Clenergy Tilt Legs Installation guide

PV-ezRack® SolarRoofTM Tilt Legs

Installation Guide

Code-Compliant Planning and Installation Guide V5.0

Complying with AS/NZS1170.2-2011 AMDT 2-2016

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

01page of 26Installation Guide PV-ezRack SolarRoof Adjustable Tilt Leg (September 2020)

Introduction

1. Introduction

The Clenergy PV-ezRack® SolarRoof™ Tilt

Legs has been developed as a universal

PV-mounting system for roof-mounting on

pitched and flat roofs. The use of patented

aluminium base rails, Z-Module technology

and telescopic mounting technology eliminates

custom cutting and enables fast installation.

Please review this manual thoroughly before

installing PV-ezRack® SolarRoof™ Tilt Legs.

This manual provides

1) Supporting documentation for building

permit applications relating to PV-ezRack®

SolarRoof™ Tilt Legs Universall PV Module

Mounting System,

2) Planning and installation instructions.

The PV-ezRack® SolarRoof™ Tilt Legs parts,

when installed in accordance with this guide,

will be structurally sound and will meet the

AS/NZS1170.2:2011 Amdt 2- 2016 standard.

During installation, and especially when

working on the roof, please comply with the

appropriate Occupational Health and Safety

regulations. Please also pay attention to any

other relevant State or Federal regulations.

Please check that you are using the latest

version of the Installation Manual, which you

can do by contacting Clenergy Australia via

email on sales@clenergy.com.au, or contacting

your local distributor in Australia.

Introduction

Planning

Tools & Components

System Overview

Installation Instruction

Certification Letter and Tilt Legs

Spacing Table

01

02

14

15

18

26

List of Contents

The installer is solely responsible for:

• Complying with all applicable local or national

building codes, including any updates that

may supersede this manual;

• Ensuring that PV-ezRack and other products

are appropriate for the particular installation

and the installation environment;

• Using only PV-ezRack parts and installer-

supplied parts as specified by PV-ezRack

project plan (substitution of parts may void the

warranty and invalidate the letter of certification);

• Recycling: Recycle according to the local

relative statute;

• Removal: Reverse installation process;

• Ensuring that there are no less than

two professionals working on panel installation;

• Ensuring the installation of related

electrical equipment is performed by licenced

electricians;

• Ensuring safe installation of all electrical

aspects of the PV array, This includes adequate

earth bonding of the PV array and PV-ezRack®

SolarRoof™ components as required in AS/

NZS 5033-2014 AMDT 2 2-2018;

• Ensuring that the roof, its rafters/purlins,

connections, and other structural support

members can support the array under building

live load conditions;

• Ensuring that screws to fix interfaces have

adequate pullout strength and shear capacities

as installed;

• Maintaining the waterproof integrity of the roof,

including selection of appropriate flashing;

•Verifying the compatibility of the installation

considering preventing electrochemical

corrosion between dissimilar metals. This

may occur between structures and the building

and also between structures, fasteners and PV

modules, as detailed in AS/NZS 5033: 2014.

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

02page of 26Installation Guide PV-ezRack SolarRoof Adjustable Tilt Leg (September 2020)

Region Definition:

Wind regions are pre-defined for the whole of

Australia by the Australian Standard 1170.2.

The Wind Region is an independent factor of

surrounding topography or buildings.

• Most of Australia is designated Region A which

indicates a Regional Wind Velocity of 43 m/s with

wind average recurrence of 200 years.

• Some areas are designated Region B (52 m/s).

Local authorities will advise if this applies in your

area.

• Region C areas (64 m/s) are generally referred to

as Cyclonic and are generally limited to northern

coastal areas. Most Region C zones end 100km

inland.

• Region D (79 m/s) is Australia's most extreme

Cyclonic Region, located between the town of

Carnarvon and Pardoo Station in Western

Australia.

2. Planning

2.1 Determine the wind region of your installation site

Planning

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

03page of 26Installation Guide PV-ezRack SolarRoof Adjustable Tilt Leg (September 2020)

Planning

You will need to determine the terrain category to ensure the installation meets the required standard.

Terrain Category 1 (TC1) – Very exposed open terrain with few or no obstructions and enclosed, limited-

sized water surfaces at serviceability and ultimate wind speeds in all wind regions, e.g. flat, treeless,

poorly grassed plains; rivers, canals and lakes; and enclosed bays extending less than 10km in the wind

direction.

Terrain Category 1.5 (TC1.5) – Open water surfaces subjected to shoaling waves at serviceability and

ultimate wind speeds in all wind regions, e.g. near-shore ocean water; larger unenclosed bays on seas and

oceans; lakes; and enclosed bays extending greater than 10km in the wind direction. The terrain height

multipliers for this terrain category shall be obtained by the linear interpolation between the values for the

TC1 and TC2.

