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Clenergy PV-ezRack SolarRoof Series Planning And Installation Manual

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PV-ezRack
SolarRoof™
Code-Compliant Planning and Installation Guide V3.0
Complying with AS/NZS1170.2-2011 AMDT 2-2016

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Summary of Contents for Clenergy PV-ezRack SolarRoof Series

  • Page 1 ® PV-ezRack SolarRoof™ Code-Compliant Planning and Installation Guide V3.0 Complying with AS/NZS1170.2-2011 AMDT 2-2016...

  • Page 2: Table Of Contents

    Installation Manual, which you corrosion between dissimilar metals. This can do by contacting Clenergy Australia via may occur between structures and the building email on sales@clenergy.com.au, or contacting and also between structures, fasteners and PV your local distributor in Australia.

  • Page 3: Planning

    • Some areas are designated Region B (52 m/s). Local authorities will advise if this applies in your area. page of 25 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 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. page of 25 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: Tools &Component List

    End Clamp, Dual 35 or End Clamp, Dual 40 or ECO Rail Splice for ECO Rail 40mm 46mm page of 25 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 Isolator Shade, non- Corrugated Iron Roof with Copper Pipe assembly (Mill Finish) AB-SR/IS/260 Angle Bracket page of 25 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 8: System Overview

    - Tin Roof End Clamp Inter Clamp ECO Rail Tin interface Splice for ECO Rail page of 25 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 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.

  • Page 10: Installation Instruction

    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...
  • Page 11 If grooved tiles are used, it will also be necessary to cut a recess in the lower tile. page of 25 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 Two to three screw turns are adequate for loose installation. ER-I-01 ER-I-02 ER-I-01/EZC/ECO ER-I-51 ER-I-23 ER-I-26 page of 25 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 PV module frame. When installing large modules (e.g. ASE250) M8 x 20 mm bolts must be used. page of 25 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 Inter Clamps and Grounding Clips. Visually check that Grounding Clips are positioned properly. Not Good page of 25 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 Universal Clamp as shown in the figure on the right. Visually check the Universal Clamp and PV module are properly installed. page of 25 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 End Clamp position is 13~14N.m. The recommend torque for Universal Clamps in the Inter Clamp position is 16~20N.m. page of 25 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 Fix the Grounding Lug at the side channel of Rail as shown in the figure on the right. page of 25 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 6 months to meet the warranty conditions of Buildex screws. page of 25 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 19 6 months to meet the warranty conditions of Buildex screws. page of 25 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 WARRANTY CONDITIONS OF BUILDEX The rail is parallel to the Rib of metal SCREWS. sheet roof page of 25 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 Note: When using Isolator Shade (black anodized), please apply External Teeth Lock Washers between Plain washer for earthing continuity. page of 25 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 Z Module in the Rail channel and fix the Isolator Shade with the bolts supplied. Recommended torque for M8 bolts is 4-5 page of 25 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 Rotate up the Cover and fix the Isolator to the Isolator Shade according to the Isolator Installation Guide in the Figure on the right. page of 25 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 - Push the other end of the clip in to the rail channel, using a rubber mallet if required. page of 25 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: 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 26: Certification Letter And

