Rayport G Eco Dealer Kit Installation Guide www.aetenergy.com Supporting a Cleaner, Greener Tomorrow
1. Table of Contents 1. Table of Contents P2 2. Installer Notes P3 3. Parts List P4-7 4. Tool List P8 5. Assembly P9-23 6. Appendix A Module Overhang P24-25 7. Appendix B AET Kit Foundation Detail Drawing P26 8. Appendix C AET Dealer Kit Array Drawing P27 P2
2. 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 evaluated for module-tosystem bonding to the requirements of UL Subject 2703 Issue 2. The system has been assessed to a maximum Over-Current Device (OCD) Protection level of 25 Amps. The recommended torques shown throughout these instructions must be followed for proper assembly and bonding of the system. Note: This installation guide must be read in its entirety prior to installation. Note: Documented inspection, maintenance, cleaning and adjustments are required annually to maintain product warranty. Visible red rust corrosion on any galvanized steel components must be repaired in accordance to ASTM A780/A780M. Note: The AET Kit Foundation Detail Drawing and the AET Dealer Kit Array Drawing for the dealer kit(s) that you ordered must be reviewed before beginning the installation. Reference Appendix B and Appendix C for examples of these drawings. Please contact your distributor or AET if these drawings were not included in your shipment. These drawings can also be accessed on the internet at www.aetenergy.com/technology-center/dealer-kit-tech/ P3
3. Parts List Post -W6 x 7 I-Beam Cross-Section -10.5 Post Length - Fits both 10 and 12 struts Connector Plate - 0.29 Thick - 3.0 x 10.98 Overall Size Z-Strut - 2.5 x 6 Z Cross-Section - 10 Length for 60 Cell Modules - 12 Length for 72 Cell Modules Brace - 1.70 x 2.25 C-Channel Cross-Section Post Brace Bracket - 0.21 Thick - 2.51 x 3.74 x 4.73 Overall Size P4
3. Parts List - Continued Z-Purlin - Lengths will vary depending on customer design constraints. (Reference the AET Dealer Kit Layout). - 2.25 x 4.0 Z Cross-Section Purlin Brace - 1.0 x 1.0 Angle Cross-Section - 10 Length for 60 Cell Modules - 12 Length for 72 Cell Modules Mid-Clamp Assembly - Fits Modules 30-51mm thick End Clamp Assembly - Fits Modules 30-51mm thick Purlin Holding Fixture - ½ x 3 ½ hex head bolt - Bolt may be shipped un-assembled to job site. It will be located in the same container as the Purlin Holding Fixture. P5
3. Parts List Continued Bolt - ½ 13 x 1 ¼ Hex Head Washer - ½ SAE Flat Hardened Nut - ½ 13 Hex w/ Lock Patch Bolt - 3 / 8 16 x 1 Hex Head Washer - 3 / 8 SAE Flat Hardened Nut - 3 / 8 16 Hex w/ Lock Patch P6
3. Parts List Continued Bolt - ½ 13 x 1 ¼ Carriage Screw - ¼ 20 x 1 1 / 8 Drill Point Nut - ¼ 20 Flange Hex w/ Lock Patch - Special Thread P7
4. Tool List Layout/BOM from AET Ratchet Wrench 3 / 4 Deep Well Socket and Open End Wrench 9 / 16 Deep Well Socket and Open End Wrench ½ Deep Well Socket and Open End Wrench 3 / 8 Deep Well Socket and Open End Wrench 7 / 16 Deep Well Socket and Open End Wrench 100 ft. Tape Measure Torque Wrench Two (2) Ratchet Straps 4 T-Square String/Laser Level 3 / 8 or ½ Drill - Used for self drilling screws. - Recommended drill is Dewalt 20V Lithium Ion drill or equivalent. - The ideal rpm range to set the self drillings screws is between 800-1350 rpms. P8
5. Assembly 1. Post Installation Reference the AET Kit Foundation Detail drawing for concrete footing requirements. See Appendix B. Establish baselines by using the first and last posts of the array. 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. 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 +/- 3.0 degrees. See figure 1a. These holes must face south Figure 1a P9
