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Clenergy PVezRack SolarRoof Installation Manual

Penetrative flush mounting with elite rail
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SolarRoof Penetrative
Flush Mounting with Elite Rail
Code-Compliant Planning and Installation Guide V 2.0 (New Zealand)
Complying with AS/NZS 1170.2-2021
Last Updated - Jul. 2024

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  • Page 1 SolarRoof Penetrative Flush Mounting with Elite Rail Code-Compliant Planning and Installation Guide V 2.0 (New Zealand) Complying with AS/NZS 1170.2-2021 Last Updated - Jul. 2024...
  • Page 2 This document should only be used as a last resort if no country-specific document is available on the respective Clenergy website. If the document does not comply with the content or standards of national legal documents, the national legal documents shall take precedence. Clenergy bears no responsibility for any inaccuracies, errors, or discrepancies that may arise from the use of this document in lieu of official, country-specific guidance and does not warrant the up-to-dateness, correctness, completeness, or quality of the information provided.

  • Page 3: Table Of Contents

    Installation Guide / SolarRoof Penetrative Flush Mounting with Elite Rail Contents List of contents Introduction Planning 03 - 07 Determine the wind region of your installation site 03 - 05 Determine the Terrain Category Verify Atmospheric Corrosivity Zone of Installation Site Determine Building Dimension Determine the Installation Area of Roof Verify Rafter/Purlin Properties of Building...

  • Page 4: Introduction

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

  • Page 5: Planning

    Installation Guide / SolarRoof Penetrative Flush Mounting with Elite Rail Planning Determine the wind region of your installation site Wind regions map below shows 4 different wind regions in New Zealand: NZ1, NZ2, NZ3 and NZ4. The lee (effect) multiplier (M1ee) shall be evaluated for New Zealand sites in the lee zones below. In wind regions of NZ1 and NZ2 with M1ee over 500 m above sea level, the interface spacing reduction is applied.
  • Page 6 “Examples” in certificate to understand how to use maximum spacing in Sub-alpine Regions. If your installation site is in Alpine regions, please contact Clenergy to obtain a project specific engineering certificate to support your installation.
  • Page 7 Installation Guide / SolarRoof Penetrative Flush Mounting with Elite Rail New Zealand – Approximate Locations of Alpine and Sub-alpine Regions - Planning - Code-Compliant Planning and Installation Guide V 2.0 (New Zealand) - Complying with AS/NZS 1170.2-2021 -...

  • Page 8: Determine The Terrain Category

    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 or 3, please contact Clenergy to obtain a project specific engineering certificate to support your installation.

  • Page 9: Determine The Installation Area Of Roof

    Installation Guide / SolarRoof Penetrative Flush Mounting with Elite Rail 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 10: Tools And Components

    Installation Guide / SolarRoof Penetrative Flush Mounting with Elite Rail Tools and Components Tools Angle Grinder with Screw Driver Torque Spanner Spanner 5m Tape Stone Disk (for M8 Hexagon Socket Screw) String & Marker Pen Components ER-EC-ST ER-IC-ST C-U/30/46-G C-U/30/46 ER-R-ELT End Clamp Inter Clamp...
  • Page 11 Installation Guide / SolarRoof Penetrative Flush Mounting with Elite Rail ER-I-01 ER-I-01/CS ER-I-01/EZC/ECO ER-I-02 ER-I-04 Tile Interface Tile Interface, Tile Interface with Flat Tile Interface Slate Interface Galvanized Steel ezClick connection for ECO-Rail ER-I-23 ER-I-26 ER-I-51 Tile Interface Tile Interface Tile Interface, 118mm -Landscape -Side mount...

  • Page 12: System Overview

    Installation Guide / SolarRoof Penetrative Flush Mounting with Elite Rail System Overview Overview of PVezRack® SolarRoof Tile Interface 1. End Clamp 2. Inter Clamp 3. Elite Rail 4. Tile interface Tin Interface 1. End Clamp 2. Inter Clamp 3. Elite Rail 4.

