PV-ezRack ComT 2.0 Technical manual

Ver 1.0 / Last Updated - Oct. 2021
ComT 2.0: 5°, 10° and 15°
Code-Compliant Planning and Installation Guide V1.0
Complying with AS/NZS1170.2-2011 AMDT 2-2016

Installation Guide / ComT 2.0: 5°, 10° and 15°
1Code-Compliant Planning and Installation Guide V1.0 - Complying with AS/NZS1170.2-2011 AMDT 2-2016
Introduction
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
pull-out strength and shear capacities as installed.
Maintaining the waterproof integrity of the roof,
including the 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.
Verifying atmospheric corrosivity zone of installation
site by referring to AS 4312-2008 or consulting local
construction business to determine appropriate
products and installation.
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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 installation and the surrounding
environment.
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The installer is solely responsible for:
List of contents
Introduction
Planning
Tools & Components
System Overview
Installation Instruction
Product Warranty
Certification
01
02 - 04
05 - 06
07 - 11
12 - 18
19 - 21
22 - 41
The PV-ezRack® ComT is developed for PV installation
on flat or pitched roofs. The unique fixing parts can be
quickly and easily installed with simple tools.
Please review this manual thoroughly before installing
PV-ezRack® ComT. This manual provides:
1) Supporting documentation for building permit
applications relating to PV-ezRack® ComT.
2) Planning and installation instructions.
The PV-ezRack® ComT 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 obtain
by contacting Clenergy Australia via email at tech@
clenergy.com.au or contacting your local distributor in
Australia.
- Introduction -

Installation Guide / ComT 2.0: 5°, 10° and 15°
2
Code-Compliant Planning and Installation Guide V1.0 - Complying with AS/NZS1170.2-2011 AMDT 2-2016
Planning
Most of Australia is designated Region A which
indicates a Regional Wind Velocity of 45 m/s with
wind average recurrence of 500 years.
Some areas are designated Region B (57 m/s). Local
authorities will advise if this applies in your area.
Region C areas (69 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 (88 m/s) is Australia's most extreme Cyclonic
Region, located between the town of Carnarvon and
Pardoo Station in Western Australia.
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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.
- Planning -
Determine the Wind Region of your Installation Site
Region Definition

Installation Guide / ComT 2.0: 5°, 10° and 15°
3Code-Compliant Planning and Installation Guide V1.0 - Complying with AS/NZS1170.2-2011 AMDT 2-2016
Determine the Terrain Category
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 very few or no obstructions, and all water surfaces, e.g. flat,
treeless, poorly grassed plains; open ocean, rivers, canals, bays and lakes.
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 some trees or isolated obstructions, terrain in developing outer urban areas
with scattered houses, or larger acreage developments with more than two and less then 10 buildings per hectare.
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-size obstructions per hectare, e.g.
suburban housing, light industrial estates or dense forests.
Terrain Category 4 (TC4) – Terrain with numerous larger, high (10m to 30m tall) and closely-spaced constructions
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.
Verify Atmospheric Corrosivity Zone of Installation Site
Please refer to “AS 4312-2008 Atmospheric Corrosivity Zones in Australia” or consult a local construction business to
verify the corrosivity category of the installation site to determine appropriate products and interface spacing. When
standard products are installed in high corrosivity zones, like C4/C5, interface spacing reduction factor needs to be
applied. Please refer to the generic note of the Certification Letter for details.
Determine the Height of the Installation Site
This document provides sufficient information for the PV-ezRack® ComT system installation up to heights of 30 meters.
If your installation site is more than 30 meters high please contact Clenergy to obtain a project specific engineering
certificate to support your installation.
- Planning -

