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Clenergy PV-ezRACK SolarRoof Installation Manual

Penetrative tilt legs
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Penetrative Tilt Legs
Code-Compliant Planning and Installation Guide V 6.0
Complying with AS/NZS 1170.2:2021
Last Updated - Nov. 2022

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Summary of Contents for Clenergy PV-ezRACK SolarRoof

  • Page 1 Penetrative Tilt Legs Code-Compliant Planning and Installation Guide V 6.0 Complying with AS/NZS 1170.2:2021 Last Updated - Nov. 2022...

  • Page 2: Table Of Contents

    Installation Guide / SolarRoof Tilt Legs Introduction The installer is solely responsible for: The Clenergy PVezRack® SolarRoof Tilt Legs has been developed as a universal PV-mounting system for roof-mounting on pitched and flat roofs. The use of • Complying with all applicable local or national...

  • Page 3: Planning

    Installation Guide / SolarRoof Tilt Legs Planning Determine the wind region of your installation site Wind Regions – Australia Wind regions are pre-defined for the whole of Australia by the Australian Standard 1170.2:2021. Comparing to 1170.2:2011, 2021 version has a lot of changes in wind regions. •...
  • Page 4 Terrain Category 4 (TC4) – Terrain with numerous large, high (10 m to 30 m tall) and closely spaced constructions, such as large city centres 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 Installation Guide / SolarRoof Tilt Legs Standard Tilt – Rails perpendicular to Roof Slope Reverse Tilt – Rails perpendicular to Roof Slope Standard Tilt – Rails parallel to Roof Slope - Planning - Code-Compliant Planning and Installation Guide V 6.0 - Complying with AS/NZS 1170.2:2021...
  • Page 6 Installation Guide / SolarRoof Tilt Legs Determine the Installation Area of Roof There are 4 different roof zones for tilt leg installation: Internal Zone, Intermediate Zone, Edge Zone and Corner Zone. Please see diagrams and steps below to define area of each zone. Step 1.
  • Page 7 1. The panels are clamped within one quarter of panel length; 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 mm; 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 8 Installation Guide / SolarRoof Tilt Legs - Planning - Code-Compliant Planning and Installation Guide V 6.0 - Complying with AS/NZS 1170.2:2021...
  • Page 9 Installation Guide / SolarRoof Tilt Legs - Planning - Code-Compliant Planning and Installation Guide V 6.0 - Complying with AS/NZS 1170.2:2021...
  • Page 10 Installation Guide / SolarRoof Tilt Legs - Planning - Code-Compliant Planning and Installation Guide V 6.0 - Complying with AS/NZS 1170.2:2021...
  • Page 11 Installation Guide / SolarRoof Tilt Legs (10) - Planning - Code-Compliant Planning and Installation Guide V 6.0 - Complying with AS/NZS 1170.2:2021...
  • Page 12 Installation Guide / SolarRoof Tilt Legs (11) (12) - Planning - Code-Compliant Planning and Installation Guide V 6.0 - Complying with AS/NZS 1170.2:2021...
  • Page 13 Installation Guide / SolarRoof Tilt Legs (13) (14) - Planning - Code-Compliant Planning and Installation Guide V 6.0 - Complying with AS/NZS 1170.2:2021...
  • Page 14 Installation Guide / SolarRoof Tilt Legs (15) - Planning - Code-Compliant Planning and Installation Guide V 6.0 - Complying with AS/NZS 1170.2:2021...

  • Page 15: Tools & Components

    Installation Guide / SolarRoof Tilt Legs Tools and Components Tools Screw Driver Torque Spanner Socket Wrench M8 5m Tape String & Marker Pen (maximum torque≥34N·m) Components ER-TL-10/15 ER-TL-15/30 ER-EC-ST ER-IC-ST C-U/30/46 C-U/30/46-G ER-TL-30/60 End Clamp Inter Clamp Universal Clamp Universal Clamp Adjustable Tilt legs, non-preassembly ER-TL-10/15/PS...