  • Page 13: Precautions During Stainless Steel Fastener Installation

    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 14: Installation Instructions

    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. 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);...

  • Page 15: Tile Interface Installation

    Remove the roof tiles at the marked positions or, if possible, simply push them up slightly. Fix the Roof Hooks to the rafter using Clenergy provided Buildex 14 gauge Hex Head Zips screw with minimum 25 mm embedment as shown in...

  • Page 16: Elite-Rail Installation

    Installation Guide / SolarRoof Penetrative Flush Mounting with Elite Rail If necessary, use an angle grinder to cut a recess in the tile covering the Roof Hook at the point where the Roof Hook extends so that the tile lies flat on the surface.
  • Page 17 Installation Guide / SolarRoof Penetrative Flush Mounting with Elite Rail In case of requiring rails cutting to be joined by Elite rail splice, please make sure cutting as straight as possible to avoid splice clip teeth mistouching rails. It is because after installation it is just 3.4 mm from the rail end to the clip teeth as shown in the diagram.

  • Page 18: Pv Module Installation

    Installation Guide / SolarRoof Penetrative Flush Mounting with Elite Rail ER-I-23 ER-I-26 ER-I-51 Adjust the vertical and horizontal positioning using the long hole in the Roof Hook and the loosely connected Z Module in the rail, as shown in the figure on the right. The roof hook should not protrude over the rail after the adjustment.

  • Page 19: Tin Interface Installation

    Installation Guide / SolarRoof Penetrative Flush Mounting with Elite Rail Tin Interface Installation For installations using ER-I-05, Tin Interface equipped with Buildex 14-11 x 70 (14 gauge, 6.3 mm, 11 TPI, 70 mm long) Hex Head Zips screw. Fix the ER-I-05 at the planned locations on metal or wood purlins as shown Clearance in the figure on the right following the Buildex screws...
  • Page 20 Installation Guide / SolarRoof Penetrative Flush Mounting with Elite Rail When fastening ER-I-05/CM with rail, it needs to lift up the bolt of click module to make click module well touch with upper rib of side channel of rail. So, the click module can be fixed into the rail properly as shown in the figure on the right.
  • Page 21 Installation Guide / SolarRoof Penetrative Flush Mounting with Elite Rail Notes: - The purlin thickness should be no less than 0.42mm and no more than 2.4mm; - Please refer to the recommended torques in "Safe Torques (Page 11)"; - Screws not exposed to frequent rain should be washed down Clearance 90~107mm with fresh water at least every 6 months to meet the warranty...

  • Page 22: Hanger Bolt Installation

    Installation Guide / SolarRoof Penetrative Flush Mounting with Elite Rail Hanger Bolt Installation Hanger Bolt for Tile Roof Installation Hanger bolt (ER-HB-8/150) installation on tile roof is only applicable for tile having some part of flat surface, where the rubber seal of hanger bot can mount flush on the tile not to cause waterproof problem.

  • Page 23: Hanger Bolt For Tin Roof Installation

    Installation Guide / SolarRoof Penetrative Flush Mounting with Elite Rail Notes: 1) Purlin thickness and tile thickness need to be verified to decide position of rubber seal for appropriate penetration depth; 2) It shall apply Sikaflex (or similar) sealant around the bolt to fill the gap between the bolt and tile before fixing hanger bolt.
  • Page 24 Installation Guide / SolarRoof Penetrative Flush Mounting with Elite Rail Drive and press the hanger bolt firmly in an axial manner to the wood purlin till the rubber seal is firmly flush on the tile and turn the nut down till touching the rubber seal.
  • Page 25 Installation Guide / SolarRoof Penetrative Flush Mounting with Elite Rail Drive and press the hanger bolt (ER-HB-MP/8/150EP) firmly in an axial manner to the metal purlin till the rubber seal is firmly flush on the tile and turn the nut down till touching the rubber seal.