Installation Guide / ComT 2.0: 5°, 10° and 15°
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Code-Compliant Planning and Installation Guide V1.0 - Complying with AS/NZS1170.2-2011 AMDT 2-2016
- Planning -
Determine System Tilt Angle
The PV-ezRack® ComT system is a fixed 5°, 10° and 15° tilt system.
Determine Roof Pitch
The PV-ezRack® ComT system can be used for roof slopes up to 10°. Please verify that the Installation site roof pitch is
less or equal to 10°.
Determine the Installation Area of Roof
Please refer to PV-ezRack® ComT Interface Spacing Table in Certification Letter.
Verify Rafter/Purlin Properties of Building
Please verify the rafter/purlin properties of the building, which could affect the interface spacing. For example, the tin
interface spacing on the metal purlin in the certification letter is based on steel purlins G450 1.9 mm thick. If the steel
purlin is less than 1.9 mm in thickness, the corresponding reduction factor of the interface spacing will be applied. For
different grade of timber purlin, the different spacing will apply as well. Please refer to the generic notes for details.
Determine the Maximum Rail Support Spacing
There are other additional factors (such as PV module dimensions, number of rails per PV module, row spacing
between PV modules) related to maximum rail support spacing. Please refer to the notes of Certification Letter. If a
project specific Certification Letter has been provided, please refer to the support spacing in the provided letter.
Verify Maximum Rail Overhang
Maximum rail overhang is 150 mm for interface fixing (or installed) spacings equal or over 700 mm. For interface fixing
spacings less than 700 mm, max rail overhang is 50 mm.
Verify PV Module’s Clamping Requirements
It is important to check PV modules clamping requirements (for example clamp dimensions, clamping distance from
the end of panel) from PV modules manufacturer before installations, which can help to avoid using incorrect size of
clamps and help to plan interface’s positions on the roof and rail’s orientation and position.

Installation Guide / ComT 2.0: 5°, 10° and 15°
5Code-Compliant Planning and Installation Guide V1.0 - Complying with AS/NZS1170.2-2011 AMDT 2-2016
Tools and Components
Tools
Impact Driver
(Max. torque≥20N.m,
for M8 bolt and nut)
StringTorque Spanner
Marker Pen
Spanner
6mm Hex Driver Bit
(in the carton provided
by the Clenergy)
Open Spanner 14mm
Tape
Components
FL-COMT/Z/G/5
Front Leg Assembly,
5°, with Z-Module and
Grounding Pins
RL-E-COMT/G/15
Rear Leg Extender, 15°,
with Grounding Pins
RL-COMT/Z/G/5
Rear Leg Assembly, 5°,
with Z-Module and
Grounding Pins
ER-R-ECO
ECO Rail
FL-COMT/Z/G/10V2
Front Leg Assembly,
10°, with Z-Module and
Grounding Pins, version 2
ER-R-T50
T50 Rail
RL-COMT/Z/G/10V2
Rear Leg Assembly,
10°, with Z-Module and
Grounding Pins, version 2
ER-R-T110
T110 Rail
FL-COMT/Z/G/15
Front Leg Assembly,
15°, with Z-Module and
Grounding Pins
S-MT/240
MT-Rail Support
- Tools and Components -

Installation Guide / ComT 2.0: 5°, 10° and 15°
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Code-Compliant Planning and Installation Guide V1.0 - Complying with AS/NZS1170.2-2011 AMDT 2-2016
Components
EZ-CT-40/40/2560
MT-rail Cable Tray
ER-I-05
Tin Interface
ER-I-05/CM
Tin Interface
with Click Module
ER-I-05A/EZC/ECO
Tin Interface A with
ezClick connection
ER-I-25
Tin Interface with
Curved Base for
Corrugated Roof
ER-RC-T/DM
Rail Clamp for T-Rail,
with Diamond Module
CO-MT/855
Cover for
MT-rail Cable Tray
EZ-GC-ST
Grounding Clip
EZ-GL-ST/UC
Grounding Lug with
U-Shape Copper
Channel
EZ-Z-STBW
Z module with
Bolt and Washer
- Tools and Components -

Installation Guide / ComT 2.0: 5°, 10° and 15°
7Code-Compliant Planning and Installation Guide V1.0 - Complying with AS/NZS1170.2-2011 AMDT 2-2016
System Overview
Tin Interface with Eco Rail
MT-Rail Support with T50/T110 Rail
A. Front Leg Assembly B. Rear Leg Assembly C. ECO Rail D. Tin Interface
A. Front Leg Assembly B. Rear Leg Assembly C. T50 Rail/T110 Rail D. Rail Clamp for T-Rail
E. MT-Rail Support
AA
DD
AA
BB
BB
CC
CC
DD
EE
Overview of PV-ezRack® ComT (North Facing)
- System Overview -

Installation Guide / ComT 2.0: 5°, 10° and 15°
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Code-Compliant Planning and Installation Guide V1.0 - Complying with AS/NZS1170.2-2011 AMDT 2-2016
Side View Drawing
5° ComT legs, 1002 mm wide, 35 mm high panel
Note: 5° tilt angle is designed based on 1002 mm wide panel
- System Overview -
10° ComT legs, 1002 mm wide, 35 mm high panel
Note: 10° tilt angle is designed based on 1002 mm wide panel
5° ComT legs, 1200 mm wide, 35 mm high panel
Note: 1200 mm wide panel is max panel width considering earthing pins on top of
legs plates can provide effective panels earthing

