Clenergy PV-ezRack SolarRoof Series Manual técnico
PV-ezRack®SolarRoof™
Code-Compliant Planning and Installation Guide V3.0
Complying with AS/NZS1170.2-2011 AMDT 2-2016
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
01page of 25
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 sales@clenergy.com.au, 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
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
02page of 25
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
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
03page of 25
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
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
04page of 25
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
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
05page of 25
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
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
06page of 25
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
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
07page of 25
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
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
08page of 25
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.
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
09page of 25
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.
Tabla de contenidos
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