  • Page 26: Engineering Certificate

    Engineering Certificate PV Array Frame Engineering Certification PV-ezRack SolarRoof Tin and Tile Flush Mount Penetrative Fixing System with ELITE Rail in New Zealand For: Clenergy Australia Suite 1, 10 Duerdin St Clayton, VIC 3168 Job No.: 13924 Date: 08/05/2024 - Certification -...
  • Page 27 Pty Ltd accepts no liability or responsibility whatsoever for or in respect of any use of or reliance upon this report by any third party. Page 2 of 5 13924(RE13708)-01-CER-Clenergy PV-ezRack Flush Mount Penetrative System with Elite Rail in New Zealand...
  • Page 28 The design check has been based on the information and test reports provided by Clenergy Australia. This certificate is only valid for Clenergy PV-ezRack SolarRoof. The roof structure or the building structure and PV panels shall be assessed separately and accordingly.
  • Page 29 ● If any of the above conditions cannot be met, the structural engineer must be notified immediately. Page 4 of 5 13924(RE13708)-01-CER-Clenergy PV-ezRack Flush Mount Penetrative System with Elite Rail in New Zealand...
  • Page 30 FIEAust CPEng NER 5038980 CMEngNZ 2003796 NT Registration: 244137ES FIEAust CPEng NER QLD Registration: 18703 APEC Engineer IntPE(Aus) VIC Registration: PE0001956 TAS Registration: CC7366 Page 5 of 5 13924(RE13708)-01-CER-Clenergy PV-ezRack Flush Mount Penetrative System with Elite Rail in New Zealand...
  • Page 31 ELITE Rails - Tin & Tile Roof (Pierced Fix Roof) With Fasteners - 14g-10 TPI screws or approved equivalent within New Zealand Terrain Category 2 & 3 For: CLENERGY AUSTRALIA 1/10 Duerdin St Clayton, VIC 3168 Job Number: 13924 (ELITE Rails &...
  • Page 32 37 Butler St, Richmond VIC 3121 Tel: 03 9543 2211 Job No: 13924 Client: CLENERGY AUSTRALIA Project: Flush Array Frame System Spacing Table with ELITE Rails - Tin & Tile Roof (Pierced Fix Roof) With Fasteners - 14g-10 TPI screws or approved equivalent...
  • Page 33 Client: CLENERGY AUSTRALIA Project: Flush Array Frame System Spacing Table Job: 13924 with ELITE Rails - Tin & Tile Roof (Pierced Fix Roof) Date: May-24 With Fasteners - 14g-10 TPI screws or approved equivalent Designed: JD Address: within New Zealand...
  • Page 34 Client: CLENERGY AUSTRALIA Project: Flush Array Frame System Spacing Table Job: 13924 with ELITE Rails - Tin & Tile Roof (Pierced Fix Roof) Date: May-24 With Fasteners - 14g-10 TPI screws or approved equivalent Designed: JD Address: within New Zealand...
  • Page 35 Client: CLENERGY AUSTRALIA Project: Flush Array Frame System Spacing Table Job: 13924 with ELITE Rails - Tin & Tile Roof (Pierced Fix Roof) Date: May-24 With Fasteners - 14g-10 TPI screws or approved equivalent Designed: JD Address: within New Zealand...
  • Page 36 Client: CLENERGY AUSTRALIA Project: Flush Array Frame System Spacing Table Job: 13924 with ELITE Rails - Tin & Tile Roof (Pierced Fix Roof) Date: May-24 With Fasteners - 14g-10 TPI screws or approved equivalent Designed: JD Address: within New Zealand...
  • Page 37 Client: CLENERGY AUSTRALIA Project: Flush Array Frame System Spacing Table Job: 13924 with ELITE Rails - Tin & Tile Roof (Pierced Fix Roof) Date: May-24 With Fasteners - 14g-10 TPI screws or approved equivalent Designed: Address: within New Zealand Checked:...