Installation Guide / ComT 2.0: 5°, 10° and 15°
9Code-Compliant Planning and Installation Guide V1.0 - Complying with AS/NZS1170.2-2011 AMDT 2-2016 - System Overview -
15° ComT legs, 1002 mm wide, 35 mm high panel
Note: 15° tilt angle is designed based on 1002 mm wide panel
10° ComT legs, 1200 mm wide, 35 mm high panel
Note: 1200 mm wide panel is max panel width considering earthing pins on top of
legs plates can provide effective panels earthing
15° ComT legs, 1200 mm wide, 35 mm high panel
Note: 1200 mm wide panel is max panel width considering earthing pins on top of legs plates can provide effective
panels earthing

Installation Guide / ComT 2.0: 5°, 10° and 15°
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Code-Compliant Planning and Installation Guide V1.0 - Complying with AS/NZS1170.2-2011 AMDT 2-2016
- System Overview -
A. Front Leg Assembly B. Rear Leg Assembly C. ECO Rail D. Tin Interface
AA
BB
DD
CC
Overview of PV-ezRack® ComT East-West
Side View Drawing (10° legs, 1002 mm wide panel as an example)
Note: Minimum distance between two rear legs is 50 mm as well for 5° and 15° tilt legs, and for other panel width.
Precautions during Stainless Steel Fastener Installation
Improper operation may lead to deadlock of Nuts and Bolts. The steps below should be applied to stainless steel nut
and bolt assembly to reduce this risk.
General Installation Instructions:
(1) Apply force to fasteners in the direction of the thread
(2) Apply force uniformly, to maintain the required torque
(3) Professional tools and tool belts are recommended
(4) In some cases, fasteners could be seized over time. To avoid galling or seizing of thread, apply lubricant (grease or
40# engine oil) to fasteners prior to tightening.

Installation Guide / ComT 2.0: 5°, 10° and 15°
11 Code-Compliant Planning and Installation Guide V1.0 - Complying with AS/NZS1170.2-2011 AMDT 2-2016
Safe Torques
Please refer to safe torques defined in this guide. When fixing mid and end clamps, if the torques range specified by
the panel manufacturer 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 cutting it. Avoid damaging the
anodized or galvanized surfaces.
- System Overview -
5° Front Leg
10° Front Leg
15° Front Leg 15° Rear Leg
5° Rear Leg
10° Rear Leg

Installation Guide / ComT 2.0: 5°, 10° and 15°
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Code-Compliant Planning and Installation Guide V1.0 - Complying with AS/NZS1170.2-2011 AMDT 2-2016
Installation Instructions
- Installation Instructions -
When using the Tin Interface (ER-I-05 as an example) with the ECO Rail
solution, please follow the steps below.
5.1.3 To connect several rails, 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 as shown in Figure 4. Tighten the second M8 Bolt using an Allen key. The total
rail length is recommended not to be over 30 meters considering the rail’s thermal expansion problem.
M8 Bolt Recommended torque is 10 ~12 N•m.
Splice provides an electrical connection between the 2 rails through the pressure bolts. This eliminates the need of
using 2 earthing lugs.
Note: It is important to run visual inspection to make sure installations above were properly done. It is important to
check and correct fasteners torques with torque wrench or similar tool if using tools without torque setting during
installations.
1. Tin Interface with ECO Rail Installation
5.1.1 Fix the Tin Interface on the metal purlin with a self-tapping screw
according to the installation plan (Clenergy Tin interface is supplied
with one Buildex 14- 11 x 70 Hex Head Zips screw). Ensure that the Tin
Interface in the front and rear or left and right directions are aligned
using string as shown in Figure 1.
5.1.2 Fix the Rail on the Tin Interface as shown in Figures 2 and 3.
Recommended torques of M8 Bolt:16-20N•m
Figure 1
Figure 2 Figure 3
Figure 4

