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Clenergy PV-ezRack SolarRoof Code-Compliant Planning And Installation Manual

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PV-ezRack
SolarRoof™
Code-Compliant Planning and Installation Guide V4.1
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™ Code-Compliant Planning and Installation Guide V4.1 Complying with AS/NZS1170.2-2011 AMDT 2-2016...

  • Page 2: Table Of Contents

    Installation Manual, which you can do by contacting Clenergy Australia via email on sales@clenergy.com.au, or contacting your local distributor in Australia. Installation Guide_PV-ezRack SolarRoof (September 2020)

  • Page 3: Planning

    Local authorities will advise if this applies in your area. Installation Guide_PV-ezRack SolarRoof (September 2020) page of 32 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 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.
  • Page 6 SCO-ECO/380 Side Channel Cover for ECO- Rail, length 380 mm Installation Guide_PV-ezRack SolarRoof (September 2020) page of 32 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 Tin Interface with Curved ezClick connection Base for Corrugated Roof Installation Guide_PV-ezRack SolarRoof (September 2020) page of 32 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 PV-ezRack Grounding Lug Isolator Shade, non- with Copper Pipe assembly (Mill Finish) Installation Guide_PV-ezRack SolarRoof (September 2020) page of 32 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: System Overview

    System Overview 4. System Overview 4.1 Overview of PV-ezRack SolarRoof - Tile Roof End Clamp Inter Clamp Tile interface Splice for ECO Rail ECO Rail - Tin Roof End Clamp Inter Clamp ECO Rail Tin interface Splice for ECO Rail...
  • Page 10 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 11: 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 12 5.1.3 The roof hook must not press against the roof tile. If necessary, pack the roof hook with max pack height of 17 mm for Clenergy provided Buildex 50 mm long screw, with max pack height of 35 mm for Clenergy provided Buildex 65 mm long screw.
  • Page 13 2 earthing lugs Recommended torque is 10 ~12 Nm. Installation Guide_PV-ezRack SolarRoof (September 2020) page of 32 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 See the figures below. ER-I-41/EZC/ECO ER-I-61/EZC/ECO Installation Guide_PV-ezRack SolarRoof (September 2020) page of 32 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 (e.g. ASE250) M8 x 20 mm bolts must be used. Installation Guide_PV-ezRack SolarRoof (September 2020) page of 32 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 Clips. Visually check that Grounding Clips are positioned properly. Not Good Installation Guide_PV-ezRack SolarRoof (September 2020) page of 32 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 Visually check the Universal Clamp and PV module are properly installed. Installation Guide_PV-ezRack SolarRoof (September 2020) page of 32 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 The recommend torque for Universal Clamps in the Inter Clamp position is 16~20N·m. Installation Guide_PV-ezRack SolarRoof (September 2020) page of 32 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 Fix the Grounding Lug at the side channel of Rail as shown in the figure on the right. Installation Guide_PV-ezRack SolarRoof (September 2020) page of 32 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 6 months to meet the warranty conditions of Buildex screws. Installation Guide_PV-ezRack SolarRoof (September 2020) page of 32 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 6 months to meet the warranty conditions of Buildex screws. Installation Guide_PV-ezRack SolarRoof (September 2020) page of 32 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 The rail is parallel to the Rib of metal SCREWS. sheet roof Installation Guide_PV-ezRack SolarRoof (September 2020) page of 32 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 For some installations, it needs to drill through two tiles (overlap) to reach the purlin; Installation Guide_PV-ezRack SolarRoof (September 2020) page of 32 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 5.6.1.6 Screw out the top nut of hanger bolt, connect and adjust tin foot position and tighten the top nut with the recommended torque of 16~20 N·m. Installation Guide_PV-ezRack SolarRoof (September 2020) page of 32 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 3) The roof sheet should not have visible deformation after hanger bolt installation. Installation Guide_PV-ezRack SolarRoof (September 2020) page of 32 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 2) The roof sheet should not have visible deformation after hanger bolt installation. Installation Guide_PV-ezRack SolarRoof (September 2020) page of 32 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 Follow sections 5.2 and 5.3 to install the Rails and PV Modules. Installation Guide_PV-ezRack SolarRoof (September 2020) page of 32 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 28 Follow sections 5.2 and 5.3 to install the Rails and PV Modules. Installation Guide_PV-ezRack SolarRoof (September 2020) page of 32 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 External Teeth Lock Washers between Plain washer for earthing continuity. Installation Guide_PV-ezRack SolarRoof (September 2020) page of 32 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 30 Isolator Shade with the bolts supplied. Recommended torque for M8 bolts is 4-5 N·m. Installation Guide_PV-ezRack SolarRoof (September 2020) page of 32 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 31 Isolator Shade according to the Isolator Installation Guide in the Figure on the right. Installation Guide_PV-ezRack SolarRoof (September 2020) page of 32 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 32 - Push the other end of the clip in to the rail channel, using a rubber mallet if required. Installation Guide_PV-ezRack SolarRoof (September 2020) page of 32 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 33: Certification Letter And

