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Clenergy PV-ezRack SolarRoof Installation Manual

Tilt legs
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PV-ezRack
SolarRoof
Tilt Legs
Installation Guide
Code-Compliant Planning and Installation Guide V4.0
Complying with AS/NZS1170.2-2011 AMDT 2-2016

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Summary of Contents for Clenergy PV-ezRack SolarRoof

  • Page 1 ® PV-ezRack SolarRoof Tilt Legs Installation Guide Code-Compliant Planning and Installation Guide V4.0 Complying with AS/NZS1170.2-2011 AMDT 2-2016...

  • Page 2: Table Of Contents

    This version of the Installation Manual, which you may occur between structures and the building can do by contacting Clenergy Australia via and also between structures, fasteners and PV email on sales@clenergy.com.au, or contacting modules, as detailed in AS/NZS 5033: 2014.

  • Page 3: Planning

    • Some areas are designated Region B (52 m/s). Local authorities will advise if this applies in your area. page of 55 Unit 1, 10 Duerdin St, Clayton VIC 3168, Australia Tel: +61 3 9239 8088 Fax: +61 3 9239 8024 E-mail: tech@clenergy.com.au www.clenergy.com.au...
  • Page 4 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.
  • Page 5 30-60° adjutable tilt legs is certified for reverse tilt installation on the south facing roof. Please refer to Certification Letter and Tilt Legs Spacing Table. page of 55 Unit 1, 10 Duerdin St, Clayton VIC 3168, Australia Tel: +61 3 9239 8088 Fax: +61 3 9239 8024 E-mail: tech@clenergy.com.au www.clenergy.com.au...
  • Page 6 0.2 × length of the building and 0.2 × width of the building Step 5: The lowest value in step 4, equates to a. page of 55 Unit 1, 10 Duerdin St, Clayton VIC 3168, Australia Tel: +61 3 9239 8088 Fax: +61 3 9239 8024 E-mail: tech@clenergy.com.au www.clenergy.com.au...
  • Page 7 2. Rear leg adjustable range: ER-TL-10/15: 260-375 mm; ER-TL-15/30: 390-635 mm; ER-TL-30/60: 675-1205 3. If the info. is different from the table and diagram, it could have different results. Please contact the Clenergy to confirm its applicability. page of 55...
  • Page 8 Planning page of 55 Unit 1, 10 Duerdin St, Clayton VIC 3168, Australia Tel: +61 3 9239 8088 Fax: +61 3 9239 8024 E-mail: tech@clenergy.com.au www.clenergy.com.au...
  • Page 9 Planning page of 55 Unit 1, 10 Duerdin St, Clayton VIC 3168, Australia Tel: +61 3 9239 8088 Fax: +61 3 9239 8024 E-mail: tech@clenergy.com.au www.clenergy.com.au...
  • Page 10 Planning page of 55 Unit 1, 10 Duerdin St, Clayton VIC 3168, Australia Tel: +61 3 9239 8088 Fax: +61 3 9239 8024 E-mail: tech@clenergy.com.au www.clenergy.com.au...
  • Page 11 Planning (10) page of 55 Unit 1, 10 Duerdin St, Clayton VIC 3168, Australia Tel: +61 3 9239 8088 Fax: +61 3 9239 8024 E-mail: tech@clenergy.com.au www.clenergy.com.au...
  • Page 12 Planning (11) (12) page of 55 Unit 1, 10 Duerdin St, Clayton VIC 3168, Australia Tel: +61 3 9239 8088 Fax: +61 3 9239 8024 E-mail: tech@clenergy.com.au www.clenergy.com.au...
  • Page 13 Planning (13) (14) page of 55 Unit 1, 10 Duerdin St, Clayton VIC 3168, Australia Tel: +61 3 9239 8088 Fax: +61 3 9239 8024 E-mail: tech@clenergy.com.au www.clenergy.com.au...
  • Page 14 Planning (15) page of 55 Unit 1, 10 Duerdin St, Clayton VIC 3168, Australia Tel: +61 3 9239 8088 Fax: +61 3 9239 8024 E-mail: tech@clenergy.com.au www.clenergy.com.au...