  • Page 38 Client: CLENERGY AUSTRALIA Project: Flush Array Frame System Spacing Table Job: 13924 with ELITE Rails - Tin & Tile Roof (Pierced Fix Roof) Date: May-24 With Fasteners - 14g-10 TPI screws or approved equivalent Designed: Address: within New Zealand Checked: Note 10 Wind direction multiplier (Md), Shielding multiplier (Ms) and Hill shape multiplier (Mh) are taken as 1.0.
  • Page 39 Client: CLENERGY AUSTRALIA Project: Flush Array Frame System Spacing Table Job: 13924 with ELITE Rails - Tin & Tile Roof (Pierced Fix Roof) Date: May-24 With Fasteners - 14g-10 TPI screws or approved equivalent Designed: Address: within New Zealand Checked: Note 25 Interface spacing to be reduced as follows for sites in wind regions NZ1 &...
  • Page 40 Client: CLENERGY AUSTRALIA Project: Flush Array Frame System Spacing Table Job: 13924 with ELITE Rails - Tin & Tile Roof (Pierced Fix Roof) Date: May-24 With Fasteners - 14g-10 TPI screws or approved equivalent Designed: Address: within New Zealand Checked: Note 27 Refer table 3 and Figure 2 of NZS 4219:2009 for zone factor (Z).
  • Page 41 (b & d are building dimensions and h is average roof height, see Figure 1) Note 31 Installation of solar array to be done in accordance with the relevant Clenergy PV installation manual. Contact Clenergy if you are unable to comply with any of the above installation specifications.
  • Page 42 Client: CLENERGY AUSTRALIA Project: Flush Array Frame System Spacing Table Job: 13924 with ELITE Rails - Tin & Tile Roof (Pierced Fix Roof) Date: May-24 With Fasteners - 14g-10 TPI screws or approved equivalent Designed: JD Address: within New Zealand...
  • Page 43 ELITE Rails – Tin Roof (Pierced Fix Roof) with Fasteners - M8x150 hanger bolts or approved equivalent within New Zealand Terrain Category 2 & 3 For: CLENERGY AUSTRALIA 1/10 Duerdin St Clayton, VIC 3168 Job Number: 13924 (ELITE Rails & M8x150 hanger bolts)
  • Page 44 37 Butler St, Richmond VIC 3121 Tel: 03 9543 2211 Job No: 13924 Client: CLENERGY AUSTRALIA Project: Flush Array Frame System Spacing Table with ELITE Rails – Tin Roof (Pierced Fix Roof) with Fasteners - M8x150 hanger bolts or approved equivalent...
  • Page 45 Client: CLENERGY AUSTRALIA Project: Flush Array Frame System Spacing Table Job: 13924 with ELITE Rails – Tin Roof (Pierced Fix Roof) Date: May-24 with Fasteners - M8x150 hanger bolts or approved equivalent Designed: JD Address: within New Zealand Checked: JG...
  • Page 46 Client: CLENERGY AUSTRALIA Project: Flush Array Frame System Spacing Table Job: 13924 with ELITE Rails – Tin Roof (Pierced Fix Roof) Date: May-24 with Fasteners - M8x150 hanger bolts or approved equivalent Designed: JD Address: within New Zealand Checked: JG...
  • Page 47 Client: CLENERGY AUSTRALIA Project: Flush Array Frame System Spacing Table Job: 13924 with ELITE Rails – Tin Roof (Pierced Fix Roof) Date: May-24 with Fasteners - M8x150 hanger bolts or approved equivalent Designed: Address: within New Zealand Checked: General Notes Note 1 Following components are satisfied to use according to AS/NZS 1170.2:2021...
  • Page 48 Client: CLENERGY AUSTRALIA Project: Flush Array Frame System Spacing Table Job: 13924 with ELITE Rails – Tin Roof (Pierced Fix Roof) Date: May-24 with Fasteners - M8x150 hanger bolts or approved equivalent Designed: Address: within New Zealand Checked: Note 10 Wind direction multiplier (Md), Shielding multiplier (Ms) and Hill shape multiplier (Mh) are taken as 1.0.

