PV-ezRACK PZ30-IM01-14 Solar Base Low Ballasted Flat Roof System Installation Guide

PV-ezRACK PZ30-IM01-14 Solar Base Low Ballasted Flat Roof System

Product Information: SolarBase Low Ballast Flat Roof System

The SolarBase Low Ballast Flat Roof System is a solar panel mounting system designed for use on flat roofs. The system includes components such as support legs, ballast bars, module clamps, wind deflectors, and grounding lugs. The system is designed to be installed using specific tools such as a 6mm inside hexagonal spanner, electric tool, 5m tape, marking pen, torque spanner, socket spanner, and string. It is important to follow the installation guide and precautions during installation to ensure proper function of the system.

Product Usage Instructions

1. Start by planning the installation of the SolarBase Low Ballast Flat Roof System.
2. Ensure that you have all the necessary tools and components before starting the installation.
3. Follow the precautions during stainless steel fastener installation to reduce the risk of deadlock of bolts and nut.
4. Refer to the safe torques defined in the guide for tightening the fasteners. Use low speed when using power tools.
5. Install the support leg team by adjusting the distance between two square neck bolts on Support Leg according to the specification of ballast and fixing the square neck bolts.
6. Put rubber protection gasket into Support Leg and make sure the hole centre of rubber gasket is aligned with bolt centre.
7. Continue with the installation of ballast bars, module clamps, wind deflectors, and grounding lugs as per the installation instructions provided in the guide.
8. Ensure that the installation is done uniformly and with required torque using professional tools and tool belts.
9. Avoid using electric tools for final tightening and working at high temperatures.

Introduction

PVezRack® SolarBase system is a roof mounting system suitable for small and medium-sized commercial roof installations. Professional structure design greatly simplifies installation steps, under the premise of guaranteeing safety, which reduces cost and improves efficiency during installation. Please review this manual thoroughly prior to installing PVezRack® SolarBase. This manual provides supporting documentation for building permit applications relating to PVezRack® SolarBase system. The PVezRack® SolarBase parts, when installed in accordance with this guide, will be structurally adequate. During installation please comply with the appropriate occupational health and safety regulations. Please also pay attention to other relevant regulations of your local region. Please check that you are using the latest version of the installation manual, which you can do by contacting Clenergy via email on sales@clenergy.com.au, or contacting your local distributor.

Product Warranty

Please refer PV-ezRack® Product Warranty on our website.

Tools and Components

Tools

Note : tools in the figure are only used for rack system (not included in supply scope); Consult system installation personnel about electronic part installation tools.

Components

System Overview

Overview of PV-ezRack SolarBase

1. Support Leg
2. Ballast Bar
3. Module Clamp 40 mm
4. Wind Deflector
5. Grounding Lug

Installation planning

Note: Red circles highlight installation of Module Clamp 40;
Take 1650x990x40 PV module as an example. Installation angle is 10° and distance between front and rear parts of component is 532mm.

Precautions during Stainless Steel Fastener Installation

Improper operation may lead to deadlock of Bolts and Nut. Follow the steps below to reduce this risk
Reduce the friction coefficient

1. Ensure that the thread surface is clean (no dirt or contaminant)
2. Apply lubricant (grease or 40# engine oil) to fasteners prior tightening to avoid galling or seizing in the threads;

General installation instructions

1. Apply force to fasteners in the direction of thread;
2. Apply force uniformly, to maintain required torque;
3. Professional tools and tool belts are recommended;
4. Avoid using electric tools for final tightening;
5. Avoid working at high temperatures;

Safe Torques
Please refer to safe torques defined in this guide as shown in below; 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 please make sure that there is no load on the fastener before you cut it. Avoid damaging the anodized or galvanized surfaces

Installation Dimensions

All drawings and dimensions in this installation guide are for a generic reference. The Clenergy PVezRack® SolarBase is to be optimized to suit specific conditions for each project and documented in a construction drawing. As a result, major components of the Clenergy PVezRack® SolarBase may be provided in section sizes and lengths that vary from those shown in this guide. The installation process detailed in this instruction guide remains the same regardless of the component size. In case you need to do any on-site modifications or alteration of the system in a way that would be different from the construction drawing please provide marked up drawings/sketches for Clenergy’s review prior modification for comment and approval.