  • Page 15: Tools & Components

    ER-TL-10/PS Grounding Lug Grounding Clip Adjustable Tilt Legs with L-feet, Fixed Tilt Legs, preassembly preassembly page of 55 Unit 1, 10 Duerdin St, Clayton VIC 3168, Australia Tel: +61 3 9239 8088 Fax: +61 3 9239 8024 E-mail: tech@clenergy.com.au www.clenergy.com.au...

  • Page 16: System Overview

    ③ Grounding Clip ④ ECO Rail ⑤ Grounding Lug ⑥ Adjustable Tilt Legs with L-feet page of 55 Unit 1, 10 Duerdin St, Clayton VIC 3168, Australia Tel: +61 3 9239 8088 Fax: +61 3 9239 8024 E-mail: tech@clenergy.com.au www.clenergy.com.au...
  • Page 17 (4) In some cases, fasteners could be seized over time. As an option, if want to avoid galling or seizing of thread, apply lubricant (grease or 40# engine oil) to fasteners prior to tightening. page of 55 Unit 1, 10 Duerdin St, Clayton VIC 3168, Australia Tel: +61 3 9239 8088 Fax: +61 3 9239 8024 E-mail: tech@clenergy.com.au www.clenergy.com.au...
  • Page 18 Please refer to safe torques defined in this guide as shown in the figure below. If 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.

  • Page 19: Installation Instruction

    Figure 2 Front Leg Installation with Single Screw Figure 3 Tin Foot Front Leg Installation page of 55 Unit 1, 10 Duerdin St, Clayton VIC 3168, Australia Tel: +61 3 9239 8088 Fax: +61 3 9239 8024 E-mail: tech@clenergy.com.au www.clenergy.com.au...
  • Page 20 Figure 6 Non-preassembly Rear Leg Installation with Single Screw Figure 7 Preassembly Rear Leg Installation with Two Screws page of 55 Unit 1, 10 Duerdin St, Clayton VIC 3168, Australia Tel: +61 3 9239 8088 Fax: +61 3 9239 8024 E-mail: tech@clenergy.com.au www.clenergy.com.au...
  • Page 21 FREQUENT RAIN SHOULD BE WASHED DOWN WITH FRESH WATER AT LEAST EVERY 6 MONTHS TO MEET THE WARRANTY CONDITIONS OF BUILDEX SCREWS. page of 55 Unit 1, 10 Duerdin St, Clayton VIC 3168, Australia Tel: +61 3 9239 8088 Fax: +61 3 9239 8024 E-mail: tech@clenergy.com.au www.clenergy.com.au...
  • Page 22 Figure 13, 14 and 15. Recommended torque for M8 bolts is 16~20 N·m Figure 13 Figure 14 Figure 15 page of 55 Unit 1, 10 Duerdin St, Clayton VIC 3168, Australia Tel: +61 3 9239 8088 Fax: +61 3 9239 8024 E-mail: tech@clenergy.com.au www.clenergy.com.au...
  • Page 23 End Clamps. Then fasten lightly with Figure 19 the Allen Key as shown in Figure 19 and 20. Figure 20 page of 55 Unit 1, 10 Duerdin St, Clayton VIC 3168, Australia Tel: +61 3 9239 8088 Fax: +61 3 9239 8024 E-mail: tech@clenergy.com.au www.clenergy.com.au...
  • Page 24 Figure 25. Figure 25 page of 55 Unit 1, 10 Duerdin St, Clayton VIC 3168, Australia Tel: +61 3 9239 8088 Fax: +61 3 9239 8024 E-mail: tech@clenergy.com.au www.clenergy.com.au...
  • Page 25 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. page of 55 Unit 1, 10 Duerdin St, Clayton VIC 3168, Australia Tel: +61 3 9239 8088 Fax: +61 3 9239 8024 E-mail: tech@clenergy.com.au www.clenergy.com.au...
  • Page 26 Fix the Grounding Lug at the side channel of Rail as shown in the figure on the right. Figure 33 page of 55 Unit 1, 10 Duerdin St, Clayton VIC 3168, Australia Tel: +61 3 9239 8088 Fax: +61 3 9239 8024 E-mail: tech@clenergy.com.au www.clenergy.com.au...

