PV-ezRack SolarBase User manual

SolarBase
Low Ballast Flat Roof System
Installation Guide V 1.4
NO.:PZ30-IM01-14
Last Updated - Mar. 2022

Installation Guide /SolarBase Low Ballast Flat Roof System
1Installation Guide V 1.4 - NO.:PZ30-IM01-14
Introduction
List of contents
Introduction
Tools & Components
System Overview
Installation Instruction
01
02
03 - 05
06 - 09
PVezRack® 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
PVezRack® SolarBase. This manual provides supporting
documentation for building permit applications relating
to PVezRack® SolarBase system.
The PVezRack® 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 [e-mail], or contacting your local
distributor.
Product Warranty:
Please refer PV-ezRack® Product Warranty on our
website.
- Introduction -

Installation Guide / SolarBase Low Ballast Flat Roof System
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Installation Guide V 1.4 - NO.:PZ30-IM01-14
Tools and Components
Tools
6mm inside
hexagonal spanner
Torque spannerElectric tool
String
5m tape
Socket spanner
Marking pen
Components
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
- Tools and Components -
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.

Installation Guide /SolarBase Low Ballast Flat Roof System
3Installation Guide V 1.4 - NO.:PZ30-IM01-14
System Overview
1. Support Leg 2. Ballast Bar 3. Module Clamp 40 mm 4. Wind Deflector 5. Grounding Lug
Overview of PV-ezRack SolarBase
- System Overview -
1
2
3
4
5

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Installation Guide V 1.4 - NO.:PZ30-IM01-14
- System Overview -
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.
Installation planning

Installation Guide /SolarBase Low Ballast Flat Roof System
5Installation Guide V 1.4 - NO.:PZ30-IM01-14
All drawings and dimensions in this installation guide are for a generic reference. The Clenergy PVezRack® 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 PVezRack® 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.
- System Overview -
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
Precautions during Stainless Steel Fastener Installation
Improper operation may lead to deadlock of Bolts and Nut. 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; 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.
Installation Dimensions

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Installation Instructions
Install Support Leg team
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.
- Installation Instructions -
According to specification of ballast,
adjust distance between both square
neck bolts.
Figure 1
Figure 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 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.

Installation Guide /SolarBase Low Ballast Flat Roof System
7Installation Guide V 1.4 - NO.:PZ30-IM01-14
Install Wind Deflector and ballast
(optional parts)
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. Figure 4 Figure 5
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.
- Installation Instructions -
Figure 6
1. Nut
2. Washer
3. Plain washer
4. Fixing plate
Figure 7 Figure 8
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
Figure 6
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 the above
instructions.)

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- Installation Instructions -
Install PV modules and Module Clamp 40
Rotate the right part of Support Leg to the required position as
shown in Figure 10.
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.
Fasten the frame of PV module and Support Leg with Module
Clamp 40 as shown in Figure 12.
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
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.
Figure 15
Figure 14
Figure 12 Figure 13
Figure 11
Figure 10

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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.
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
Install Grounding Lug
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.
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.
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.
- Installation Instructions -
Figure 16 Figure 17
Figure 18
Repeat above operations to install the rest PV modules
as shown in Figure18.
Figure 19
Figure 20

Clenergy
1/10 Duerdin St
Clayton VIC 2168
Australia
Phone: [phone]
Email: [e-mail]
Web: www.clenergy.com.au
@Clenergy@Clenergy_global
@ClenergyClub@Clenergy
@ClenergyGlobal / @ClenergyClub / ClenergyAUS
A Clenergy Technologies Company