Clenergy PV-ezRack SolarTerrace II-A User manual

PV-ezRack®SolarTerrace II-A™
Code-Compliant Planning and Installation V2.0
Complying with AS/NZS1170.2:2011 AMDT 3-2012

Installation Guide_PV-ezRack_SolarTerraceII-A_AU_V2.0
1/10 Duerdin Street, Clayton VIC 3168 Australia
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Introduction
Clenergy PV-ezRack®SolarTerrace II-A™ is a
pre-assembled ground mount system suitable
for large scale commercial and utility scale
installations. PV-ezRackSolarTerrace II-A has
been developed to fit any PV module. The
innovative and patented SolarTerrace II-A
T-Rails simplify and improve the accuracy
of the installation. SolarTerrace II-A uses
high quality engineered components, saving
developers and installers’ time and money
when delivering ground mount projects.
Please review this instruction guide thoroughly
before installing PV-ezRackSolarTerrace II-
A. This manual provides the supporting
documentation for building permit applications
relating to PV-ezRackSolarTerrace II-A
Universal PV Mounting System.
The PV-ezRackSolarTerrace II-A components,
when installed in accordance with this guide,
will be structurally adequate and will meet the
AS/NZS1170.2:2011 Amdt. 3-2012 standard.
During installation and especially when working
on the ground, you will need to comply with
the appropriate occupational health and safety
regulations. Please also check other regulations
relevant to your local region. Make sure that you
are using the latest version of the installation
instruction guide, which you can do by
contacting Clenergy by email on sales@clenergy.
com.au, or contacting your local distributor.
The installer is solely responsible for:
•Complying with all applicable local or national
building codes, including any that may
supersede this manual;
•Ensuring that ezRack and other products are
appropriate for the particular installation and the
installation environment;
•Using only ezRack parts and installer-supplied
parts as specified by ezRack (substitution of
parts may void the warranty and invalidate the
letter of certification);
•Ensuring that the ground condition are suitable;
•How to recycle: according to the local relative
statute.
•How to disassemble: reverse installation
process.
•Ensure that there are no less than two
professionals working on the panel installation.
•Ensure the installation of the electrical
equipment is performed by a professional and
accredited electrician.
•Ensuring safe installation of all electrical aspects
of the PV array including providing adequate
earth bonding of the PV array and PV-ezRack®
SolarTerraceII-A™components as required in AS/
NZS 5033-2014 ADMT 2 2-2018.
Introduction
Planning
Tools & Components
System Overview
Installation Instruction
Warranty
01
02
04
06
08
21
List of Contents
1. Introduction

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2. Planning
2.1 Installation Spacing
Table 1 Max Frame Spacing and Footing Options of Panel Dimensions 1.7m x 1.1m
Planning
Wind Region RegionA RegionB RegionC RegionD
Panels tilt angle,degrees 20 30 20 30 20 20
Wind speed,m/s 41 48 59 73
Panel clearance (Cp), mm,max/min 583/446 501/501 583/446 501/501 583 / 446 583 / 446
Max/Min post height above the ground,
mm, from Clenergy 1000/863 1300/1300 1000/863 1300/1300 1000 / 863 1000 / 863
Spacing(S),m 3.50 3.35 3.40 3.25 2.95 1.95
Max Vertical Uplift Reaction,kN 6.1 6.9 8.8 9.9 12.3 13.0
Max Vertical Down Reaction,kN 13.2 13.9 16.6 17.5 20.7 20.2
Max Horizontal Reaction,kN 3.9 6.5 5.1 8.6 6.7 6.8
Max Moment at GL,kNm 7.9 5.5 9.9 6.8 12.2 11.8
Soil Class Driven post minimum embedment depth (D), m
Compact sand 1.33 1.23 1.47 1.37 1.62 1.60
Medium dense sand 1.74 N/A N/A N/A N/A N/A
Very Stiff to Hard Clays 1.36 1.24 1.51 1.39 1.67 1.66
Firm to Stiff Clays N/A N/A N/A N/A N/A N/A
Driven post maximum embedment depth
based on standard 2800 mm long post (m),
from Clenergy
1.937 1.500 1.937 1.500 1.937 1.937
Soil Class Post embedded in concrete pier: 300 mm diameter concrete piers
minimum depth (D), m
Compact sand 0.85 0.80 0.95 0.85 1.05 1.00
Medium dense sand 1.10 1.00 1.20 1.10 1.30 1.30
Very Stiff to Hard Clays 0.85 0.75 0.95 0.85 1.05 1.00
Firm to Stiff Clays 1.20 1.10 1.35 1.25 1.50 1.45