Installation Guide / ComT 2.0: 5°, 10° and 15°
13 Code-Compliant Planning and Installation Guide V1.0 - Complying with AS/NZS1170.2-2011 AMDT 2-2016
In case of large purlin spacing, MT-Rail Support with T50 or T110 Rail will be an option. Please follow the steps below.
2. MT-Rail Support with T50/T110 Rail Installation (optional)
5.2.1 Based on the rib spacing of the metal roof
sheet, mark out the positions of self-tapping screws
on the MT-Rail Support and then attach the glued
EPDM rubber pad under the MT–Rail Support as
shown in Figure 5 (Clenergy 240 mm long MT rail
section is supplied with two Buildex 14-11 x 70 Hex
Head Zips screws).
Insert half of Splice
into T Rail
Two sets of
Self-tapping screws in
each side of T Rail
Insert the other half of
the Splice into T Rail
Two sets of Self-tapping
screws in each side of T Rail
- Installation Instructions -
Figure 5
Figure 6
Figure 7
Figure 9
Figure 8
5.2.2 Confirm the position of the purlin for the
MT-Rail Support installation, then fix the MT Rail
Support by screwing through two ribs on the purlin
as shown in Figure 6.
5.2.3 Fix the Rail onto the MT-Rail Support with T-Rail Clamps as shown in Figures 7 and 8.
Recommended torques of M8 Bolt:16-20N•m
5.2.4 If the T Rail is not long enough, please use Splice for T Rail to connect two T Rails together. Insert half of the Splice
into T Rail and fasten with two sets of Self-tapping screws in each side of the T Rail, and then insert the other half of
the Splice into T Rail and fasten with Self-tapping screws as shown in Figure 9.

Installation Guide / ComT 2.0: 5°, 10° and 15°
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Code-Compliant Planning and Installation Guide V1.0 - Complying with AS/NZS1170.2-2011 AMDT 2-2016
In this step, the Tin Interface with ECO Rail is used as an example.
3. Front and Rear Leg Installation
Fix a 5° Rear Leg into the top channel of ECO
Rail, then fasten the Rear Leg after the position
is adjusted properly as shown in Figure 12.
Recommended torques of M8 Bolt:16-20N•m.
5.3.2. The same steps in 5.3.1 applies for 10° front and
rear legs installations as shown in Figures 10, 11 and
13.
5.3.3. Please follow steps below for 15° front and rear
legs installations.
Follow 5.3.1 to install a 15° front leg on top of the
ECO rail.
There are two ways to install a 15° Rear Leg.
5.3.1 Fix a 5° Front Leg into the top channel of ECO Rail, then fasten the Front Leg after the position is adjusted properly
as shown in Figures 10 and 11.
Recommended torques of M8 Bolt: 16-20N•m.
Option 1:
Install 10° Rear Leg on top of the ECO rail as shown in Figure 13. Add a 15° rear leg extender on the 10° Rear Leg as
shown in Figures 14-15. Don’t forget to use the teeth lock washer when fastening the bolt as shown in Figure 15.
- Installation Instructions -
Figure 10
Figure 13 10° Rear LegFigure 12 5° Rear Leg
Figure 11

Installation Guide / ComT 2.0: 5°, 10° and 15°
15 Code-Compliant Planning and Installation Guide V1.0 - Complying with AS/NZS1170.2-2011 AMDT 2-2016 - Installation Instructions -
Note: The teeth lock washer must be placed next to a 15° rear leg extender to achieve earthing continuity between
from 15° rear leg extender to the 10° rear leg.
Figure 14 Figure 15
Figure 16
Figure 17 Figure 18
Option 2:
Assemble a 15° rear leg extender on a 10° rear leg
before installing it on ECO rail as shown in Figure 16.
The teeth lock washer must be placed for earthing
continuity purpose. Then, fix the assembled 15° rear
leg on ECO rail as shown in Figure 17.
Note: It is important to run visual inspection to
make sure the installations above were properly
done. It is important to check and correct fasteners
torques with torque wrench or similar tool if using
tools without torque setting during installations.

Installation Guide / ComT 2.0: 5°, 10° and 15°
16
Code-Compliant Planning and Installation Guide V1.0 - Complying with AS/NZS1170.2-2011 AMDT 2-2016
- Installation Instructions -
4. MT-rail Cable Tray Installation (optional)
The installation instruction below uses ECO Rail as
an example, the installation instruction using T-rail is
similar.
5.4.1 According to the installation plan and MT-rail
cable tray load vs. span data below, mark fixing
positions of Cable Tray on top of ECO rail.
5.4.2 Insert the Z module with bolt (EZ-Z-STBW) into
the slot hole of Cable Tray for each fixing point, as
shown in Figure 20.
5.4.3 Position the Cable Tray on the top of the ECO
Rail by installing a z module into the top channel as
shown in Figure 21. Leave z module untightened.
5.4.4 Insert the Grounding Clip (EZ-GC-ST) between
Cable Tray and ECO Rail for each fixing point, as
shown in Figure 22.
Note: when using cutter rail (mill finish ECO rail),
grounding clip is not necessary.
Figure 11
Figure 20
Figure 21
Figure 22
Load vs.span data:
LOAD PER METER
2.5m
2.0m
1.5m
1.0m
38 kg
59 kg
106 kg
239 kg
SPAN