  • Page 27: Warranty

    Clenergy’s written installation instructions, or if the Product has been modified, repaired, or reworked in a manner not previously authorized by Clenergy IN WRITING, or if the Product is installed in an environment for which it was not designed. Clenergy shall not be liable for consequential, contingent or incidental damages arising out of the use of the Product by Purchaser under any circumstances.

  • Page 28: Certification Letter And Tilt Legs

    Certification Letter and Tilt Legs Spacing Table (Two Screws) page of 55 Unit 1, 10 Duerdin St, Clayton VIC 3168, Australia Tel: +61 3 9239 8088 Fax: +61 3 9239 8024 E-mail: tech@clenergy.com.au www.clenergy.com.au...
  • Page 29 SolarRoof Adjustable Tilt Legs installation within Australia. The design check has been based on the information in the PV-ezRack SolarRoof Adjustable Tilt Legs_Code Compilant Installation Guide_AU_V3.3 and schematic drawings of the system components by Clenergy (Xiamen) Technology Co. Ltd, provided by Clenergy Australia.
  • Page 30 According to AS 1170.2011 for all wind regions with ECO-Rails Within Australia Terrain Category 2 For: Clenergy Australia Job Number: 2078 Date: 25 February 2016 COPYRIGHT: The concepts and information contained in this document are the property of Gamcorp (Melbourne) Pty Ltd.
  • Page 31 Fax: 03 9802 9125 melbourne@gamcorp.com.au Client Name www.gamcorp.com.au ISO 9001:2008 Registered Firm Certificate No: AU1222 Job No: 2078 Client: Clenergy Australia Project: PV-ezRack ® SolarRoof Adjustable Tilt Legs Spacing Table Address: Within Australia Australian Standards AS 1170. 2011 – Structural Design Actions Part 0 –...
  • Page 32 Client: Clenergy Australia Job: 2078 Project: Date: PV-ezRack ® SolarRoof Adjust. Tilt Legs Spacing Table Feb-16 Address: Within Australia Designed: M.A REV K PV-ezRack ® SolarRoof Frame spacing Table for Adjustable Tilt Leg Type of Rail ER-R-ECO Type of Interface...
  • Page 33 Client: Clenergy Australia Job: 2078 Project: Date: PV-ezRack ® SolarRoof Adjust. Tilt Legs Spacing Table Feb-16 Address: Within Australia Designed: REV K PV-ezRack ® SolarRoof Frame spacing Table for Adjustable Reverse Tilt Leg Type of Rail ER-R-ECO Type of Interface...
  • Page 34 Client: Clenergy Australia Job: 2078 Project: PV-ezRack ® SolarRoof Adjust. Tilt Legs Spacing Table Date: Feb-16 Address: Within Australia Designed: REV K General Notes Note 1 Screws minimum embedment length into timber 35 mm Note 2 Recommended screws Metal Purlins/Battens Fasteners to use 0.55 mm –...
  • Page 35 According to AS 1170.2011 for all wind regions with ECO-Rails Within Australia Terrain Category 3 For: Clenergy Australia Job Number: 2078 Date: 25 February 2016 COPYRIGHT: The concepts and information contained in this document are the property of Gamcorp (Melbourne) Pty Ltd.
  • Page 36 Fax: 03 9802 9125 melbourne@gamcorp.com.au Client Name www.gamcorp.com.au ISO 9001:2008 Registered Firm Certificate No: AU1222 Job No: 2078 Client: Clenergy Australia Project: PV-ezRack ® SolarRoof Adjustable Tilt Legs Spacing Table Address: Within Australia Australian Standards AS 1170. 2011 – Structural Design Actions Part 0 –...
  • Page 37 Client: Clenergy Australia Job: 2078 PV-ezRack ® SolarRoof Adjust. Tilt Legs Spacing Table Project: Date: Feb-16 Address: Within Australia Designed: REV K PV-ezRack ® SolarRoof Frame spacing Table for Adjustable Tilt Leg Type of Rail ER-R-ECO Type of Interface ER-TL (Adjustable Tilt Leg)
  • Page 38 Client: Clenergy Australia Job: 2078 PV-ezRack ® SolarRoof Adjust. Tilt Legs Spacing Table Project: Date: Feb-16 Address: Within Australia Designed: REV K PV-ezRack ® SolarRoof Frame spacing Table for Adjustable Reverse Tilt Leg Type of Rail ER-R-ECO Type of Interface...
  • Page 39 Client: Clenergy Australia Job: 2078 PV-ezRack ® SolarRoof Adjust. Tilt Legs Spacing Table Project: Date: Feb-16 Address: Within Australia Designed: REV K General Notes Note 1 Screws minimum embedding length into timber 35 mm Note 2 Recommended screws Metal Purlins/Battens Fasteners to use 0.55 mm –...
  • Page 40 Gamcorp (Melbourne) Pty Ltd A.C.N 141 076 904 A.B.N 73 015 060 240 www.gamcorp.com.au melbourne@gamcorp.com.au Suite 4, 346 Ferntree Gully Rd, Notting Hill VIC 3168 Tel: 03 9543 2211 Fax: 03 9543 4046 Definition of Roof Zones 1. For flush mounted systems installed on a pitched roof Conditions: a.
  • Page 41 Gamcorp (Melbourne) Pty Ltd A.C.N 141 076 904 A.B.N 73 015 060 240 www.gamcorp.com.au melbourne@gamcorp.com.au Suite 4, 346 Ferntree Gully Rd, Notting Hill VIC 3168 Tel: 03 9543 2211 Fax: 03 9543 4046 2. For flush mounted systems installed on a pitched roof Conditions: a.
  • Page 42 Gamcorp (Melbourne) Pty Ltd A.C.N 141 076 904 A.B.N 73 015 060 240 www.gamcorp.com.au melbourne@gamcorp.com.au Suite 4, 346 Ferntree Gully Rd, Notting Hill VIC 3168 Tel: 03 9543 2211 Fax: 03 9543 4046 3. For tilt array systems Condition: a. For pitched roofs where roof angle is between 1˚ and 45˚. In the front figure h= height, b =width and d= length of the building.

