Installation Manual
Contents
1. 80msec Australia s worst Cyclonic Region between Carnarvon and Pardoo in Western Australia 2 Determine the height of the of your installation site This document provides sufficient information for SolarRoof system installation height less then 20 meters If your installation site is more than 20 meters in height please contact Clenergy to obtain engineering data to support your installation 3 Determine the Maximum Rail Support Spacing Please use the following table to determine the base rail support spacing for tile roof installations Installation Region A Region B Region C Region D Height mm mm mm mm 2130 1690 1380 1080 10 Meters 1940 1540 1260 990 15 Meters 1840 1460 1190 20 Meters 1740 1380 1130 e The figures above are based on attaching 200W PV modules length of 1600mm weight of 20KG to SolarRoof system These figures should be sufficient for installing smaller PV modules Please consult Clenergy for installing PV modules greater than length of 1600mm and weight of 20KG e The Tile roof hooks should be fixed to the rafter using three 6x80mm wood screws minimum Please use the following table to determine the base rail support spacing for sheet metal roof installations Installation Region A amp B mm Region C amp D mm Height 1320 10 Meters 1200 15 Meters 1140 20 Meters 1080 e The figures above are based on attaching 200W PV modules length of 1600mm weight of 20KG to S2. at tik oA A lt the marked positions or if possible simply lift them up slightly 2 Fix the roof hooks to the rafter using three 6 x 80 mm wood screws 3 The roof hook must not press Incorrect Correct against the roof tile If necessary shim the roof hook with wood i 4 If necessary use an angle grinder or hammer to cut a recess in the tile that covers the roof hook at the point where the roof hook comes through so that the tile lies flat on the surface If grooved tiles are used it will also be necessary to cut a recess in the lower tile 5 Caution Do not use fitted roof hooks as a ladder as this extreme point load could damage the tile below Page 8 of 13 EzRack SolarRoof Code Compliant Planning and Installation Guide AU V1 4 Clenergy Co Ltd Clenergy Photovoltaic Mounting Systems Tile Roof Hook Installation ezRack SolarRoof Installation Guide 6 Variation for installation on plain tile roofs With plain tile roof cladding a recess must be cut into the tiles around the position of the roof hook 7 A titanium zinc metal sheet must be cut to fit on site with an overlap of at least 20 mm around the recess and installed under the roof hooks Caution Please take note of Figure 3 10 For easy use of the Z module you must make sure that the thread of the screws does not project through the lower side of the Z Module max flush Position the Z Module in the rail channel an
3. including any that may superseded this manual e Ensuring that ezRack and other products are appropriate for the particular installation and the installation environment e Ensuring that the roof its rafters connections and other structural support members can support the array under building live load conditions this total assembly is hereafter referred to as the roof rafter assembly e Using only ezRack parts and installer supplied parts as specified by ezRack substitution of parts may void the warranty and invalidate the letter of certification on page 2 e Ensuring that lag screws have adequate pullout strength and shear capacities as installed e Maintaining the waterproof integrity of the roof including selection of appropriate flashing and e Ensuring safe installation of all electrical aspects of the PV array Installation tools e 6mm Allen key e Cordless drill Open end spanner set 9 10 17 19 mm required only for mounting with hanger bolts Torx 30 AW 30 bit Angle grinder with stone disk Power Cord If necessary timber to shim the roof hooks Page 2 of 13 EzRack SolarRoof Code Compliant Planning and Installation Guide AU V1 4 Clenergy Co Ltd Clenergy Photovoltaic Mounting Systems ezRack SolarRoof Installation Guide This document is designed to support for installations using SolarRoof PV Module Mounting System manufactured by Clenergy Co Lid Follow the six steps below and the install