2. Connector 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 one (1) connector plate on the top of each post in the array aligning them in the Up-Down direction relative to the benchmark line. Fasten the connector plates to the post using two (2) ½ x 1 1 / 4 carriage bolts, two (2) ½ washers and two (2) ½ nuts each. Torque each carriage bolt to 40-45 ft-lb. Note: the connector plate must be positioned on the east side of the post web. The connector plates are now aligned in the Up-Down direction. Post Web East 3. Connector Plate to Post Assembly (North-South Alignment) Establish a benchmark line using the top of the connector plates located on the first and last posts of the array. Note: To ensure a smooth transition between adjacent arrays establish the benchmark line using the first post of the two adjacent arrays. Place a mark on the west side of the upper horizontal slot of each connector 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 connector plates are now aligned in the North-South direction. P10
4. Post Brace Bracket to Post Assembly Attached the post brace bracket to the post using two (2) ½ x 1 ¼ bolts, four (4) ½ washers and two (2) ½ nuts. Position the fasteners in the middle of the slots and torque to 40-45 ft-lb. Note: Use the upper set of holes if installing a 10 strut and the lower set of holes if installing a 12 strut. Also, the bracket must be positioned on the post as show in figure 4. Bracket location for 10 strut Bracket location for 12 strut 5. Z-Strut to Connector Plate Assembly Loosely attach the z-strut to the connector plate using one (1) ½ x 1 ¼ carriage bolt, one (1) ½ washer, and one (1) ½ nut. Use the horizontal slot position that was marked in step 3. The z-strut must be positioned on the east side of the connector plate. See figures 5a, 5b and 5c. North Figure 4 East North North East East Figure 5a Figure 5b Figure 5c P11
6. Brace to Z-Strut Assembly With one person holding the lower end of the z-strut, have a second person loosely attach the brace to the z-strut with one (1) ½ x 1 ¼ bolt, two (2) ½ washers and one (1) ½ nut. See figure 6. Brace to Post Brace Bracket attachment location 7. Brace to Post Brace Bracket Assembly While one person continues to hold the lower end of the z-strut, the angle can be adjusted while a second person holds the brace to its rough location on the post brace bracket. Verify the angle of the z-strut with a protractor (digital or manual). Choose one of the three hole locations on the post brace bracket that will position the z-strut at the angle shown on the AET Dealer Kit Array drawing. Note: The post brace bracket to post interface is slotted. It can be repositioned if additional adjustment is required. See figure 4 and 7a. Attach the brace to the post brace bracket with one (1) ½ x 1 ¼ bolt, two (2) ½ washers and one (1) ½ nut. See figures 6 and 7a. Torque the fasteners at the (3) joint locations to the values shown in figure 7b. Figure 6 Torque to 40-45 ft-lb. Brace to Z-Strut attachment location Adjust height for angle adjustment Figure 7b Figure 7a P12
8. Z-Purlin Assembly Note: The z-purlins are shipped in different lengths to the job site. They are spliced together to create z-purlin assemblies. The order of how the different lengths are spliced together is important to ensure that the midclamp assemblies are not located at a splice joint when attaching the modules. The AET Dealer Kit Array drawing that came with your shipment identifies the East West order, relative to length, that must be followed when splicing the z-purlins together. See Appendix C. Also, the orientation of the z-purlins on the z-struts must follow a specific pattern. The z-purlin lengths must be assembled such that they match that pattern when attached to the z-struts. See figure 9f. Figure 8a Overlap two (2) z-purlins to form the splice joint. Align the pre-punched slots to achieve the correct amount of overlap. See figures 8a, 8b and 8c. Beginning with the upper flange, attach the z-purlins together using two (2) 3 / 8 x 1 bolts, four (4) 3 / 8 washers and two (2) 3 / 8 nuts. Torque the fasteners to 20-25 ft-lb. See figure 8d. Continuing with the lower flange, complete the splice joint assembly using four (4) 3 / 8 x 1 bolts, eight (8) 3 / 8 washers and four (4) 3 / 8 nuts. Torque the fasteners to 20-25 ft-lb. See figures 8e and 8f. Figure 8b Aligned pre-punched slots. Note: The entire z-purlin length for the array must be assembled before attaching it to the z-struts. Figure 8c P13