  • Page 16: System Overview

    Installation Guide / SolarRoof Tilt Legs System Overview Overview of PV-ezRack® SolarRoof Adjustable Tilt Legs Adjustable Tilt Legs ② ① ⑤ ③ ④ ⑥ 1. End Clamp 2. Inter Clamp 3. Grounding Clip 4. ECO-Rail 5. Grounding Lug 6. Adjustable Tilt Legs Adjustable Tilt Legs with L-feet ②...
  • Page 17 Installation Guide / SolarRoof Tilt Legs Fixed Tilt Legs ② ① ⑤ ③ ⑥ ④ 1. End Clamp 2. Inter Clamp 3. Grounding Clip 4. ECO-Rail 5. Grounding Lug 6. Fixed Tilt Legs 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.
  • Page 18 Safe Torques 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 Guide / SolarRoof Tilt Legs 2) Adjustable Tilt Legs with L-feet Note: Grounding Z Module, External Teeth Lock Washers, Spring washer and corrugated shim (with pins) on the diagram above are to create the electrical continuity between rail and rear leg tubes. 3) Fixed Tilt Legs Note: Grounding Z Module,External Teeth Lock Washer and Spring washer on the diagram above are to create the...

  • Page 20: Installation Instruction

    Installation Guide / SolarRoof Tilt Legs Installation Instructions Front & Rear Leg Installation Front Leg Installation According to the installation plan, determine the mounting position and direction of the front legs. Either two screws or single screw (Buildex 14-11 x 70 Hex Head Zips screw) is required depending on the installation spacing requirement. See two screws and single screw options in Figures 1 and 2.
  • Page 21 Installation Guide / SolarRoof Tilt Legs Rear Leg Installation According to the installation plan, after confirming the length L of the Rear Leg, fasten two M8*12 bolts as shown in Figure 4. Recommended torque for M8*12 bolts is 18~20 N·m Figure 4 According to the installation plan, either two screws or single screw (Buildex 14-11 x 70 Hex Head Zips screw) is used to install rear leg.
  • Page 22 Installation Guide / SolarRoof Tilt Legs Install the remaining Front and Rear Legs in Figure 10. NOTE: WHEN USING TIN INTERFACES FOR INSTALLATION WORKS, SCREWS NOT EXPOSED TO FREQUENT RAIN SHOULD BE WASHED DOWN WITH FRESH WATER AT LEAST EVERY 6 MONTHS TO MEET THE WARRANTY CONDITIONS OF BUILDEX SCREWS.
  • Page 23 Installation Guide / SolarRoof Tilt Legs Figure 14 Figure 15 PV Module Installation 1) Please refer PVezRack® Grounding System for PV modules clamps and grounding lugs installations. 2) 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 "Safe Torques (P17)".