  • Page 43: Certification Letter And Tilt Legs

    Certification Letter and Tilt Legs Spacing Table (One Screw) page page of 55 Unit 1, 10 Duerdin St, Clayton VIC 3168, Australia Tel: +61 3 9239 8088 Fax: +61 3 9239 8024 E-mail: tech@clenergy.com.au www.clenergy.com.au...
  • Page 44 Building Regulations, have carried out a structural design check of PV-ezRack ® SolarRoof Adjustable Tilt Legs installation within Australia and New Zealand. The design check has been based on the information in the PV-ezRack SolarRoof Adjustable Tilt Legs_Code Compilant Installation Guide_AU_V3.3 and schematic drawings and test reports of the system components by Clenergy (Xiamen) Technology Co.
  • Page 45 Gamcorp (Melbourne) Pty Ltd A.C.N 141 076 904 A.B.N 73 015 060 240 www.gamcorp.com.au Email: melbourne@gamcorp.com.au Suite 4, 346 Ferntree Gully Rd, Notting Hill VIC 3149. Tel: 03 9543 2211 Fax: 03 9543 4046 The certification excludes assessment of roof structure and PV panels •...
  • Page 46 Consulting Structural & Civil Engineers A.C.N 141 076 904 A.B.N 73 015 060 240 www.gamcorp.com.au melbourne@gamcorp.com.au Structural Design Documentation PV-ezRack SolarRoof Adjustable Tilt Legs Spacing Table According to AS 1170.2-2011 Amdt 3-2013 With ECO-Rail Within Australia & New Zealand Terrain Category 2&3 For:...
  • Page 47 Certificate No: AU1222 Job No: 2597 Client: Clenergy Australia Project: PV-ezRack SolarRoof Adjustable Tilt Legs Spacing Table Address: Within Australia & New Zealand Australian Standards AS/NZS 1170. 2011 – Structural Design Actions Part 0 – General Principles Part 1 – Permanent imposed and other actions Part 2 –...
  • Page 48 2597 Clenergy Australia Client: Job: Date: Aug-16 PV-ezRack SolarRoof Adjustable Tilt Legs Spacing Table Project: Within Australia & New Zealand Address: Designed: Checked: PV-ezRack SolarRoof Adjustable Tilt Legs Spacing Table Type of Rail ER-R-ECO Type of Interface ER-TL-10/15, ER-TL-15/30, ER-TL-30/60 Solar Panel Dimension 1.67m x 1m...
  • Page 49 PV-ezRack SolarRoof Adjustable Tilt Legs Spacing Table Type of Rail ER-R-ECO Type of Interface ER-TL-10/15, ER-TL-15/30, ER-TL-30/60 Solar Panel Dimension 1.67m x 1m Terrain category Tilt Angle to Roof 31° -60° Roof Angle (Φ) – ≤10° Building Height – H (m)