8. Z-Purlin Assembly - Continued Web Figure 8d Upper flange Attach the lower flange and torque bolts before completing the web assembly. Figure 8e Figure 8f Web assembly is completed last P14
Top Face 9. Z-Purlin to Z-Strut Assembly Position a purlin holding fixture at the top (north) hole located on the top face of each z-strut in the array. See figure 9a, 9b and 9c. Note: The purlin holding fixture may need adjustment if the ½ x 3 ½ bolt does not line up with the hole in the z-strut. The two (2) brackets on the fixture are slotted for adjustability if needed. They can be adjusted by loosening the 5 / 16 nuts and moving the brackets until the ½ x 3 ½ bolt aligns with the hole in the z-strut. Push ½ x 3 ½ bolt into thru hole to position purlin holding fixture Figure 9a Brackets may need adjustment if the ½ x 3 ½ bolt will not push into the thru hole on z- purlin Figure 9b Purlin Holding Fixtures placed at top (north) holes Figure 9c P15
9. Z-Purlin to Z-Strut Assembly - Continued Rest the upper z-purlin assembly against the purlin holding fixtures and across the z-struts. Note: The z- purlin assembly must be in the proper orientation. See figure 9d, 9e and 9f. Figure 9d Z-Purlin assembly resting against the purlin holding fixtures Purlin Holding Fixtures Figure 9e P16
9. Z-Purlin to Z-Strut Assembly - Continued Purlin Orientation Figure 9f P17
Dimension is shown on the AET Dealer Kit Array drawing. 9. Z-Purlin to Z-Strut Assembly - Continued Using a 4 T-Square, position the z-purlins/z-struts such that they are at a 90 angle. Note: The south end of the z-strut can be rotated about the post (the post will twist) to achieve the 90 angle. See figure 9g. 90 90 90 90 It is important to hold the east and west z-struts at a 90 angle with the upper z-purlin assembly during the assembly process. This can be accomplished by using ratchet straps as shown in figure 9h. Note: The middle z- struts will stay at a 90 angle to the z-purlins once they are attached to the z-purlins. See figure 9k for the attachment sequence. 90 90 90 90 Z-Purlins Starting at the west end of the array, position the end of the upper z-purlin assembly from the center of the post to the dimension shown on the AET Dealer Kit Array drawing. See figure 9g. Z-Strut Figure 9g South end of z-strut can be rotated about the post Hook ratchet strap onto the post and the south end of the z-strut. Hook ratchet strap onto the post and the south end of the z-strut. Figure 9h P18
9. Z-Purlin to Z-Strut Assembly - Continued Attach the upper z-purlin assembly to the z-struts using two (2) ¼ x 1 1 / 8 self drilling screws and two (2) ¼ nuts per joint. Torque to 5-7 ft-lb. See figure 9i, 9j and 9k. Note: The entire z-purlin assembly for the array must be assembled prior to completing this step. Note: ¼ nut is not shown in these illustrations. Figure 9i Figure 9j Two (2) ¼ self drilling screws and nuts per joint Attach east end 2nd Attach west end 1 st Ratchet Strap Ratchet Strap Figure 9k P19
9. Z-Purlin to Z-Strut Assembly Continued Re-position the purlin holding fixtures to the bottom (south) holes located on the top face of each z-strut in the array. Rest the lower z-purlin assembly against the purlin holding fixtures. See figure 9l. Note: The z- purlin assembly must be in the proper orientation. See figure 9f. Using a straight edge, square the west end of the lower z-purlin assembly to the upper z-purlin assembly. See figure 9g. Attach the lower z-purlin assembly to the z- struts using two (2) ¼ x 1-1 / 8 self drilling screws and two (2) ¼ nuts per joint. Torque to 5-7 ft-lb. See figure 9i and 9j. Note: The entire purlin assembly for the array must be assembled prior to completing this step. Install the remaining z-purlin assemblies using the steps described above. Purlin Holding Fixtures Ratchet Strap Ratchet Strap Figure 9l P20
10. Purlin Brace to Z-Purlin Assembly Attach the purlin brace to the z-purlin assemblies using one (1) ¼ x 1-1 / 8 self drilling screw and one (1) ¼ nut per joint. See figures 10a and 10b. Note: One (1) purlin brace is centered between two (2) posts. A five (5) post array requires four (4) purlin braces. Reference the AET Dealer Kit Array drawing. Torque fasteners to 5 7 ft-lb. Z-Purlins Z-Strut Figure 10a 4 places Figure 10b P21