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Planning
Table 2 Max Frame Spacing and Footing Options of Panel Dimensions 2m x 1.1m
Notes.
- For 25 degrees tilt angle the spacing and footing options for 30 degrees can be adopted (Cp=474-
585mm, post hight = 1200-1085mm AG, max post depth1.715m).
- For concrete piers foundation we recommend to use 25 MPa strength concrete. Other pier sizes
possible,contact Gamcorp.The minimum post embedment depth in the pier shall be approximately
0.9 of the pier depth.
- T-Rails overhang: 0.4*S maximum.
Notes.
- For concrete piers foundation we recommend to use 25 MPa
strength concrete. Other pier sizes possible, contact Gamcorp.
The minimum post embedment depth in the pier shall be
approximately 0.9 of the pier depth.
- (*): when using Clenergy East-West adaptor (if different to the
spacing without adaptor);
- T-Rails overhang: 0.4*S maximum.
Explanation of the adopted soil classes
ABC (Allowable Bearing
Capacity), kPa
Compact sand
Medium dense sand
Very Stiff to Hard clays
Firm to Stiff Clays
≥300
150 - 300
300 – 600
100 – 150
Wind Region RegionA RegionB RegionC RegionD
Panels tilt angle,degrees 20 30 20 30 20 20
Wind speed,m/s 41 48 59 73
Panel clearance (Cp), mm,max/min 691/554 560/445 691/554 560/445 691/554 691/554
Max/Min post height above the ground,
mm, from Clenergy 1000/863 1200/1085 1000/863 1200/1085 1000 / 863 1000 / 863
Spacing(S),m 3.30 3.20 3.20 2.95(2.85*) 2.85 1.95(1.90*)
Max Vertical Uplift Reaction,kN 6.7 7.8 9.7 10.6 14.0 15.3
Max Vertical Down Reaction,kN 14.6 15.6 18.4 18.7 23.5 23.7
Max Horizontal Reaction,kN 4.3 7.3 5.7 9.2 7.7 8.0
Max Moment at GL,kNm 8.2 12.3 10.9 15.4 14.5 15.2
Soil Class Driven post minimum embedment depth (D), m
Compact sand 1.34 1.61 1.51 N/A 1.71 N/A
Medium dense sand 1.76 N/A N/A N/A N/A N/A
Very Stiff to Hard Clays 1.38 1.67 1.56 N/A 1.78 N/A
Firm to Stiff Clays N/A N/A N/A N/A N/A N/A
Driven post maximum embedment depth
based on standard 2800 mm long post (m),
from Clenergy
1.937 1.715 1.937 1.715 1.937 1.937
Soil Class Post embedded in concrete pier: 300 mm diameter concrete piers
minimum depth (D), m
Compact sand 0.90 1.05 1.00 1.10 1.10 1.10
Medium dense sand 1.10 1.30 1.25 1.45 1.40 1.40
Very Stiff to Hard Clays 0.85 1.05 1.00 1.15 1.10 1.10
Firm to Stiff Clays 1.25 1.50 1.40 1.65 1.60 1.60

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Tools & Components
3.1 Tools
3. Tools & Components
Socket Wrench with
19 mm socket
Torque WrenchAllen Key 6mm
(M8
Hexagon
Socket
Screw)
Electric Drill
(ST4.8x16
self-tapping
screw & M8
Hexagon
Socket
Screw)
WrenchMarker PenMeasuring Tape String
Electronic Total
Station
( optional )
Hydraulic Driver

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C-U/30/46-G
EZ-GL-STEZ-GC-ST
ER-CAP-T110
ER-S-STIIA/D
ER-PB-CP/A
ER-PH-CP/A
ER-R-T110ER-IC-ST
Tools & Components
Note: ER-PB-CP/D/A and ER-S-STIIA/D only used on STII double support mounting system
3.2 Components
ER-SP-T110
Inter Clamp T-Rail 110 Splice for T-110 Rail
ER-CP-2800/A
ER-RC-T/G
Rail Clamp
for T-Rail
with
grounding
pins
Post head
for C-Post
with
Grounding
C-Post,2800mm post brace for C-Post
ER-S-STIIA/S
ER-PB-CP/D/A
Post brace
for C-Post
on double
support
with
Grounding
Support
(pre-assembled)
Double support
(pre-assembled)
Cap for T-110 Rail
ER-CAP-G/A
Cap for
Square
Girder
Grounding Clip Grounding Lug Universal
Clamp for
Frame Height
30-46mm with
Grounding
Clip
C-U/30/46
Universal
Clamp
for Frame
Height 30-
46mm
ER-EC-ST
End Clamp

