC/ECO
Tin Interface A with
ezClick connection

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System Overview
4. System Overview
4.1 Overview of PV-ezRack SolarRoof
- Tile Roof
- Tin Roof
1
1
2
2
3
3
4
4
5
5
End Clamp
1 Inter Clamp
2 ECO Rail
3 Tile interface 4 Splice for ECO Rail 5
End Clamp
1 Inter Clamp
2 ECO Rail
3 Tin interface 4 Splice for ECO Rail 5

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ER-I-01 and other tile interfaces ER-I-05 and ER-I-25
ER-I-05/CM ER-I-05A/EZC/ECO
System Overview
Improper operation may lead to deadlock of Nuts and Bolts. The steps below should be applied to
every stainless steel nut and bolt assembly to reduce this risk.
4.2 Precautions during 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 of
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 defined in this guide as shown in the figures below. When fixing mid and end
clamps, if the torques range specified by the panel manfuacturer is different, it should be used instead. 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, ensure that there is
no load on the fastener before you cut it. Avoid damaging the anodized or galvanized surfaces.

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Installation Instruction
4.3 Installation Dimensions
All drawings and dimensions in this Installation Guide are a generic reference only. PV-ezRack®
SolarRoof™ is to be optimized to suit specific conditions for each project and should be
documented in a construction drawing.
Major components of PV-ezRack®SolarRoof™ may be provided in section sizes and lengths
varying from those shown in this guide. The installation process detailed in this instruction guide
remains the same regardless of changes in component size.
If you need to do any on-site modifications or alteration of the system please provide marked up
drawings/sketches for Clenergy’s review, prior to modification, for comment and approval.
5. Installation Instruction
- Assess the number of modules in the vertical direction using the module height plus at
least 18mm between modules (please check the installation manual of the solar module
manufacturer);
- Assess the Number of modules in the horizontal direction using the module width plus 18 mm
(20 mm if using Universal Clamps) between the modules.
Note: The standard end clamp will also add 20 mm (except for dual end clamps) on each
side to the space required;
- Assess the horizontal spacing of the Roof Hooks;
- Assess the vertical spacing of the Roof Hooks = approx. 1⁄2 to 3⁄4 of module height;
- 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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Installation Instruction
5.1 Tile Interface Installation
5.1.1 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.
5.1.2 Fix the Roof Hooks to the rafter using
Buildex 14-10 x 50 (14 gauge, 6.3 mm, 10
TPI, 50 mm long) Hex Head Zips screw with
at least 35 mm embedment as shown in
the figure on the right following the Buildex
screws installation guide below:
- Use a 3/8" Hex Socket.
- Use a mains powered or cordless screw
driver with a drive speed of 3,000 RPM
maximum.
- 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.
5.1.4 If necessary, use an angle grinder
to cut a recess in the tile covering the Roof Hook at the point where the Roof Hook extends so that
the tile lies flat on the surface. If grooved tiles are used, it will also be necessary to cut a recess in
the lower tile.
5.1.3 The roof hook must not press against
the roof tile. If necessary, shim the roof hook
with wood.
Incorrect Correct

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5.1.5 Caution! Do not use fitted roof hooks
as a ladder, as this extreme point load could
damage the tile below.
5.1.6 Variation for installation on plain tile
roofs with plain tile roof cladding: A recess
must be cut into the tiles around the position
of the roof hook.The tile flashing should be
used if necessary to prevent ingress of water.
5.2 Rail Installation
5.2.1 To connect several rails together, slide
half of the splice into the rear side of the
rail. Fasten the first M8 Bolt using an Allen
key, and slide the next rail into the splice.
Tighten the second M8 Bolt using an Allen
key. The total rail length is recommended
not to be over 30 meters considering rails
thermal expansion problem. Splice provides
the electrical connection between the 2 rails
through the pressure bolts. This eliminates
the need of using 2 earthing lugs
Recommended torque is 10 ~12 Nm.
5.2.2 If the rails consist of different lengths,
always begin with the shortest piece. Install
the PV modules on the Roof Hooks and
fasten loosely with M8 x 25 bolt and washers
as shown in the figure on the right. Two to
three screw turns are adequate for loose
installation.
Installation Instruction
ER-I-01
ER-I-01/EZC/ECO ER-I-51 ER-I-23
ER-I-02
ER-I-26