Installation Guide / ComT 2.0: 5°, 10° and 15°
17 Code-Compliant Planning and Installation Guide V1.0 - Complying with AS/NZS1170.2-2011 AMDT 2-2016
5.5.1 Place the PV Modules on the Front and Rear Leg as shown in Figure 26. The outside edge of the frame of the PV
Modules must overlap the marking lines on the Front and Rear Legs as shown in Figure 27. The pins of the Front and
Rear legs are used for creating earthing continuity from PV modules to both legs.
Figure 23
Figure 24
Figure 25
Figure 26 Figure 27
Figure 28 Figure 29
5.4.5 Fasten all M8 bolts with the recommended
torque of 15-17N•m.
Note: Check the electrical resistance between the
ECO rail and the cable tray to ensure the bonding is
made.
5.4.6 Align and click MT-rail cable tray cover as
showed in Figure 24.
5.5.2 Fix the clamp on the Rear Leg as shown in
Figure 28. Fasten the clamps of the Front and Rear
legs till the PV Modules are properly installed as
shown in Figure 29. Recommended torques of M8
Bolt:16-20N•m
5. PV Module Installation
- Installation Instructions -

Installation Guide / ComT 2.0: 5°, 10° and 15°
18
Code-Compliant Planning and Installation Guide V1.0 - Complying with AS/NZS1170.2-2011 AMDT 2-2016
Figure 30
Figure 31
Figure 32
Figure 33
Once the grounding lug is attached to the rail,
insert U-Shape Copper Channel into the grounding
lug as shown in Figure 31. Strip earthing cable (the
maximum size is 10 mm2), insert the conductor into
the Copper Channel and tighten the bolt M6*14
with 5~6 N•m to ensure the earthing cable is tight.
Note: Please check the electrical resistance between
the rail and earthing cable conductor to ensure the
bonding is made.
Option 1
Fix the Grounding Lug into the top channel of the
Rail as shown in Figure 32.
Option 2
Fix the Grounding Lug at the side channel of Rail as
shown in Figure 33.
6. Grounding Lug Installation
5.5.3 Repeat the above steps to install other Front
and Rear Legs, and PV modules.
5.5.4 The installers must ensure panel clamps are
installed flush mounted to the panel frame and
apply correct torque value of clamp fastener as
shown in section 4.3.2.
It is required to install one Grounding Lug per row of rail. The recommended fasten torque of the bolt M8*25 is 16~20
N•m.
There are two options for Grounding Lug installation.
- Installation Instructions -

Installation Guide / ComT 2.0: 5°, 10° and 15°
19 Code-Compliant Planning and Installation Guide V1.0 - Complying with AS/NZS1170.2-2011 AMDT 2-2016
Product Warranty
As the manufacturer of quality solar mounting systems, Clenergy Australia provides a warranty for all PV-ezRack®
products it supplies in Australia and New Zealand (“Products”). The warranty provided by Clenergy Australia is subject
to the conditions contained in this document (“Warranty”). No other warranty provision implied or otherwise is to be
assumed. Your Warranty coverage is in accordance with this document. Based on choice of mounting setup, the letters
are appended in their corresponding installation manuals hyperlinked in the table below:
Product Warranty Table for Installations in Corrosivity Category 1, 2, 3, 4 and 5 (ISO 9223)
Product Material
Standard or
Customized
Product
Product Warranty
Corrosivity
Category 1,
2 and 3
Corrosivity
Category 4
Corrosivity
Category 5
1Aluminium
Components
6005CL-T5 mill finish
Standard
10 years
10 years*
6005-T5 anodized to 10 microns
6005-T5 anodized to 15 microns
Customized
10 years
10 years*
6005-T5 anodized to 20 microns 10 years
2Galvanized Steel
Components
Galvanized Steel
at 85 microns in average Standard Not warranted
3Stainless Steel
Components SUS304 Standard
10 years
4Fasteners (bolts/
nuts/washers)
SUS304 Standard
SUS316 Customized
5Screws for Tile
Interface
Carbon Steel SAE 1022 with
Climaseal C3 Rated Finish Standard 10 years**
6Screws for Tin
Interface
Carbon Steel with C3 Rated Finish
Standard
Not warranted
Carbon Steel with C5 Rated Finish 30 years 25 years 10 years
*Subject to interface spacing reduction as advised by Clenergy Australia. Please contact us for more details.
** The screws under tile interface are assumed to be installed in category 1, 2 or 3 micro-climate within the roof
structure.
- Product Warranty -
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