    Certification Letter and Interface Spacing Table Installation Guide_PV-ezRack SolarRoof (September 2020) page of 32 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 34             30 August 2020  Clenergy Australia  1/10 Duerdin Street  Clayton, VIC 3168  CERTIFICATION LETTER      Clenergy PV‐ezRack Solar Roof Certification – TC2, 2.5, 3 – Wind Region A, B, C, D. Internal REF: 00115.  Project REF: CL‐10088‐SM‐REV‐G.    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 2.2m ...
  • Page 35 MW Engineering Melbourne constitutes an infringement in copyright. Limitation: This report has been prepared for the exclusive use of Clenergy Australia, and is subject to and issued in connection with the provisions of the agreement between MW Engineering Melbourne and Clenergy Australia.
  • Page 36 Internal REF: 00115 Client: Clenergy Australia Project: PV-ezRack SolarRoof tin and tile flush interface spacing tables 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 1664.1:1997-Amdt 1:1999 Aluminium Wind Terrain Category: 2, 2.5 & 3...
  • Page 37 Contents ER-I-01 - T.C 2 ................................4 ER-I-01 - T.C 2.5 ................................. 6 ER-I-01 - T.C 3 ................................8 ER-I-05 - T.C 2 ................................10 ER-I-05 - T.C 2.5 ............................... 12 ER-I-05 - T.C 3 ................................14 General Notes ............................... 16 Standard screws shipped for tin and tile roof interfaces ................
  • Page 38 PV-ezRack SolarRoof Interface spacing tables Type of Rail ER-R-ECO (Refer to Note 7 for other compatible rails) Type of Interface ER-I-01 (Tile Interface) Solar Panel Dimension 2 m x 1 m (Refer to Note 13 for other panel sizes) Terrain Category Roof Angle - 0°...
  • Page 39 PV-ezRack SolarRoof Interface spacing tables (Cont.) Type of Rail ER-R-ECO (Refer to Note 7 for other compatible rails) Type of Interface ER-I-01 (Tile Interface) Solar Panel Dimension 2 m x 1 m (Refer to Note 13 for other panel sizes) Terrain Category Roof Angle - 30°...
  • Page 40 PV-ezRack SolarRoof Interface spacing tables Type of Rail ER-R-ECO (Refer to Note 7 for other compatible rails) Type of Interface ER-I-01 (Tile Interface) Solar Panel Dimension 2 m x 1 m (Refer to Note 13 for other panel sizes) Terrain Category Roof Angle - 0°...
  • Page 41 PV-ezRack SolarRoof Interface spacing tables (Cont.) Type of Rail ER-R-ECO (Refer to Note 7 for other compatible rails) Type of Interface ER-I-01 (Tile Interface) Solar Panel Dimension 2 m x 1 m (Refer to Note 13 for other panel sizes) Terrain Category Roof Angle - 30°...
  • Page 42 PV-ezRack SolarRoof Interface spacing tables Type of Rail ER-R-ECO (Refer to Note 7 for other compatible rails) Type of Interface ER-I-01 (Tile Interface) Solar Panel Dimension 2 m x 1 m (Refer to Note 13 for other panel sizes) Terrain Category Roof Angle - 0°...
  • Page 43 PV-ezRack SolarRoof Interface spacing tables (Cont.) Type of Rail ER-R-ECO (Refer to Note 7 for other compatible rails) Type of Interface ER-I-01 (Tile Interface) Solar Panel Dimension 2 m x 1 m (Refer to Note 13 for other panel sizes) Terrain Category Roof Angle - 30°...
  • Page 44 PV-ezRack SolarRoof Interface spacing tables Type of Rail ER-R-ECO (Refer to Note 7 for other compatible rails) Type of Interface ER-I-05 (Tin Interface) Solar Panel Dimension 2 m x 1 m (Refer to Note 13 for other panel sizes) Terrain Category Roof Angle - 0°...
  • Page 45 PV-ezRack SolarRoof Interface spacing tables (Cont.) Type of Rail ER-R-ECO (Refer to Note 7 for other compatible rails) Type of Interface ER-I-05 (Tin Interface) Solar Panel Dimension 2 m x 1 m (Refer to Note 13 for other panel sizes) Terrain Category Roof Angle - 30°...