Terrain Category 2 (TC2) – Open terrain, including grassland, with well-scattered obstructions having

heights generally from 1.5m to 5m, with no more than two obstructions per hectare, e.g. farmland and

cleared subdivisions with isolated trees and uncut grass.

Terrain Category 2.5 (TC2.5) – Terrain with a few trees or isolated obstructions. This category is

intermediate between TC2 and TC3 and represents the terrain in developing outer urban areas with

scattered houses, or larger acreage developments with fewer than ten buildings per hectare. The terrain-

height multipliers for this terrain category shall be obtained by linear interpolation between the values for

the TC2 and TC3.

Terrain Category 3 (TC3) – Terrain with numerous closely spaced obstructions having heights generally

from 3m to 10m. The minimum density of obstructions shall be at least the equivalent of 10 house sized

obstructions per hectare, e.g. suburban housing or light industrial estates.

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.

2.2 Determine the Terrain Category

This document provides sufficient information for the PV-ezRack® SolarRoof™ Tilt Legs system installation

up to heights of 20 meters. If your installation site is more than 20 meters high please contact Clenergy to

obtain project specific engineering certificate to support your installation.

2.3 Determine the Height of the Installation Site

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

04page of 26Installation Guide PV-ezRack SolarRoof Adjustable Tilt Leg (September 2020)

Planning

The PV-ezRack® SolarRoof™ Tilt Legs system can be used for roof slopes up to 30°. Please verify that

the Installation site roof slope is between 0° and 30°.

2.4 Determine Roof slope

On the north facing roof, the angle of rear leg is between 30° and 90° with the roof plane.

On the south facing roof to make the panels facing the north (reverse tilt), the angle of rear leg should be

no more than 90° with the horizontal.

30-60° adjutable tilt legs is certified for reverse tilt installation on the south facing roof. Please refer to

Certification Letter and Tilt Legs Spacing Table.

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

05page of 26Installation Guide PV-ezRack SolarRoof Adjustable Tilt Leg (September 2020)

Planning

On pitched roof, there are four different roof zones for installation. See the diagrams and steps below

to determine area of each zone.

2.5 Determine the Installation Area of Roof

In the front figure h= height, b =width and d= length of the

building.

Step 1: Determine building height, width and length.

Step 2: Multiply the width of the building by 0.2

Step 3: Multiply the length of the building by 0.2

Step 4: Determine lowest value between: (height of the building)

and 0.2 × length of the building and 0.2 × width of the building

Step 5: The lowest value in step 4, equates to a.

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

06page of 26Installation Guide PV-ezRack SolarRoof Adjustable Tilt Leg (September 2020)

Please refer to the Certification Letter and Tilt Legs Spacing Table. If a project specific Certification

Letter has been provided, please refer to the support spacing in this letter.

2.7 Determine the Maximum Rail Support Spacing

There are options of using two screws or one screw for installations of adjustable and fixed tilt legs,

depending on the project details, like required support spacing, purlin spacing, rib spacing of roof

sheet and so on. Please find both two screws and one screw engineering certificates at the end of

installation guides for max support spacing.

2.6 Determine Two Screws or One Screw Installations of Tilt Legs

Application of Adjustable Tilt Legs

Purlin spacing 1200 mm 1400 mm 1700 mm

Product 10° 15° 30° 45° 60° 10° 15° 30° 45° 60° 10° 15° 30° 45° 60°

1650 mm panel

in portrait

ER-TL-10/15 √

（1）

√

（2） × × × √

（6） ×××××××××

ER-TL-15/30 ×××××× √

（8） × × × × × × × ×

ER-TL-30/60 × × √

（3）

√

（4） × × × √

（10）

√

（12） × × × √

（14） × ×

1960 mm panel

in portrait

ER-TL-10/15 ××××× √

（7） ×××××××××

ER-TL-15/30 ×××××× √

（9） × × × × × × × ×

ER-TL-30/60 ××× √

（5） × × × √

（11）

√

（13） × × × √

（15） × ×

Note: √indicates applicable; × indicates not applicable

The table above is based on:

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.

Following the tilt angle rules of 2.4 on the north or south facing roof, the actual panel tilt angles using the

adjustable tilt legs installed at the different purlin spacing could be applicable or not. Please see the table and

side view diagrams below.

2.9 The application of Adjustable Tilt Legs

Rail end overhang should not be over 40% of the Tilt Legs spacing. For example, if the Tilt Legs

spacing is 1500mm, the Rail end overhang can be up to 600mm only.