    Certification Letter and Interface Spacing Table page of 25 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              December 2019  Clenergy Australia  1/10 Duerdin Street  Clayton, VIC 3168  CERTIFICATION LETTER      Clenergy PV ez‐Rack Solar Roof Certification – TC2, 2.5, 3 – Wind Region A, B, C, D. Internal REF:  00115. Project REF: CL‐10088‐SM‐REV‐C.    MW  Engineering  Melbourne,  being  Structural  Engineers  within  the  meaning  of  Australian  regulations, have calculated the maximum spacings for the PV ez‐Rack rail system for the following  conditions:    ‐ Wind Loads to AS 1170.2‐2011 AMDT 4‐2016  o Wind Terrain Category 2, 2.5 and 3  o Wind average recurrence of 200 years  o Wind Region A, B, C, D  ‐ Solar panel length up to 2.1m ...
  • Page 28 Australia, and is subject to and issued in connection with the provisions of the agreement between MW Engineering Melbourne and Clenergy Australia. MW Engineering Melbourne accepts no liability or responsibility whatsoever for any use of or reliance upon this report by any third party other than Clenergy's clients. Final Copy 11/12/2019...
  • Page 29 Project: CL-10088-SM-REV-C Client: Clenergy Australia PV-ezRack Engineering Certificate Internal REF: 00115 Client: Clenergy Australia Project: PV ez-Rack SolarRoof Interface Spacing table Australian Standards AS/NZS 1170.0:2002 (R2016) General Principles AS/NZS 1170.1:2002 (R2016) Imposed loadings AS/NZS 1170.2:2011 (R2016) Wind Loadings AS/NZS 1252.2:2016...
  • Page 30 Project: CL-10088-SM-REV-C Client: Clenergy Australia PV-ezRack Engineering Certificate PV ez-Rack SolarRoof Interface spacing Table for Tile Roof Type of Rail ER-R-ECO (ECO Rail) Type of Interface ER-I-01 (Tile Interface) Solar Panel Dimension 2 m x 1 m Terrain Category Roof Angle - 0° < α < 10°...
  • Page 31 Project: CL-10088-SM-REV-C Client: Clenergy Australia PV-ezRack Engineering Certificate PV ez-Rack SolarRoof Interface spacing Table for Tile Roof (Cont.) Type of Rail ER-R-ECO (ECO Rail) ER-I-01 (Tile Interface) Type of Interface Solar Panel Dimension 2 m x 1 m Terrain Category Roof Angle - 30°...
  • Page 32 Project: CL-10088-SM-REV-C Client: Clenergy Australia PV-ezRack Engineering Certificate PV ez-Rack SolarRoof Interface spacing Table for Tile Roof Type of Rail ER-R-ECO (ECO Rail) Type of Interface ER-I-01 (Tile Interface) Solar Panel Dimension 2 m x 1 m Terrain Category Roof Angle - 0° < α < 10°...
  • Page 33 Project: CL-10088-SM-REV-C Client: Clenergy Australia PV-ezRack Engineering Certificate PV ez-Rack SolarRoof Interface spacing Table for Tile Roof (Cont.) Type of Rail ER-R-ECO (ECO Rail) ER-I-01 (Tile Interface) Type of Interface Solar Panel Dimension 2 m x 1 m Terrain Category Roof Angle - 30°...
  • Page 34 Project: CL-10088-SM-REV-C Client: Clenergy Australia PV-ezRack Engineering Certificate PV ez-Rack SolarRoof Interface spacing Table for Tile Roof Type of Rail ER-R-ECO (ECO Rail) Type of Interface ER-I-01 (Tile Interface) Solar Panel Dimension 2 m x 1 m Terrain Category Roof Angle - 0° < α < 10°...
  • Page 35 Project: CL-10088-SM-REV-C Client: Clenergy Australia PV-ezRack Engineering Certificate PV ez-Rack SolarRoof Interface spacing Table for Tile Roof (Cont.) Type of Rail ER-R-ECO (ECO Rail) ER-I-01 (Tile Interface) Type of Interface Solar Panel Dimension 2 m x 1 m Terrain Category Roof Angle - 30°...
  • Page 36 Project: CL-10088-SM-REV-C Client: Clenergy Australia PV-ezRack Engineering Certificate PV ez-Rack SolarRoof Interface spacing Table for Tin Roof Type of Rail ER-R-ECO (ECO Rail) Type of Interface ER-I-05 (Tin Interface) Solar Panel Dimension 2 m x 1 m Terrain Category Purlin Thickness 1.5 mm...
  • Page 37 Project: CL-10088-SM-REV-C Client: Clenergy Australia PV-ezRack Engineering Certificate PV ez-Rack SolarRoof Interface spacing Table for Tin Roof Type of Rail ER-R-ECO (ECO Rail) Type of Interface ER-I-05 (Tin Interface) Solar Panel Dimension 2 m x 1 m Terrain Category Purlin Thickness 1.5 mm...