Installation Instructions

Install Support Leg team

• According to specification of ballast, adjust distance between two square neck bolts on Support Leg and fix square neck bolts, as shown in Figure 1.
• Put rubber protection gasket into Support Leg and make sure the hole centre of rubber gasket is aligned with bolt centre, as shown in Figure 2. Figure 3
• According to installation specification, use tools such as tape, string and marker pen to make out position and then place Support Leg, as shown in

Install Wind Deflector and ballast
(optional parts)

Fix Wind Deflector on the pre-assembled bolts of Support Leg team and make it press against Support Leg, and make sure the position of Support Leg team unchanged as  shown in Figure 4. Figure 4 Figure 5
Fix Ballast Bar into the bolts of Support Leg team, and add M8 plain washer, washer and nut and fasten tightly as shown in Figure 4 and 5.
Recommended torque:
8-9 N·m for M8 Bolts

Attention : Wind Deflectors are installed on Support Legs of the last row. Two adjacent Wind Deflectors will be overlapped as shown in Figure 6

Use U-bolt M858 to lock Wind Deflector tightly as shown in Figures 7 and 8.
Recommended torque:
8-9 N·m for U-bolt M858

After Wind Deflector and Ballast bar are installed, load ballast orderly. Ballast height should be no more than 145mm as shown in Figure 9.
(If Wind Deflector is not required, please ignore the above instructions.)

Install PV modules and Module Clamp 40 Rotate the right part of Support Leg to the required position as shown in Figure 10.
Place PV module smoothly on Support Leg. According to installation planning, adjust left and right positions of PV module and guarantee frame of PV module attach to the rotating part of Support Leg. Pay attention to installation
direction of PV module as shown in Figure 11.

Fasten the frame of PV module and Support Leg with Module Clamp 40 as shown in Figure 12.
Adjust Module Clamp 40 to ensure that it’s located in the middle of preassembled parts of Support Leg and fasten tightly. While fasten the Bolts M825, hold the Module Clamp 40 to ensure it unmovable, as shown in Figure 13 and 14.
Recommended torque: 18-20N.m for Bolts M825
After fasten the Module Clamp 40, lay PV Module slightly down on the preassembled part of Support Leg in the rear row as shown in Figure15.

Adjust Module Frame Back Mounting Clip along fore-aft direction; ensure the frame of PV module will be held by Mounting Clip as shown in Figure 16 and 17.
Fasten Bolts M835 and Square Neck Bolts M845 tightly in order.
Recommended torque: 10-12N·m for Bolts M8*35
Recommended torque: 18-20N·m for Square Neck Bolts M8
Repeat above operations to install the rest PV modules as shown in Figure18.

Install Grounding Lug
Fix the Grounding Lug on Ballast Bar of the longest row along vertical direction as shown in Figure 19, install one Grounding Lug per row and fasten tightly.
Fix the Grounding Lug on Ballast Bar of the longest row along vertical direction as shown in Figure 19, install one Grounding Lug per row and fasten tightly.
Fix the Grounding Lug on Ballast Bar of the longest row along vertical direction as shown in Figure 19, install one Grounding Lug per row and fasten tightly.

Clenergy
1/10 Duerdin St
Clayton VIC 2168
Australia
Phone: +61 3 9239 8088
Email: sales@clenergy.com.au
Web: www.clenergy.com.au

@ClenergyGlobal / @ClenergyClub / ClenergyAUS @Clenergy @ClenergyClub
@Clenergy_global @Clenergy
A Clenergy Technologies Company

References

• Home | Clenergy | Solar Racking | Cable Management | PV mountings | Fasten your solar panels to the Rooftop or ground

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