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Installation Instruction
5.2.3 Adjust the vertical and horizontal
positioning using the long hole in the Roof
Hook and the loosely connected Z Module in
the rail, as shown in the figure on the right. The
roof hook should not protrude over the rail after
the adjustment.
The recommended torque is 16 ~20Nm.
5.3 PV Module Installation
5.3.1 Deployment of Grounding Clips
1) When there is an even number of PV Module
in each row:
Install the grounding clips at the positions
marked X in the figure shown. Then the number
of Grounding Clips = number of PV Module.
Eg; 4 grounding clips in the figure shown.
2) When there is an odd number of PV Module
in each row:
Install grounding clips at positions marked X in
figure shown.
Then the number of Grounding Clips = number
of PV Module +1. Eg; 6 grounding clips in
figure shown.
Please note:
When replacing a defective PV Module, it is
required to replace the grounding clip under
the defective PV Module.
5.3.2 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.
±19mm

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Installation Instruction
5.3.3 Place the PV Modules on to the rails and
fix with End Clamps, Inter Clamps or Universal
Clamps. Fasten with the Allen key. Please
use Solution 1 or 2 below according to your
project.
-Solution 1 (Apply Standard Clamps)
-Step 1 Place the first PV Module on the Rail
according to your plan, and fix it in place
using the End Clamps. Then fasten lightly
with the Allen Key as shown in the figure on
the right.
-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 in the figure on
the right.
-Step 3 loosely place the next framed PV
Module into the other side of the Inter Clamp
and Grounding Clip as shown in the figure on
the right.
Important Notes:
-To fix the Grounding Clip properly, ensure the
frames of PV Modules are completely pressed
against the Inter Clamps and Grounding
Clips. Visually check that Grounding Clips are
positioned properly.
OK
Not Good

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Installation Instruction
-Grounding Clips are intended for SINGLE USE
ONLY! Only fasten the bolts down when the
position of the PV Module is finalized. (Only slightly
tighten bolts to keep PV Modules in place prior to
the final check)
-Solution 2 (Apply Universal Clamps)
Step 1 Twisting the head of the Universal Clamp
changes the functionality from End to Inter Clamp as
shown in the figure on the right.
NOTE: Please ensure the Universal Clamp
C-U/30/46 or Universal Clamp with Grounding Clip
C-U/30/46-G is positioned correctly according to
5.3.1: Deployment of Grounding Clip.
Step 2 Incline the Universal Clamp to fit the lower
channel against the lower channel of the Rail, and
press the Universal Clamp down towards the other
side to securely fit the upper channel against the
upper rail channel, as shown in the figure on the righ
Note: Before installation, make sure there is enough
clearance between the screw and lower module of
Universal Clamp as shown in the figure on the right.
Step 3 Place the first PV Module on the Rails and
apply the Universal Clamp in the End Clamp
position and fasten slightly with the Allen Key. Make
sure the frame of the PV Module is fully in contact
with the Universal Clamp as shown in the figure on
the right. Visually check the Universal Clamp and PV
module are properly installed.
18mm

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Installation Instruction
Step 4 When using as an Inter Clamp, click the
Universal Clamp into the rail channel and slightly lift
the framed PV Module to ensure the Grounding Clip
is fully covered as shown in the figure on the right
Step 5 Loosely place the next framed PV Module
into the other side of the Universal Clamp. Ensure
the Grounding Clip is fully covered and ensure the
frame of the PV Module is in close contact with
Universal Clamp as shown in the figure on the right.
Step 6 Repeat steps above to install all PV Modules.
Visually check the Universal Clamps and PV
modules are properly positioned and then fasten all
Clamps.
When you using Universal Clamps, the gap
between two adjacent PV Modules is 20mm.
The recommend torque for Universal Clamps in the
End Clamp position is 13~14N.m.
The recommend torque for Universal Clamps in the
Inter Clamp position is 16~20N.m.