  • Page 38 Project: CL-10088-SM-REV-C Client: Clenergy Australia PV-ezRack Engineering Certificate PV ez-Rack SolarRoof Interface spacing Table for Tin Roof Type of Rail ER-R-ECO (ECO Rail) Type of Interface ER-I-05 (Tin Interface) Solar Panel Dimension 2 m x 1 m Terrain Category Purlin Thickness 1.5 mm...
  • Page 39 Project: CL-10088-SM-REV-C Client: Clenergy Australia PV-ezRack Engineering Certificate PV ez-Rack SolarRoof Interface spacing Table for Tin Roof Type of Rail ER-R-ECO (ECO Rail) Type of Interface ER-I-05 (Tin Interface) Solar Panel Dimension 2 m x 1 m Terrain Category Purlin Thickness 1.5 mm...
  • Page 40 Project: CL-10088-SM-REV-C Client: Clenergy Australia PV-ezRack Engineering Certificate PV ez-Rack SolarRoof Interface spacing Table for Tin Roof Type of Rail ER-R-ECO (ECO Rail) Type of Interface ER-I-05 (Tin Interface) Solar Panel Dimension 2 m x 1 m Terrain Category Purlin Thickness 1.5 mm...
  • Page 41 Project: CL-10088-SM-REV-C Client: Clenergy Australia PV-ezRack Engineering Certificate PV ez-Rack SolarRoof Interface spacing Table for Tin Roof Type of Rail ER-R-ECO (ECO Rail) Type of Interface ER-I-05 (Tin Interface) Solar Panel Dimension 2 m x 1 m Terrain Category Purlin Thickness 1.5 mm...
  • Page 42 Note 5 This Engineering Document was designed to cater for most common installation scenarios however, it does not cater for all of them. Contact Clenergy if you are unable to comply with any of the installation specifications listed on this document.
  • Page 43 Project: CL-10088-SM-REV-C Client: Clenergy Australia PV-ezRack Engineering Certificate Components Part No. Description ST-Rail ER-R-STXXXX Standard Rail PV-ezRack Splice for Standard Rail Splice ER-SP-ST 200mm Inter Clamp = clamp + Z-Module + Inter Clamp ER-IC-STXX Bolt. End Clamp ER-EC-STXX End Clamp = clamp + Z-Module + bolt...
  • Page 44 For Terrain Category (TC) definition, please refer to clause 4.2.1 of AS/NZS 1170.2:2011 (R2016). Note 8 The installed frame must comply with the clamping zone of the PV Panel. Note 9 Capacities checked and compared against testing data from Clenergy Australia and MTS (NATA certified). Final Copy 11/12/2019...
  • Page 45 No consideration has been taken on the effect that the solar panel will have over the roof structure. It has been assumed that the roof will be able to resist the additional loadings imposed by the installation of the solar panels in conjunction with the Clenergy Mounting System.
  • Page 46 Project: CL-10088-SM-REV-C Client: Clenergy Australia PV-ezRack Engineering Certificate General conditions Note 18 Note 18.1 Minimum grade for steel purlins/battens of 450 Mpa. Note 18.2 Timber Grade members: F7 (Pine) and F17 (Hardwood). Note 18.3 If any of the screws of the interfaces go into pre‐existing holes, they will have to be one size  up compared to the screws that were previously installed. This is to ensure that the pullout  capacity remains the same or higher. Spacings on Tile Interfaces will be reduced as follows:...
  • Page 47 Project: CL-10088-SM-REV-C Client: Clenergy Australia PV-ezRack Engineering Certificate Conditions for flush mounted systems installed on flat and pitched roofs according to the D6 Note 25 Appendix of the AS/NZS 1170.2:2011 (R2016). Roof pitch to be between 1° and 30°. h/d < 0.5 and h/b < 0.5. Being h= height, b= width and d= length of the building as per the below picture.
  • Page 48 Project: CL-10088-SM-REV-C Client: Clenergy Australia PV-ezRack Engineering Certificate Roof Pitch < 10° Roof Pitch > 10° Flat/Mono – Slope Roof < 10° Flat/Mono – Slope Roof > 10° Internal = Central Intermediate = Up Wind End and Down Wind End...
  • Page 49 Tel: +66 63 228 0200, +66 81 969 5152 Australia E-mail: sales_th@clenergy.com,support_th@clenergy.com Clenergy Singapore 24 Raffles Place #28-01 Clifford Centre Singapore 048621 Tel: +65 9743 1425 E-mail: vincent.chan@clenergy.com Warranty Clenergy Vietnam Tel: +86 592 3110095 Clenergy Installation Guide PV-ezRack SolarRoof 202001 E-mail: sales_vietnam@clenergy.com; susie.chen@clenergy.com; ducnguyen@clenergy.com...