  • Page 46 PV-ezRack SolarRoof Interface spacing tables Type of Rail ER-R-ECO (Refer to Note 7 for other compatible rails) Type of Interface ER-I-05 (Tin Interface) Solar Panel Dimension 2 m x 1 m (Refer to Note 13 for other panel sizes) Terrain Category Roof Angle - 0°...
  • Page 47 PV-ezRack SolarRoof Interface spacing tables (Cont.) Type of Rail ER-R-ECO (Refer to Note 7 for other compatible rails) Type of Interface ER-I-05 (Tin Interface) Solar Panel Dimension 2 m x 1 m (Refer to Note 13 for other panel sizes) Terrain Category Roof Angle - 30°...
  • Page 48 PV-ezRack SolarRoof Interface spacing tables Type of Rail ER-R-ECO (Refer to Note 7 for other compatible rails) Type of Interface ER-I-05 (Tin Interface) Solar Panel Dimension 2 m x 1 m (Refer to Note 13 for other panel sizes) Terrain Category Roof Angle - 0°...
  • Page 49 PV-ezRack SolarRoof Interface spacing tables (Cont.) Type of Rail ER-R-ECO (Refer to Note 7 for other compatible rails) Type of Interface ER-I-05 (Tin Interface) Solar Panel Dimension 2 m x 1 m (Refer to Note 13 for other panel sizes) Terrain Category Roof Angle - 30°...
  • Page 50 General Notes Note 1. Tile Roof Interface Spacing tables based on a minimum depth into F7 (Pine) timber of 25mm and Tin Roof Interface Spacing tables based on a minimum depth into F7 (Pine) timber of 35mm and Steel Purlins G450 1.5mm thick. Note 2.
  • Page 51 Note 6. 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 52 Description ER-I-01, 02, 04, 23, 26 Interface Tile Interface and 51 Interface ER-I-01/CS Carbon Steel Tile Interface Tile Interface with PV-ezRack SolarRoof, Tile Interface ezClick connection for ER-I-01/EZC/ECO with ezClick connection for ECO-Rail ECO-Rail Interface ER-I-05 Tin Interface Black Interface...
  • Page 53 Components Part No. Description Adapter for Adapted for Corrugated Iron Roof EZ-AD-C43 Corrugated Roof for Tin interface ER-I-05 Black Adapter for Corrugated Roof Black Adapted for Corrugated Iron EZ-AD-C43/BA Roof for Tin interface ER-I-05 PV-ezRack Adapter for Corrugated Corrugated Adapter EZ-AD-C110 Iron Roof.
  • Page 54 (R2016). Note 9. The installed frame must comply with the clamping zone of the PV Panel. Note 10. Capacities checked and compared against testing data from Clenergy Australia and MTS (NATA certified). Note 11. Maximum permitted rail overhang of 40%.
  • Page 55 Clenergy mounting system. Note 19. Neither Clenergy nor MW Engineering Melbourne are not to be responsible for external factors leading to compression of the tile interfaces.
  • Page 56 Note 29. Conditions for flush mounted systems installed on flat and pitched roofs according to the D6 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 57 Roof Pitch < 10° Roof Pitch > 10° Flat/Mono – Slope Roof < 10° August 2020 | Page 23...
  • Page 58 ER-HB-8/150 and ER-HB-10/200A. The Hanger Bolt for metal purlin/rafter is ER-HB- MP/8/150EP. Note 36. Neither Clenergy nor MW Engineering Melbourne will be responsible for the integrity of the roof tiles when using hanger bolts for the solar installation. It will be the clients' responsibility to check the hanger bolt installation feasibility.
  • Page 59 Tel: +81 45 228 8226 Fax: +81 45 228 8316 E-mail: sales@clenergy.co.jp Worldwide Network www.clenergy.jp Clenergy Philippines 145 Yakal St., San Antonio village, Makati City, Philippines Tel: +63 977 8407240 E-mail: sales_ph@clenergy.com www.clenergy.ph Germany Japan South Korea China Thailand Philippines Vietnam Singapore Australia Clenergy Installation Guide_PV-ezRack SolarRoof (September 2020)