Rayport G Eco Ballasted

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1 Rayport G Eco Ballasted Dealer Kit Installation Guide Contents 1. Installer Notes..... P2 2. Parts List P Tool List.... P7 4. Assembly.... P Supporting a Cleaner, Greener Tomorrow

2 1. Installer Notes Thank you for purchasing AET s Rayport G Eco Ballasted ground mount racking system manufactured in Maumee, Ohio. The system has been configured to accommodate framed (30-51mm thick) modules at two-high in portrait. Designed with the installer in mind, the Rayport G Eco Ballasted system allows for a top down installation, common fasteners, and integrated panel grounding with single point rack grounding. The Rayport G Eco Ballasted racking system has been internally tested to withstand snow loads as high as 50psf and winds of 120mph with a tilt angle of 10 to 45 degrees. P2

3 2. Parts List Post -Variable lengths are available based on customer design constraints. Strut Post/Strut Hardware Brace(Post) - 2 x 2 Angle Cross-Section P3

4 2. Parts List Continued Post/Brace Hardware Purlin -Lengths will vary depending on customer design constraints Purlin Splice Front -P/N: / 4 thru holes (8) places Purlin Splice Back - P/N: / 16 thru holes (8) places Purlin Splice Hardware P4

5 2. Parts List Continued Purlin Hardware (2 per joint) Brace(Purlin) - 1 x 1 Angle Cross-Section Purlin/Brace Hardware Mid Clamp Assembly -Module thickness 30-51mm thick P5

6 2. Parts List Continued End Clamp Assembly -Module thickness mm thick Purlin Holding Fixture P6

7 3. Tool List Layout/BOM from AET Impact Driver Socket Wrench 3 / 4 Deep Well Socket ½ Deep Well Socket 3 / 8 Deep Well Socket 7 / 16 Deep Well Socket 100 ft. Tape Measure Torque Wrench String/Laser Level P7

8 4. Assembly 1. Ballast Installation Establish benchmarks by using the first and last ballast blocks of the array. All ballast blocks and bolt patterns must meet the following tolerances. Note: To ensure a smooth transition between adjacent arrays and to eliminate stepping height differences, establish the benchmark using the first ballast block of the two adjacent arrays. North/South bolt pattern must be held within +/ inches. East/West bolt pattern must be held within +/ inches. East/West ballast spacing must be held within +/- 2.0 inches. Overall height must be maintained within +/ inches. Maximum angle tolerance of +/- 0.5 degrees. See Figure 1. Figure 1 P8

9 4. Assembly Continued 2. Strut to Post Assembly Loosely attach a strut to (1) front post and (1) rear post using (2) ½ x 3.5 bolts, (4) washers and (2) nuts. Note: Strut must be positioned on the east side of the posts. (See figure 2). Front Post East Rear Post Figure 2 3. Strut Post Assembly to Ballast Attach the Strut-Post Assembly to the ballast. Torque to the values specified by the anchor bolt manufacturer. (See figure 3a and 3b). Torque the strut post assembly fasteners to ft-lb. (See figure 3b). Note: This must be completed after the posts have been secured to the ballast. Torque to ft-lb Figure 3a Torque to anchor bolt manufacturers specifications Figure 3b P9

10 4. Assembly Continued 4. Brace to Post (Optional) Position the brace on the front post such that the top edge is approximately ½ below the strut and the thru hole is centered. Loosely attach the brace to the front post using (1) ¼ x 1-1 / 8 self drilling screw. (See figure 4a and 4b). Rotate the other end of the brace until the thru hole is centered on the side of the rear post. Attach the brace to the rear post using (1) ¼ x 1-1 / 8 self drilling screw. (See figure 4b and 4c). Torque the self drilling screws to 5 ft-lb. Figure 4a Center brace thru hole on front post. Rotate brace until thru hole is centered on rear post ½ gap between strut and brace Figure 4b Figure 4c P10