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Installation Instruction
5.3.4 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
mm2 or similar) Fasten the bolt M6*14 with 5~6 N.m
and the bolt M8*25 with 16~20 N.m as shown in the
figure on the right.
Copper Pipe will be supplied for the case that using
small size Copper Wire.
There are three solutions for Grounding Lug
installation
-Solution 1
Fix the Grounding Lug at the end of Rail as shown
in the figure on the right.
-Solution 2
Fix the Grounding Lug at the Rail where just under
the PV Module as shown in the figure on the right.
-Solution 3
Fix the Grounding Lug at the side channel of Rail
as shown in the figure on the right.
20mm

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Installation Instruction
5.3.5 Slide the first PV module of the second row
onto the corresponding module of the first row.
Separation from the lower PV module can be
maintained for aesthetic reasons. An Inter Clamp
can be used as a separator, so that the vertical and
horizontal separation of the PV modules is identical.
Continue mounting the modules as described in
steps 5.3.1 to 5.3.6 until all PV modules are installed.
5.4 Tin Interface Installation
5.4.1 For installations using ER-I-05,Tin Interface
equipped with Buildex 14-11 x 70 (14 gauge, 6.3
mm, 11 TPI, 70 mm long) Hex Head Zips screw.
Fix the ER-I-05 at the planned locations on metal
or wood purlins as shown in the figure on the right
following the Buildex screws installation guide
below:
- Use a 3/8" Hex Socket.
- Use a mains powered or cordless screw driver
with a drive speed of 3,000 RPM maximum.
- 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.
Repeat 5.2 and 5.3 to install the Rails and PV
Modules.
Note:
- The purlin thickness should be no less than 0.75mm
and no more than 2.4mm;
- Please refer to the recommended torques in 4.2.3
Safe Torques;
- 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.
Clearance
85~100mm

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Installation Instruction
5.4.2 For installations using ER-I-05/CM, Tin
Interface with Click Module, equipped with Buildex
14-11 x 70 (14 gauge, 6.3 mm, 11 TPI, 70 mm
long) Hex Head Zips screw. . Fix the ER-I-05/CM at
the planned locations on metal or wood purlins as
shown in the figure on the right following the Buildex
screws installation guide above.
Repeat 5.2 and 5.3 to install the Rails and PV
Modules.
When fastening ER-I-05/CM with rail, it needs to lift
up the bolt of click module to make click module
well touch with upper rib of side channel of rail. So,
the click module can be fixed into the rail properly
as shown in the figure on the right.
Note:
- The purlin thickness should be no less than 0.75mm
and no more than 2.4mm;
- Please refer to the recommended torques in 4.2.3
Safe Torques;
- 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.
5.4.3 For installations using ER-I-05A/EZC/ECO, Tin
Interface with ezClick connection with Buildex 14-
11 x 70 (14 gauge, 6.3 mm, 11 TPI, 70 mm long)
Hex Head Zips screw. Fix the ER-I-05A/EZC/ECO
at the planned locations on metal or wood purlins as
shown in the figure on the right following the Buildex
screws installation guide above.
Repeat 5.2 and 5.3 to install Rails and PV Modules.
Note:
- The purlin thickness should be no less than 0.75mm
and no more than 2.4mm;
- Please refer to the recommended torques in 4.2.3
Safe Torques;
- 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.
Clearance
105~128mm
Clearance
85~100mm

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Installation Instruction
5.4.4 For installations using ER-I-25, Tin Interface
with Curved Base for Corrugated Roof with Buildex
14-11 x 70 (14 gauge, 6.3 mm, 11 TPI, 70 mm
long) Hex Head Zips screw. Fix the ER-I-25 at
the planned locations on metal or wood purlins
as shown in the figure on the right following the
Buildex screws installation guide above.
Repeat 5.2 and 5.3 to install Rails and PV Modules.
Note:
- The purlin thickness should be no less than
0.75mm and no more than 2.4mm;
- Please refer to the recommended torques in 4.2.3
Safe Torques;
- 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.
5.4.5 For installations using EZ-AD-C43 and ER-
I-05, Adapter (Puck) for Corrugated Iron Roof
and Tin Interface. Attach the EZ-AD-C43 on the
planned position and then fix the ER-I-05 on metal
or wood purlins as shown in the figure on the right
following the Buildex screws installation guide
above.
Repeat 5.2 and 5.3 to install Rails and PV Modules.
Note: The purlin thickness should be no less than
0.75mm and no more than 2.4mm.
Note:
- The purlin thickness should be no less than
0.75mm and no more than 2.4mm;
- Please refer to the recommended torques in 4.2.3
Safe Torques;
- 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.
Clearance
89~104mm
The rail is perpendicular to the Rib of
metal sheet roof
Clearance
89~104mm
Clearance
89~104mm
NOTE:
WHEN USING TIN INTERFACES 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. The rail is parallel to the Rib of metal
sheet roof