4. mm galvanised Corrugated Hanger bolt corrugated Screw G12x65mm with metal Gasket G12x75mm G12x90mm screws are available Page 6 of 13 EzRack SolarRoof Code Compliant Planning and Installation Guide AU V1 4 Clenergy Co Ltd Clenergy Photovoltaic Mounting Systems ezRack SolarRoof Installation Guide Overview of system components J 3 Ys Mle IN SS a ezRack rails ARK Vf YU if b Inter module clamp aaa c Roof hook ipa LLL TTT d Splice gt e Module end clamp f Telescopic mounting optional Planning the module area 1 Number of modules in the vertical direction x module height please check also the installation manual of the manufacturer of the solar module 2 Number of modules in horizontal direction x module width 18 mm 32 mm 3 Horizontal spacing of the roof hooks up to 2 0 m 4 Vertical spacing of the roof hooks approx 1 2 to 34 of module height 5 Distance between the modules 17 mm Caution Installations that are exposed to the wind or are located on the edge or corners of the roof may make it necessary to leave smaller soaces between modules Page 7 of 13 EzRack SolarRoof Code Compliant Planning and Installation Guide AU V1 4 Clenergy Co Ltd Clenergy Photovoltaic Mounting Systems ezRack SolarRoof Installation Guide Tile Roof Hook Installation 1 Determine the positions of the roof hooks according to your plans Remove the roof tiles
5. to the type of tin roof to ensure that the minimum embedment requirement 50mm into timber purlins 4 Verify acceptable Rail End Overhang Rail End Overhang must equal 50 percent or less of foot spacing Thus if foot spacing is 1200mm the Rail End Over hang can be up to 600mm In this case two feet can support a rail of as much as 2400mm 1200mm between the feet and 600mm of overhang at each end 5 Determine Roof slope SsolarRoof system can be used for roof slope up to 60 degrees Please verify the Installation site roof slope should be between 0 degrees and 60 degrees 6 Determine Roof Installation Roof Areas SolarRoof racks should not to be installed within the minimum of 0 2b and 0 2d of a roof edge or ridge where b and d are the plan dimensions of the building Page 5 of 13 EzRack SolarRoof Code Compliant Planning and Installation Guide AU V1 4 Clenergy Co Ltd Clenergy Photovoltaic Mounting Systems ezRack SolarRoof Installation Guide Overview of system components Inter module clamp with Z ezRack Rails Telescopic mountings Module Module end clamp with Z Roof hook double Roman Module tile M8X25 933 A2 70 Srinlece Steel od galvanised Corrugated Screw 12x65mm with Gasket Overview of system components Inter module clamp with Z ezRack Rails Telescopic mountings Module Module end clamp with Z Module for frame height 46 Module end clamp with Z mm Module for all frame heights except 46
6. Clenergy Photovoltaic Mounting Systems ezRack SolarRoof Installation Guide The ezRack has been developed as a universal system for roof mounting on pitched roofs The use of patented pending aluminium base rails the Z module technology and the telescopic mounting technology eliminates custom cutting and enables particularly fast installation Please review this manual thoroughly before installing your SolarRoof system This manual provides 1 supporting documentation for building permit applications relating to ezRack SolarRoof Universal PV Module Mounting system and 2 planning and installation instructions for SolarRoof SsolarRoof products when installed in accordance with this guide will be structurally adequate and will meet the AS NZS1170 standards During installation and especially when working on the roof be sure to observe the appropriate safety regulations and please pay attention to the relevant regulations of your local region Please check that you are using the current version of the installation manual by contacting Clenergy Australia by email on Sales clenergy com cn or your local representative in Australia Page 1 of 13 EzRack SolarRoof Code Compliant Planning and Installation Guide AU V1 4 Clenergy Co Ltd Clenergy Photovoltaic Mounting Systems ezRack SolarRoof Installation Guide The installer is solely responsible for e Complying with all applicable local or national building codes
7. ation instructions section to install SolarRoof in compliance with the AS NZS1170 Before proceeding note the following e This document addresses only wind loads on the assumption that wind produces the maximum load factor affecting an installation Verify that other local factors such as snow loads and earth quake effects do not exceed the wind loads Give precedence to any factor that does Wind loads are considered to act on the entire projected area or may be perpendicular to any surface e The roof on which the SolarRoof will be installed must have the capacity to resist the combined Design Dead Load and Live Load per footing 1 Determine the wind region of your installation site Hapim D Region Definition Wind regions are pre defined for all of Australia by Australian Standard 1170 The Wind Region has nothing to do with surrounding topography or buildings e Most of Australia is designated Region A which indicates a Regional Ultimate Basic Wind Velocity of 45msec Page 3 of 13 EzRack SolarRoof Code Compliant Planning and Installation Guide AU V1 4 Clenergy Co Ltd Clenergy Photovoltaic Mounting Systems ezRack SolarRoof Installation Guide e Some areas are designated Region B 57msec Local authorities will advise if this applies in your area e Region C areas 66msec are generally refered to as Cyclonic and are generally limited to northern coastal areas Most Region C zones end 100km inland e Region D
