Rayport G Eco Dealer Kit Installation Guide Contents 1. Installer Notes..... P2 2. Parts List........ P3-7 3. Tool List.... P8 4. Assembly.... P9-19 www.aetenergy.com Supporting a Cleaner, Greener Tomorrow
1. Installer Notes Thank you for purchasing AET s Rayport G Eco 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 system allows for a top down installation, common fasteners, and integrated panel grounding with single point rack grounding. The Rayport G Eco 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
2. Installation - Parts List Post -Variable lengths are available based on customer design constraints. Capital Plate Post/Capital Plate Hardware Strut P3
2. Installation - Parts List Cont. Capital Plate/Strut Hardware Bracket Bracket - Post Hardware Bracket Post / Brace Hardware P4
2. Installation - Parts List Cont. Purlin -Lengths will vary depending on customer design constraints Purlin Splice Front - P/N: 81029-1 / 4 thru holes (8) places Purlin Splice Back - P/N: 81077-5 / 16 thru holes (8) places Purlin Splice Hardware P5
2. Installation - Parts List Cont. Purlin Hardware (2 per joint) Brace(Purlin) - 1 x 1 Angle Cross-Section Purlin/Brace Hardware Mid Clamp Assembly -Module thickness 30-51mm thick P6
2. Installation - Parts List Cont. End Clamp Assembly -Module thickness 30-51 mm thick Purlin Holding Fixture P7
3. Installation - 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 P8
4. Installation - Assembly Instructions 1. Post Installation Pursuant to a geotech analysis and report of the project location, AET can provide the minimum depth that each post in the given array must be driven. In some cases, it may be necessary to use concrete footings. AET can provide this design information as well. Consult the AET sales team for project specific pricing. Establish baselines by using the first and last posts of the array. All posts must meet the following tolerances. North/South alignment must be held within +/- 0.75 inches. East/West spacing must be held within +/- 2.0 inches. Overall height must be maintained within +/- 0.75 inches. Maximum angle tolerance of +/- 0.5 degrees. See figure 1. Figure 1 P9
4. Installation - Assembly Instructions Cont. Post Section for Driver Head Figure 2 - W6 x 7 Post Section Figure 3 - W6 x 8.5 Post Section P10
4. Installation - Assembly Instructions Cont. 2. Capital Plate to Post Assembly (Up-Down Alignment) Establish a benchmark line using the top of the first and last posts of the array. Note: The height of the benchmark line may require adjustment if the middle posts are higher than the end posts. Also, to ensure a smooth transition between adjacent arrays and to eliminate stepping height differences, establish the benchmark line using the first post of the two adjacent arrays. Up/Down Direction North Place (1) capital plate on the top of each post in the array aligning them in the Up-Down direction relative to the benchmark line. Fasten the capital plates to the post using (2) ½ x 1-1/4 carriage bolts, washers and nuts each. Torque each carriage bolt to 40-45 ft-lb. Note: the capital plate must be positioned on the east side of the post web. The capital plates are now aligned in the Up-Down direction. Post Web East 3. Capital Plate to Post Assembly (North-South Alignment) Establish a benchmark line using the top of the capital plates located on the first and last posts of the array. Place a mark on the west side of the upper horizontal slot of each capital plate to identify which position aligns to the benchmark line in the North- South direction. This position is where the strut will be installed in the next step. East North Torque to 40-45 ft-lb. (after height adjustment) The capital plates are now aligned in the North-South direction. P11
4. Installation - Assembly Instructions Cont. 4. Bracket to Post Assembly Attached a bracket to the post using (2) ½ x 1-1/2 bolts, washers and nuts. Position the fasteners in the middle of the slots and torque to 40-45 ft-lb. Note: The bracket must be positioned on the post as show in figure 4. 5. Strut to Capital Assembly Loosely attach the strut to the capital plate using (1) ½ x 1-1/4 carriage bolt, washer, and nut. Use the slot position that was marked in step 2. See figures 5a, 5b and 5c Note: The strut must be positioned on the east side of the capital plate. North Figure 4 East North North East East Figure 5a Figure 5b Figure 5c P12
4. Installation - Assembly Instructions Cont. 6. Brace to Strut Assembly With one person holding the lower end of the strut, have a second person loosely attach the brace to the strut with a ½ x 3 ½ bolt, washers and nut (see figure 6). Brace to Bracket-Post attachment location 7. Brace to Bracket-Post Assembly While one person continues to hold the lower end of the strut, the angle can be adjusted while a second person holds the brace to its rough location on the bracket-post. Verify the angle of the strut with a protractor (digital or manual). Choose one of the three hole locations that matches the angle shown on the layout. Note: The bracket to post interface is slotted. It can be re-positioned if additional adjustment is required (see figure 4). Attach the brace to the bracket -post with a ½ x 3 ½ bolt, washers and nut (see figures 6 and 7a). Torque the fasteners at the (3) joint locations to the value shown in figure 7b. Figure 6 Torque to 40-45 ft-lbs. Brace to Strut attachment location Adjust height for angle adjustment Figure 7b Figure 7a P13
4. Installation - Assembly Instructions Cont. 8. 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 8a). Top flange of the purlin Figure 8a Complete the attachment of the front splice to the purlin using (8) ¼ x 1-1 / 8 self drilling. (See figures 8b and 8c). Complete the purlin to splice assembly using the back splice and (10) ¼ nuts. Torque the fasteners to 5-7 ft-lb. (see figures 8d, 8f and 8e). Figure 8b Figure 8c Figure 8d Figure 8f Figure 8e P14
4. Installation - Assembly Instructions Cont. 9. Purlin to Strut Assembly Position the purlin holding fixtures at the top (north) holes located on the top face of each strut of the array. (See figure 9a). Note: The bottom brackets of the fixture are slotted for adjustability. This can be accomplished by loosing the wind nuts and moving the brackets to the desired location. Rest the upper purlin against the purlin fixtures and across the struts. Note: The purlin must be in the proper orientation. (See figure 9b and 9c). 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 9d). 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 9e and 9f). Note: The entire purlin length for the array should be assembled prior to completing this step. Top Face Figure 9b Push bolt into thru hole to position purlin fixture Figure 9a Purlin Orientation Figure 9c P15
4. Installation - Assembly Instructions Cont. 9. Purlin to Strut Assembly Cont. 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 9c). 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 purlin. (See figure 9d). 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 9f, 9f and 9h). 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 9d Figure 9e (2) self drilling screws and nuts per joint Figure 9f P16
4. Installation - Assembly Instructions Cont. 10. 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 posts. (See figure 10a and 10b). Torque fasteners to 5 7 ft-lb. Purlins Strut Figure 10a 4 places Figure 10b P17
4. Installation - Assembly Instructions Cont. 11. 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 11a). 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 11a). Fasten the end-clamps to hold the module in place but do not torque them down at this time. (See figure 11b). Approximately a 1 gap between modules End of purlin to module distance 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 hits the side of the module and the angled barb is under the module. Fasten the mid-clamps to hold the module in place but do not torque them down at this time. (See figure 11c and 11d). 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-lb. 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 11a Overhang Figure 11b Mid-Clamp Lower Grounding Barb Figure 11c Figure 11d P18
4. Installation - Assembly Instructions Cont. 12. Grounding One post per array is required to be grounded. This will effectively ground each entire sub-array (usually 24-36 panels). P19