11 4. Assembly Continued 5. Purlin to Splice Assembly Align the (2) slots of the front splice to the prepunched holes located at the ends of each purlin. Attach the front splice to the purlins using (2) ¼ x 1-1 / 8 self drilling screws. Note: The purlins should form a straight line through the splice joint. This can be accomplished by pushing the front splice against the top flange of the purlin and using it as a straight edge to align the purlins. (See figure 5a). Top flange of the purlin Figure 5a Complete the attachment of the front splice to the purlin using (8) ¼ x 1-1 / 8 self drilling screws. (See figures 5b and 5c). Complete the purlin to splice assembly using the back splice and (10) ¼ nuts. Torque the fasteners to 5-7 ft-lb. (see figures 5d, 5f and 5e). Figure 5b Figure 5c Figure 5d Figure 5f Figure 5e P11

12 4. Assembly Continued 6. Purlin to Strut Assembly Position the purlin holding fixtures at the top (north) holes located on the top face of each strut in the array. (See figure 6a). Note: The bottom brackets of the fixtures are slotted. They may need to be adjusted in order for the positioning bolt to fit into the thru hole. Rest the upper purlin against the purlin fixtures and across the struts. Note: The purlin must be in the proper orientation. (See figure 6b and 6c). Starting at the west end of the array, position the end of the upper purlin from the center of the strut to the distance shown on the layout. (See figure 6d). Attach the upper purlin to the of struts using (2) ¼ x 1-1 / 8 self drilling screws and nuts per joint. Torque to 5-7 ft-lb. (See figure 6e and 6f). Note: The entire purlin length for the array should be assembled prior to completing this step. Top Face Push bolt into thru hole to position purlin fixture Figure 6a Figure 6b Purlin Orientation Figure 6c P12

13 4. Assembly Continued 6. Purlin to Strut Assembly Continued Re-position the purlin holding fixtures to the bottom (south) holes located on the top face of each strut in the array. Rest the lower purlin against the holding fixtures. Note: The purlin must be in the proper orientation. (See figure 6c). End of purlin to centerline of strut distance. Using a string line or a straight edge, align the west end of the lower purlin to the upper purlin. (See figure 6d). Attach the lower purlin to the struts using (2) ¼ x 1-1 / 8 self drilling screws and nuts per joint. Torque to 5-7 ft-lb. (See figure 6e and 6f). Note: The entire purlin length for the array should be assembled prior to completing this step. Install the remaining purlins using the steps described above. Figure 6d (2) self drilling screws and nuts per joint Figure 6e Figure 6f P13

14 4. Assembly Continued 7. Brace to Purlin Assembly Attach the brace to the purlins using (1) ¼ x 1-1/8 self drilling screw and nut per joint. Reference the layout to determine the approximate location between the post. (See figure 7a and 7b) Torque fasteners to 5 ft-lb. Figure 7a 4 places Figure 7b P14

15 4. Assembly Continued 8. Panel Assembly Establish a benchmark line along the entire length of the lower purlin at a distance which is slightly greater than the overhang distance shown on the layout. (See figure 8a). Starting from the west end of the array, square up a bottom module to the benchmark line. Reference the layout to determine the distance the module should be positioned in from the west end of the purlins. The distance from the lower edge of the module to the middle of the lower purlin should be set to the overhang distance. (See figure 8a). Note: The purlin ends should NOT be used to square the modules on the array. The layout dimension is an approximate dimension only. Approximately a 1 gap between modules End of purlin to module distance Fasten the end-clamps to hold the module in place. Do not torque them down at this time. (See figure 8b). On the opposite side of the module position a midclamp assembly on the purlins. Slide the mid-clamp assembly until the side of the mid-clamp lower contacts the side of the module and the grounding barb is positioned under the module. Fasten the midclamps to hold the module in place but do not torque them down at this time. (See figure 8c and 8d). Continue installing the next module on the bottom row using the steps described above. Use the string line to align the bottom edge of the remaining modules. Torque each mid-clamp and end clamp to 5-7 ft-lbs. Starting from the west end of the array, square up the top modules to the bottom modules. Factor in approximately a 1 gap between the modules on the top and bottom rows. Fasten the top modules to the purlins using the steps described above. Figure 8a Overhang Figure 8b Mid-Clamp Lower Grounding Barb Figure 8d P15 Figure 8c

16 4. Assembly Continued 9. Grounding One post per array is required to be grounded. This will effectively ground each entire sub-array (usually panels). P16

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