8. commended torque is 8 Nm Please take note of Figure 10 21 Cross section through the module end clamp when installation step 20 has been correctly performed 22 Slide the pre assembled inter module clamp into the rails from above place it firmly against the module and fasten loosely approx 2 3 turns Please also take note of Figure 10 23 Now slide the next module against the previously installed module and tighten the inter module clamp using the Allen key recommended torque is 8 Nm Take care that the anti slip protection sits in the rail channel of the lowest row of rails Please also take note of Figure 10 24 If your system does not use a telescopic mounting position the last module of the row in the base rail and fasten the module using the module end clamp recommended torque is 8 Nm For systems with telescopic mountings please take note of Figure 25 below Page 12 of 13 EzRack SolarRoof Code Compliant Planning and Installation Guide AU V1 4 Clenergy Co Ltd Clenergy Photovoltaic Mounting Systems ezRack SolarRoof Installation Guide PV Module Installation 25 Installation using telescopic mounting Position the telescopic mounting which was loosely mounted in step 16 so that there is sufficient room for the last module the last inter module clamp and the end clamp calculation module width or length in mm 43 mm Now tighten the telescopic mounting using the Allen key left si
9. d fasten it loosely with 2 to 3 turns of the screw The screws can still be freely moved in the rail channel Slide the screws to their final position in connection with the inter module clamp module end clamp or roof hooks hanger bolts and fasten firmly recommended torque is 8 Nm 11 Installation of the rails on roof hooks If your set of rails consists of rails of different lengths always begin with the shortest piece Install the framing for each row of modules loosely on the roof hooks using an M8 x 25 mm Allen bolt washers retaining washers and the Z Module 2 to 3 turns of the screw are adequate for loose installation Please take note of Figure 10 12 An optimum adjustment of the vertical and horizontal position can be made by taking advantage of the long hole in the roof hooks and the still loose connection of the Z Module or T head bolts in the rail Please take note of Figure 13 below Position Page 9 of 13 EzRack SolarRoof Code Compliant Planning and Installation Guide AU V1 4 Clenergy Co Ltd Clenergy Photovoltaic Mounting Systems Colorbond Roof Hook Installation 8 Variation for installation on corrugated metal In the case of corrugated roof cladding hanger bolts are used instead of roof hooks Drill through the roof cladding at the planned location and screw the hanger bolts into the purlins Then mount the L brackets 9 Cross section of a hanger bolt installation Take sp
10. de 26 Place the last module in the row on the rails with the first row of modules take care that the anti slip protection sits properly in the rail channel and fasten the last inter module clamp and the module end clamp using the Allen key recommended torque is 8 Nm 27 Now slide in the first module of the next row from above onto the corresponding module of the row beneath A separation from the lower module can be maintained for optical reasons An inter module clamp can be used as a separator so that the vertical and horizontal separation of the modules is identical Continue mounting the modules as described in steps 20 to 26 until all modules are installed The installation is finished 10 year limited Product Warranty 5 year limited Finish Warranty Clenergy co Ltd warrants to the original purchaser Purchaser of product s that it manufactures Product at the original installation site that the Product shall be free from defects in material and workmanship for a period of ten 10 years except for the anodised finish which finish shall be free from visible peeling or cracking or chalking under normal atmospheric conditions for a period of five 5 years from the earlier of 1 the date the installation of the Product is completed or 2 30 days after the purchase of the Product by the original Purchaser Finish Warranty The Finish Warranty does not apply to any foreign residue deposited on