11. Panel Assembly Establish a benchmark line along the entire length of the lower z-purlin assembly at a distance which is slightly greater than the overhang distance. Reference Appendix A to determine the overhang distance. (See figure 11a). Starting from the west end of the array, square up a bottom module to the benchmark line. Reference the AET Dealer Kit Array drawing to determine the distance the module should be positioned in from the west end of the z-purlin assemblies. The distance from the lower edge of the module to the middle of the lower purlin assembly 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 A dimension shown on AET Dealer Kit Array drawing. On the opposite side of the module position a mid-clamp assembly on the z-purlin assemblies. Slide the mid-clamp assembly until the side of the mid-clamp lower hits the side of the module and the angled barb, which bonds the module to the rack, 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 Distance Figure 11b Mid-Clamp Lower Grounding Barb Figure 11c Figure 11d P22
12. Cable Management Cables must be secured using UV-resistant cable ties or other similar devices. Loose and unsecured cables should be protected from abrasion, sharp objects, pinch points and animals. Avoid exposing cables to direct sunlight and permanent tension. Cables can be placed in trough. Note: Two z-purlin assemblies in each array are positioned such that a trough is formed and can be used for cable management. See figure 12. 13. Grounding At least one post per array must be grounded. Reference the National Electrical Code (NEC) to determine the grounding conductor size relative to the short circuit current rating of the array. A grounding lug may be attached to the base of a post as shown in figure 13. Figure 12 WEEB Lug 6.7 or similar grounding lug. Figure 13 P23
5. Appendix A - Module Overhang 14. Module Overhang 60 Cell Module with 10 Strut The AET Dealer Kit is compatible with various modules. The overhang distance needs to be calculated using the length of the module that was selected for the project you are working on. Module Width See figure 14a to determine the overhang distance for an array using a 10 strut and a 60 cell module. Module Length 60 Cell Module X = Module Length 12 7 / 8 39 1 / 8 Module Overhang Distance 10 Strut This hole represents the center point of the strut Figure 14a P24
5. Appendix A Module Overhang - Continued 14. Module Overhang Continued - 72 Cell Module with 12 Strut The AET Dealer Kit is compatible with various modules. The overhang distance needs to be calculated using the length of the module that was selected for the project you are working on. Module Width See figure 14b to determine the overhang distance for an array using a 12 strut and a 72 cell module. Module Length 72 Cell Module X = Module Length 12 7 / 8 51 1 / 8 Module Overhang Distance 12 Strut This hole represents the center point of the strut Figure 14b P25
5. Appendix B AET Kit Foundation Detail Drawing 16. AET Kit Foundation Detail Drawing Shown below is an example of the AET Kit Foundation Detail drawing for 60 cell modules. One is also available for 72 cell modules. An AET Kit Foundation Detail drawing was included with your shipment and must be reviewed prior to installing the posts. P26
5. Appendix C AET Dealer Kit Array Drawing 17. AET Dealer Kit Array Drawing An example of a AET Dealer Kit Array drawing is shown in figure 17b. Dealer kits range in size from 2x6 to 2x20 arrays. A dealer kit array drawing is available for each array size. Multiple arrays, based on the module size and the number of post, are shown on each array drawing. A smart part numbering system is used to identify which array on the drawing should be referenced during the installation process. See figure 17a. OL60416 Overlapped Z-Purlin Splice 60 Cell Module Number of Post in the Array Number of Modules per Row Figure 17a These are all considered 2 x 16 arrays. The difference is the number of post in each array. Figure 17b P27