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4. System Overview
4.1 Overview of PV-ezRack SolarTerraceII-A
4.2 Precautions during Stainless Steel Fastener Installation
Improper operation may lead to deadlock of Bolts and Nuts. The below steps should be applied to every
stainless steel nut and bolt assembly to reduce this risk.
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 in the
threads;
① STII-A, Support (pre-assembled)/ Double support (pre-assembled)
② STII-A, C-Post
③ STII-A, Post brace for C-Post/Post brace for C-Post On double support
④ STII-A, Post head for C-Post
⑤ T-Rail 110
①
②
③
④
⑤
System Overview

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4.2.2 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
4.2.3 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 ensure that there is no load on the fastener
before you cut it. Avoid scratching the anodized or galvanized surfaces.
Set screw M8*12:1.5-2N·m
Set screw M8*12:7-8N·m
M12:40-45N·m
M8 on Clamp:18-20N·m
M12 on Post Brace:50-55N·m
M12:23-25N·m
M12:50-55N·m
System Overview
Set screw M8*12:1.5-2N·m
M12:50-55N·m

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4.3 Installation Dimensions
All drawings and dimensions in this installation guide are a generic reference only. PV-ezRack®SolarTerrace II-
A™ 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®SolarTerrace II-A™ 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.
Installation Instruction
Below are the side view drawings of support for 60 cell panels(up to 1700 x 1100 mm)and 72 cell
panels (up to 2000 x 1100 mm) at 20° and 30° tilt angles.
Side view drawings of support for 60 cell panels (up to 1700 x 1100 mm)
Side view drawings of support for 72 cell panels (up to 2000x1100mm)
INTRODUCTION

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5. Installation instructions
Apply Zinc Coating to upper section
of C Post after ramming
1a. Before starting, check you have
the installation tools needed. Position
the required components close to the
installation location. Make sure that the
hydraulic pile driver equipment is suitable
for your particular installation.
Mark the line of the post array.
1b. Obtain the maximum allowed
distance between posts and the
minimum embedment length from the
relevant engineering certificate and/or
project drawing. If you don’t have this
document, please contact Clenergy
technical support.
Mark the positions of the posts using a
string and tape measure or GPS and
drive the posts into the ground. Use a
sting or a laser tool to make sure all posts
are in line and set to the correct height
according to the drawing.
Notes: apply zinc coating to upper
section (circled) of C-Post after piling to
repair any damage to the galvanisation
caused by ramming.
5.1 C-Post Installation
Installation Instruction

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① ②
Install the post head and fix it with the two M12 bolts and nuts supplied. To avoid stainless steel galling/
seizing apply grease or lubricant if needed.
Recommended torques:
Bolt 1 with 50-55 N·m
Bolt 2 with 23-25 N·m
5.2 Post Head Installation
3a.
Click the Post brace into C-Post as shown and connect with the two M12 bolts and nuts supplied.
Recommended torque:
Bolt M12 50~55N·m
5.3 Post Brace Installation
Installation Instruction
Fig. 1
Fig. 2
Bolt 1
Bolt 2
To achieve earthing/
grounding function using
set screws
To achieve earthing/
grounding function using
set screws

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Installation Instruction
3b.
Post brace on double support installation.
Click two post braces into C-Post as
shown and connect with the two M12
bolts and nuts supplied.
Recommended torque:
Bolt M12 50~55N·m
5.4 Pre-assembled Support Installation
Place the (pre-assembled) support into post head as shown in Fig.5.
Fig. 3
Fig. 4
Fig. 5

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Installation Instruction
Connect the brace to the post using the M12 bolt and nut supplied.
Recommended torque:
M12 : 50-55N·m
Tube of the
pre-assembled support
Horizontal rotation is 10 degree Horizontal rotation is 10 degree
Post Brace
±20mm
Fig. 6
Fig. 7

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Installation Instruction
5.5 Double Support Installation
Place the double support (pre-assembled) into post head. Connect the tubes of the support the to the post
braces on the post using the M12 bolt and nut supplied.
Recommended torque:
M12 : 40-45N·m
Note:
① The lengths of the two tubes are different.
Make sure the shorter one is positioned at the
lower part of the tilt as shown.
② Connect the shorter Tube Support to post
brace.
③ Adjust the bolt position of T head to align
the post brace to the Tube Support.
④ Rotate the orientation of T head to fit the
Tube Support to the post brace.
Fig. 8
Fig. 9
Fig. 10
Fig. 11

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Installation Instruction
Note:
Make sure all of Tri-groove beams are
parallel prior to installation of T-Rails.
Check the torque value of bolt:
Bolt 1 with 50-55 N·m
Bolt 2 with 50-55 N·m
Bolt 3 with 40-45 N·m
Bolt 4 with 50-55 N·m
Bolt 5 with 40-45 N·m
Bolt 6 with 18-20 N·m
Make final adjustments to Racking
System.
Adjust vertically: Loosen Bolt 1 and slide
along ellipse hole.
Adjust Tri-groove beam parallel: Loosen
Bolt 2 and Bolt 3, turn Post Head slightly,
move Al Tube left and right until being
parallel. Keep all of Tri-groove beams
parallel at same level.
5.6 System Adjusting
Tube Support
Bolt 6
Bolt 2
Bolt 5
Bolt 1
Bolt 6
Bolt 3 Bolt 4
Fig. 12
Fig. 13
Fig. 14
Fig. 15