  • Page 50 PV-ezRack SolarRoof Adjustable Tilt Legs Spacing Table Type of Rail ER-R-ECO Type of Interface ER-TL-10/15, ER-TL-15/30, ER-TL-30/60 Solar Panel Dimension 1.67m x 1m Terrain category Tilt Angle to Roof 10° -15° Roof Angle (Φ) – ≤10° Building Height – H (m)
  • Page 51 PV-ezRack SolarRoof Adjustable Tilt Legs Spacing Table Type of Rail ER-R-ECO Type of Interface ER-TL-10/15, ER-TL-15/30, ER-TL-30/60 Solar Panel Dimension 1.67m x 1m Terrain category Tilt Angle to Roof 31° -60° Roof Angle (Φ) – ≤10° Building Height – H (m)
  • Page 52 2597 Clenergy Australia Client: Job: Date: Aug-16 PV-ezRack SolarRoof Adjustable Tilt Legs Spacing Table Project: Within Australia & New Zealand Address: Designed: Checked: PV-ezRack SolarRoof Adjustable Tilt Legs Spacing Table Type of Rail ER-R-ECO Type of Interface ER-TL-10/15, ER-TL-15/30, ER-TL-30/60...
  • Page 53 PV-ezRack SolarRoof Adjustable Tilt Legs Spacing Table Type of Rail ER-R-ECO Type of Interface ER-TL-10/15, ER-TL-15/30, ER-TL-30/60 Solar Panel Dimension 2m x 1m Terrain category Tilt Angle to Roof 31° -60° Roof Angle (Φ) – ≤10° Building Height – H (m)
  • Page 54 PV-ezRack SolarRoof Adjustable Tilt Legs Spacing Table Type of Rail ER-R-ECO Type of Interface ER-TL-10/15, ER-TL-15/30, ER-TL-30/60 Solar Panel Dimension 2m x 1m Terrain category Tilt Angle to Roof 10° -15° Roof Angle (Φ) – ≤10° Building Height – H (m)
  • Page 55 PV-ezRack SolarRoof Adjustable Tilt Legs Spacing Table Type of Rail ER-R-ECO Type of Interface ER-TL-10/15, ER-TL-15/30, ER-TL-30/60 Solar Panel Dimension 2m x 1m Terrain category Tilt Angle to Roof 31° -60° Roof Angle (Φ) – ≤10° Building Height – H (m)
  • Page 56 General Notes Note 1 Screws minimum embedment length into timber 35 mm Note 2 Recommended screws Metal Purlins/Battens Fasteners to use 0.55 mm – 1.5 mm M6-11 TPI RoofZips 1.9 mm M6-11 TPI RoofZips OR 14g-10 TPI Teks screws 2.4 mm and Above 14g-10 TPI Teks screws Wood purlins and Rafter Fasteners to use...
  • Page 57 Tel: +66 63 228 0200, +66 81 969 5152 E-mail: sales_th@clenergy.com,support_th@clenergy.com Australia Clenergy Singapore 24 Raffles Place #28-01 Clifford Centre Singapore 048621 Tel: +65 9743 1425 E-mail: vincent.chan@clenergy.com Clenergy Vietnam Warranty Tel: +86 592 3110095 E-mail: sales_vietnam@clenergy.com; Clenergy Installation Guide PV-ezRack SolarRoof Adjustable Tilt Leg 202004 susie.chen@clenergy.com; ducnguyen@clenergy.com...