11. ecial care that the nut tightly fastens the sealing washer without damaging the roof cladding When performing the installation take care that the thread of the hanger bolt does not cover the long hole in the L bracket Base Rail Installation 13 Position the first frame rails for each row and fasten them temporarily to the roof cladding using a cord Tighten the Allen bolts or the nuts on the T head bolts that are used to fasten the i i i ea roof hooks hanger bolts recommended torque is 8 Nm Please also pay attention to Figure 10 I 14 Installation of the splice with base rails To connect multiple rails together slide the splices on the rear side of the pre assembled rails halfway to the side Fasten the first M8 Allen bolt firmly using the Allen key Now slide the next rail segment into the splice 15 Tighten the second M8 Allen bolt using the Allen key The connection is finished An expansion gap at the rail joints is recommended For this purpose leave a gap about the same width as a finger between the rail joints and then loosely tighten the M8 allen bolt Page 10 of 13 zuun Tanum ezRack SolarRoof Installation Guide C ea Be S g l EE a a s A ant fa 1 B m at ae a a n n EzRack SolarRoof Code Compliant Planning and Installation Guide AU V1 4 Clenergy Co Ltd Clenergy Photov
12. olarRoof system These figures should be sufficient for installing smaller PV modules Please consult Clenergy for installing PV modules greater than length of 1600mm and weight of 20KG e The L Feet should be fixed to the purlins under using 12GX65 screws through sheet metal roofs with gasket Page 4 of 13 EzRack SolarRoof Code Compliant Planning and Installation Guide AU V1 4 Clenergy Co Ltd Clenergy Photovoltaic Mounting Systems ezRack SolarRoof Installation Guide e The above spacings apply for fixing through thin sheet purlins greater than 1mm thickness ora minimum embedment of 50mm into timber purlins Please use the following table to determine the base rail support spacing when using Tilt Roof Mounting kit Installation Region A amp B mm Region C amp D mm Height 1320 10 Meters 1200 15 Meters 1140 20 Meters 1080 e The figures above are based on attaching 200W PV modules length of 1600mm weight of 20KG to SolarRoof system These figures should be sufficient for installing smaller PV modules Please consult Clenergy for installing PV modules greater than length of 1600mm and weight of 20KG e Each T Feet should be fixed to the purlins under using two 12GX65 screws through sheet metal roofs with gasket e The above spacings apply for fixing through thin sheet purlins greater than 1mm thickness ora minimum embedment of 50mm into timber purlins The length of these screws should be chosen according
13. oltaic Mounting Systems Base Rail Installation 16 When planning a system using a telescopic mounting please mount a telescopic mounting at the end of every row of rails To do this you insert the end of the telescopic mounting into the rail The mountings can be adjusted to their correct positions later For this reason you should not yet fasten the M8 Allen bolt to the rear of the telescopic mounting left side 17 Fasten any remaining roof hooks to the movable rail element of the telescopic mounting Please repeat steps 14 to 16 until all base rail rows in your system are installed PV Module Installation 18 Before installing the modules add anti slip protection to the lowest row of modules horizontal rail installation only To do this fasten M6 x 20 mm bolts with the shank downwards to the lower mounting holes of the module frame using M6 nuts When installing large modules e g ASE250 M8 x 20 mm bolts must be used 19 Place the first module of the bottom row so that the anti slip protection sits in the rail channel of the lowest row of rails ezRack SolarRoof Installation Guide Page 11 of 13 EzRack SolarRoof Code Compliant Planning and Installation Guide AU V1 4 Clenergy Co Ltd Clenergy Photovoltaic Mounting Systems PV Module Installation ezRack SolarRoof Installation Guide 20 Slide the module end clamp tightly against the module and fasten tightly using the Allen bolt re
14. rranties of their own Clenergy s limited Warranty covers only its Product and not any related items Page 13 of 13 EzRack SolarRoof Code Compliant Planning and Installation Guide AU V1 4 Clenergy Co Ltd
15. the finish All installations in corrosive atmospheric conditions are excluded The Finish Warranty is VOID if the practices specified by AAMA 609 amp 610 02 Cleaning and Maintenance for Architecturally Finished Aluminum www aamanet org are not followed by Purchaser This Warranty does not cover damage to the Product that occurs during its shipment storage or installation This Warranty shall be VOID if installation of the Product is not performed in accordance with 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 If within the specified Warranty periods the Product shall be reasonably proven to be defective then Clenergy shall repair or replace the defective Product or any part thereof in Clenergy s sole discretion Such repair or replacement shall completely satisfy and discharge all of Clenergy s liability with respect to this limited Warranty Under no circumstances shall Clenergy be liable for special indirect or consequential damages arising out of or related to use by Purchaser of the Product Manufacturers of related items such as PV modules and flashings may provide written wa
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