2.8 Verify Maximum Rail End Overhang

Planning

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

07page of 26Installation Guide PV-ezRack SolarRoof Adjustable Tilt Leg (September 2020)

Planning

(1)

(2)

(3)

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

08page of 26Installation Guide PV-ezRack SolarRoof Adjustable Tilt Leg (September 2020)

Planning

(5)

(4)

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

09page of 26Installation Guide PV-ezRack SolarRoof Adjustable Tilt Leg (September 2020)

Planning

(6)

(8)

(7)

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

10page of 26Installation Guide PV-ezRack SolarRoof Adjustable Tilt Leg (September 2020)

Planning

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(10)

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

11page of 26Installation Guide PV-ezRack SolarRoof Adjustable Tilt Leg (September 2020)

Planning

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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

12page of 26Installation Guide PV-ezRack SolarRoof Adjustable Tilt Leg (September 2020)

(13)

Planning

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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

13page of 26Installation Guide PV-ezRack SolarRoof Adjustable Tilt Leg (September 2020)

Planning

(15)

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

14page of 26Installation Guide PV-ezRack SolarRoof Adjustable Tilt Leg (September 2020)

3.2 Components

ER-EC-ST

End Clamp

ER-TL-10/15

ER-TL-15/30 ER-TL-30/60

Adjustable Tilt legs,

non-preassembly

Component list

ER-R-ECO

ECO Rail

ER-SP-ECO

Splice for ECO Rail

ER-TL-10/15/PS

ER-TL-15/30/PS

Adjustable Tilt legs,

preassembly

TL-10/15/L/PS

TL-15/30/L/PS

Adjustable Tilt Legs with L-feet,

preassembly

ER-TL-5/PS

ER-TL-10/PS

Fixed Tilt Legs,

preassembly

Tools and Components

3. Tools and Components

3.1 Tools

Screw Driver

(maximum torque≥34N·m)

5m Tape

Torque Spanner Socket Wrench M8

String & Marker Pen

Tools

EZ-GL-ST

Grounding Lug

EZ-GC-ST

Grounding Clip

ER-IC-ST

Inter Clamp

C-U/30/46

Universal Clamp

C-U/30/46-G

Universal Clamp

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

15page of 26Installation Guide PV-ezRack SolarRoof Adjustable Tilt Leg (September 2020)

System Overview

4. System Overview

4.1 Overview of PV-ezRack® SolarRoofTM Adjustable Tilt Legs

4.1.1 Adjustable Tilt Legs

4.1.2 Adjustable Tilt Legs with L-feet

①End Clamp ②Inter Clamp ③Grounding Clip ④ECO Rail ⑤Grounding Lug

⑥Adjustable Tilt Legs

①End Clamp ②Inter Clamp ③Grounding Clip ④ECO Rail ⑤Grounding Lug

⑥Adjustable Tilt Legs with L-feet

①

②

③④

⑤

⑥

①

②

③

④

⑤

⑥

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

16page of 26Installation Guide PV-ezRack SolarRoof Adjustable Tilt Leg (September 2020)

System Overview

4.1.3 Fixed Tilt Legs

①End Clamp ②Inter Clamp ③Grounding Clip ④ECO Rail ⑤Grounding Lug

⑥Fixed Tilt Legs

①

②

③

④

⑤

⑥

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.

4.2 Precautions during Stainless Steel Fastener Installation

4.2.1 General installation instructions:

(1) Apply force to fasteners in the direction of thread

(2) Apply force uniformly, to maintain the required torque

(3) Professional tools and tool belts are recommended

(4) In some cases, fasteners could be seized over time. As an option, if want to avoid galling or seizing of thread,

apply lubricant (grease or 40# engine oil) to fasteners prior to tightening.

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

17page of 26Installation Guide PV-ezRack SolarRoof Adjustable Tilt Leg (September 2020)

System Overview

4.2.2 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. Avoid damaging the anodized or galvanized surfaces.

①Adjustable Tilt Legs

②Adjustable Tilt Legs with L-feet

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

18page of 26Installation Guide PV-ezRack SolarRoof Adjustable Tilt Leg (September 2020)

Installation Instruction

③ Fixed Tilt Legs

5. Installation Instruction

5.1 Front & Rear Leg Installation

5.1.1 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. Tin foot front leg

installation is in Figure 3.

Figure 2 Front Leg Installation with Single Screw Figure 3 Tin Foot Front Leg Installation

Figure 1 Front Leg Installation with Two Screws

Unit 1, 10 Duerdin St, Clayton VIC 3168, Australia

Tel: +61 3 9239 8088 Fax: +61 3 9239 8024

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19page of 26Installation Guide PV-ezRack SolarRoof Adjustable Tilt Leg (September 2020)

Installation Instruction

Figure 4

5.1.2 Rear Leg Installation:

According to the installation plan, after

confirming the length L of the Rear Leg, fasten

M8*12 set screws as shown in Figure 4.

Recommended torque for M8*12 Set screws is

10~12 N·m

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. Using preassembly or non-preassembly rear legs will make installation

steps a bit different as well. See the installation images in Figures 5-9.

Figure 5 Non-preassembly Rear Leg Installation with Two Screws

Figure 6 Non-preassembly Rear Leg Installation with Single Screw

Figure 7 Preassembly Rear Leg Installation with Two Screws

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Clenergy Tilt Legs Installation guide

Clenergy Tilt Legs Installation guide

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