  • Page 49: Certificate User Guideline

    Client: CLENERGY AUSTRALIA Project: Flush Array Frame System Spacing Table Job: 13924 with ELITE Rails – Tin Roof (Pierced Fix Roof) Date: May-24 with Fasteners - M8x150 hanger bolts or approved equivalent Designed: Address: within New Zealand Checked: Note 24 Interface spacing to be reduced as follows for sites in wind regions NZ1 &...
  • Page 50 Client: CLENERGY AUSTRALIA Project: Flush Array Frame System Spacing Table Job: 13924 with ELITE Rails – Tin Roof (Pierced Fix Roof) Date: May-24 with Fasteners - M8x150 hanger bolts or approved equivalent Designed: Address: within New Zealand Checked: Note 26 Refer table 3 and Figure 2 of NZS 4219:2009 for zone factor (Z).
  • Page 51 (b & d are building dimensions and h is average roof height, see Figure 1) Note 30 Installation of solar array to be done in accordance with the relevant Clenergy PV installation manual. Contact Clenergy if you are unable to comply with any of the above installation specifications.
  • Page 52 Client: CLENERGY AUSTRALIA Project: Flush Array Frame System Spacing Table Job: 13924 with ELITE Rails – Tin Roof (Pierced Fix Roof) Date: Dec-99 with Fasteners - M8x150 hanger bolts or approved equivalent Designed: JD Address: within New Zealand Checked: JG...
  • Page 53 Appendix 1. Refer Figure 3.1(B) of AS/NZS 1170.2:2021 for the wind region...
  • Page 54 2. Refer Table 4.4 and Figure 4.6 of AS/NZS 1170.2:2021 for the location of New Zealand Lee zone...
  • Page 56 3. Refer section 2.3 and Figure 2.2 of AS/NZS 1170.3:2003 for Sub-alpine zone the location of New Zealand Lee zone NEW ZEALAND Alpine and sub-alpine regions are defined as follows: N1 (southern portion of North Island of New Zealand, see Figure 2.2): Sub-alpine between 400 m and 1200 m.
  • Page 57 NOTE: This map is approximate only and altitude above mean sea level shall be used to determine snow region. For sub-alpine regions in the South Island (N2, N3, N4 and N5) the regions coincide with the 1988 county boundaries. Where an alpine region exists between sub-alpine regions, the alpine region separates the 2 sub-alpine regions (which extend downwards from 1200 m altitude).
  • Page 58 4. Refer table 3 and Figure 2 of NZS 4219:2009 for zone factor (Z) Table 3 – Zone factors for New Zealand locations (north to south) Location Location Kaitaia 0.13 Taupo 0.28 Paihia/Russell 0.13 Taumarunui 0.21 Kaikohe 0.13 Turangi 0.27 Whangarei 0.13 Gisborne...
  • Page 59 Table 3 – Zone factors for New Zealand locations (north to south) (continued) Location Location Porirua 0.40 Christchurch 0.22 Wellington CBD 0.40 Geraldine 0.19 (north of Basin Ashburton 0.20 Reserve) Fairlie 0.24 Wellington 0.40 Temuka 0.17 Hutt Valley – south 0.40 Timaru 0.15...
  • Page 60 Figure 2 – Zone factor, Z...
  • Page 61 Gamcorp Pty Ltd Clenegy PV-ezRack SolarRoof Flush and Tilt Roof Mount systems with ER-R-ECO & ER-R-ELT Penetrative fixing refer Certification Letter 13708-01(Eco Rail) & 13924-01(Elite Rail) for Flush Mount system & 13708-02 (Eco Rail) &13924-02(Elite Rail) for Tilt Mount system refer Certification Letter 13708-01(Eco Rail) &...
  • Page 63 Installation Guide / SolarRoof Penetrative Flush Mounting with Elite Rail Certificate User Guideline Guidelines for flush array frame system spacing (Tin & Tile Roof): 1. Building dimensions, b, d & h. Generally we study buildings for 2 main directions. So b & d will be swapped regarding the considered wind blowing direction.
  • Page 64 Clenergy 3/10 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...

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