  • Page 24: Certification

    Installation Guide / SolarRoof Tilt Legs Certification             25 November 2022  Clenergy Australia  1/10 Duerdin Street  Clayton, VIC 3168  CERTIFICATION LETTER      Clenergy PV ez‐Rack penetrative tilt Certification – TC2, 2.5, 3 – Wind Region A, B1, B2, C, D. Project  No.: CL‐530‐S‐REV 2. Internal REF: 00631.     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 1170.2‐2021  o Wind Terrain Category 2, 2.5 and 3 ...
  • Page 25 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 26 2 (200 years wind average recurrence) such as residential shed or garage, small - isolated warehouses and farm sheds, residential carports, and one or double storey dwelling. If the project conditions do not fit on the above criteria, please contact Clenergy for an assessment. From 1 May 2023 installers must follow AS/NZS1170.2:2021 only.
  • Page 27 Refer to note 2 to find out installation exclusion zones. This certificate document is only valid for installations up to 100kW or 250 panels per roof area at a given building height. Contact engineering@clenergy.com.au for installations that exceed the aforementioned requirement.
  • Page 28 Refer to note 2 to find out installation exclusion zones. This certificate document is only valid for installations up to 100kW or 250 panels per roof area at a given building height. Contact engineering@clenergy.com.au for installations that exceed the aforementioned requirement.
  • Page 29 Refer to note 2 to find out installation exclusion zones. This certificate document is only valid for installations up to 100kW or 250 panels per roof area at a given building height. Contact engineering@clenergy.com.au for installations that exceed the aforementioned requirement.
  • Page 30 Refer to note 2 to find out installation exclusion zones. This certificate document is only valid for installations up to 100kW or 250 panels per roof area at a given building height. Contact engineering@clenergy.com.au for installations that exceed the aforementioned requirement.
  • Page 31 Refer to note 2 to find out installation exclusion zones. This certificate document is only valid for installations up to 100kW or 250 panels per roof area at a given building height. Contact engineering@clenergy.com.au for installations that exceed the aforementioned requirement.
  • Page 32 Refer to note 2 to find out installation exclusion zones. This certificate document is only valid for installations up to 100kW or 250 panels per roof area at a given building height. Contact engineering@clenergy.com.au for installations that exceed the aforementioned requirement.
  • Page 33 Refer to note 2 to find out installation exclusion zones. This certificate document is only valid for installations up to 100kW or 250 panels per roof area at a given building height. Contact engineering@clenergy.com.au for installations that exceed the aforementioned requirement.
  • Page 34 Note 1. 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 35 Note 11. In case the installation is done with one screw and the purlin thickness differs from Note 6, a site-specific certificate shall be issued. Contact Clenergy for more information. Note 12. The following components are satisfied for use according to AS/NZS 1664.1:1997-Amdt 1:1999 and AS/NZS 1170.2:2021.
  • Page 36 Installation Guide / SolarRoof Tilt Legs Components Part No. Description ECO-Rail ER-R-ECO/XXXX ECO-Rail Splice ER-SP-ECO PV-ezRack Splice for ECO-rail Australian Made Mill R-ECO/XXXX/AUMF PV-ezRack Australian Made Mill Finish ECO-Rail Black ECO-Rail ER-R-ECO/XXXX/BA Black ECO-Rail Black Splice ECO-Rail ER-SP-ECO/BA Splice ECO-Rail Black Inter Clamp ER-IC-STXX Inter Clamp = Clamp + Z-Module + Bolt...
  • Page 37 Installation Guide / SolarRoof Tilt Legs Tilt Legs ER-TL-5/PS 5° Fixed Tilt Legs, Preassembly Tilt Legs ER-TL-10/PS 10° Fixed Tilt Legs, Preassembly Tilt Legs ER-TL-FF Front Foot of Tilt Legs Black Tilt Legs ER-TL-10/15/BA Black 10°/15° Adjustable Tilt Legs Black Tilt Legs ER-TL-15/30/BA Black 15°/30°...
  • Page 38 Note 22. Only hip and gable roofs installations are covered on this certificate. Contact Clenergy if you are planning to install on a different roof type such as curved, multi-span (pitched and saw-tooth), mansard, circular bin, silo, tank, pitched free, troughed free, hypar free, canopy, awning and cantilivered roof.
  • Page 39 Installation Guide / SolarRoof Tilt Legs 2 rails < 2300 - 20 % - 12 % 2 rails < 2400 - 25 % - 15 % Note 26. Panel width cannot exceed 1.20 m for any of the above panel length dimensions and panel weight cannot exceed 15 kg/m Note 27.
  • Page 40 Installation Guide / SolarRoof Tilt Legs ECO – Rail parallel to ribs Back leg angle between 30° and 90° Note 29. This certificate can be used for the installation of tilt legs on uncracked concrete roofs using one Chemset per tilt leg. The minimum Chemset tensile capacity should be 6.1 kN and this should be confirmed by the manufacturer.
  • Page 41 Installation Guide / SolarRoof Tilt Legs Roof zone definition Roof Pitch < 10° Top view Flat/Mono – Slope Roof > 10° Flat/Mono – Slope Roof < 10° Flat/Mono – Slope Roof > 10° Legend: - Certification - Code-Compliant Planning and Installation Guide V 6.0 - Complying with AS/NZS 1170.2:2021...
  • Page 42 Installation Guide / SolarRoof Tilt Legs Note 31. The below flow chart is intended to be used as a guideline to define if the project conditions are covered on this generic certificate. Example 1: Wind Region: A Terrain Category: 3 Building Height: 6 m Roof Pitch: 3°...
  • Page 43 Installation Guide / SolarRoof Tilt Legs Example 2: Wind Region: B1 Terrain Category: 2 Building Height: 12 m Roof Pitch: 5° Panel Tilt Angle: 20° Tilt Condition (Standard or Reverse): Reverse No. of screws per tilt leg: 2 (refer to Note 11) Purlin type and thickness: F7 Pine 30mm (Spacing -5%, refer to Note 7) Panel Dimension: 1750 mm x 1000 mm...
  • Page 44 Clenergy 1/10 Duerdin St Phone: +61 3 9239 8088 Clayton VIC 3168 Email: sales@clenergy.com.au Australia Web: www.clenergy.com.au @ClenergyGlobal / @ClenergyClub / ClenergyAUS @Clenergy @ClenergyClub @Clenergy_global @Clenergy A Clenergy Technologies Company...