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Installation Instruction
5.7 T-Rail Installation
7a. Slide T-Rails into Pre-assembled rail
clamp on Tri-groove beams and use a
6mm Allen key (Hex) to fasten on another
side via Rail Clamp for T-Rail.
Recommended Torque:
M8:18Nm
Note: Rail clamps can work on both sides
with no pre-assembled rail clamp.
7b. Determine the necessary length of
T-Rail prior to installation, if T-Rail isn’t
long enough; join two rails via Rail splice
as shown before installing the T-Rail as
directed in step 7a.
Note:
Connecting Rails on Structure system
are not recommended.
Rail Clamp
Pre-assembled
Rail Clamp
7c. Racking System installation is complete.
Fig. 16
Fig. 17
Fig. 18

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Installation Instruction
5.8.1 Deployment of Grounding Clip
5.8.1.1 Even of PV Module in each row:
Install Grounding Clips at positions marked in diagram.
Installation number of Grounding Clip = number of PV Module. Eg: 4 Grounding
Clips in image shown.
5.8 PV Modules Installation
5.8.1.2 Odd number of PV Module in each row:
Install Grounding Clips at positions marked in diagram.
Installation number of Grounding Clip = number of PV Module +1. Eg: 5+1=6 Grounding
Clips image shown.
Key point: When replacing a single defective PV Module, it’s required to replace the
Grounding Clip under the PV Module.

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Installation Instruction
5.8.2 Place PV Modules on Rails, and fix them with End Clamps and Inter Clamps or Universal
Clamps, then fasten them with Allen Key. Please choose below Solution 1 or 2 according to your
project.
-Solution 1 (Apply End Clamps and Inter Clamps)
Step 1 Place the first PV Module on T Rails according to your plan and apply the End Clamps to fix it
and then fasten lightly with Allen Key as shown in figure below .
Step2 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 right Figure.
Step 3 Loosely place the next framed
PV Module into the other side of Inter
Clamp and Grounding Clip as shown
in right Figure.
Important Notes:
-To fix 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.
-Grounding Clips are intended for SINGLE USE ONLY! Do not fasten the bolts down if the
position of PV Module is not finalized. Only slightly tighten bolts to keep PV Modules in place.
Fig. 19
Fig. 20
Fig. 21

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Installation Instruction
Step 4 Maintain 18mm vertical gap and
18mm horizontal gap between the two
adjacent rows of PV Modules. You can use
two Inter Clamps as separation between
two PV Modules, and remove them after
installation finished as shown in right
Figure.
Step 5 Repeat above steps to install all PV
Modules. Fasten all End Clamps and Inter
Clamps tightly with18~20N.muntil all PV
Modules are properly installed.
-Solution 2 (Apply Universal Clamps)
Step 1 Twist the head of Universal Clamp
to change functionality from end to inter
clamp as shown in right figure.
18
18
NOTE: Properly apply the Universal Clamp C-U/30/46 or Universal Clamp with Grounding Clip
C-U/30/46-G according to 5.8.1. Deployment of Grounding Clip.
Step 2 Incline the Universal Clamp to fit the channel on its lower part against the lower channel of T
Rail, and press down the Universal Clamp towards the other side to fit the channel on its upper part
against the upper channel of T Rail as shown in figure below .
Note: before installation, make sure there will be enough clearance between screw and module of
Universal Clamp as shown in figure below .
90°
Fig. 22
Fig. 23
Fig. 24

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Installation Instruction
Step 4 When using as Inter Clamp, click Universal
Clamp into the channel of T Rail and then slightly
lift the framed PV Module to make sure the
Grounding Clip of Universal Clamp will be fully
covered as shown in right Figure.
Step 3 Place the first PV Module on the T Rails and apply the Universal Clamp in the End Clamp
position to fix it and then fasten slightly with Allen Key. Make sure the frame of PV Module is fully in
contact with the Universal Clamp as shown in figure below. Visually check the Universal Clamp and
PV module are properly installed.
Step 5 Slightly place the next framed PV Module
into the other side of Universal Clamp, Making
sure the Grounding Clip of Universal Clamp will
be fully covered and the frame of PV Module is
closely in contact with Universal Clamp as shown
in right Figure.
20
Fig. 25
Fig. 26
Fig. 27