APA READYRACK User manual

STANDARD GROUND MOUNT
Assembly Instructions
step-by-step
assembly and installation

C O N T E N T S
A P A L T E R N A T I V E S © 2020
I N S T A L L A T I O N M A N U A L - 2
CHECKLISTS........................................................3
PARTS..................................................................4
D-SERIES PARTS..................................................5
HARDWARE .......................................................5
SITE LAYOUT .......................................................6
POST INSTALLATION ..........................................6
NORTH/SOUTH CEE...........................................8
EAST/WEST STRUT...............................................8
STRUT JOINING ..................................................10
MODULE INSTALLATION ...................................11
CABLE BRACING...............................................13
INFORMATION & CONTACT ............................14

C H E C K L I S T S
I N S T A L L A T I O N M A N U A L - 3
A P A L T E R N A T I V E S © 2020
E Q U I P M E N T R E Q U I R E D
□ Anchor Driver Cart or Single Mast Unit
T O O L S R E Q U I R E D
□ Tape Measure
□ Level
□ Torque Wrench
□ Cordless Drill
□ Rubber Mallet
□ Socket Wrench
□ Socket Drivers (1/2”)
□ Box End Wrenches (1/2”)
□ Anchor Adjustment Rod
□ String
□ Angle Meter
□ Other standard construction tools as required
S A F E T Y E Q U I P M E N T ( P P E )
□ Safety Glasses
□ Hard Hat
□ Gloves
□ Steel-toe Boots
□ Reflective Safety Vest
□ Kevlar Sleeves or equivalent -
for installing solar panels (Optional)
T O R Q U E V A L U E S
□ 1/4-20 Hardware = 6.3 Ft. Lbs.
□ 3/8-16 Hardware = 19.6 Ft. Lbs.
□ M8 = 15.6 Ft. Lb
BE SAFE!

P A R T S
A P A L T E R N A T I V E S © 2020
I N S T A L L A T I O N M A N U A L - 4
1 NORTH/SOUTH POST A711
2 CEE CHANNEL A725-001
3 STRUT A732
4 SPLICE 184MM A392-055
5 CABLE CLAMP A352-002
6 CABLE A354/A353
7 PANEL MID CLAMP A337-175
8 PANEL END CLAMP
5
Cable Clamp
7
Panel Mid Clamp
8
Panel
End Clamp
6
Bracing Cable
2
1
NORTH
POST
POST
LENGTHS
DETERMINED
BY PROJECT
SPECS
NORTH/SOUTH
CEE CHANNEL
EAST/WEST
STRUTS 11'
SOUTH
POST
3
4
Strut Splice

H A R D W A R E
A P A L T E R N A T I V E S © 2020
I N S T A L L A T I O N M A N U A L - 5
A 5/16-18 X 1.125” FLANGE BOLT (GALV) A381-002
B M8 X 70MM HEX HEAD BOLT (S/S) A381-006
C 3/8-16 x 2.75" HEX HEAD BOLT A388-035
D 3/8-16X1” HEX HEADBOLT (S/S) A388-036
E 3/8 (.875 OD) FLAT WASHER (S/S) A388-010
F 3/8 (1.25 OD) FENDER WASHER (S/S) A388-025
G 3/8-16 HEX NUT (S/S) A388-005
H M8 (.5 OD) LOCK WASHER (S/S) A387-002
I 3/8 (.68 OD) LOCK WASHER (S/S) A388-011
J M8 SPRING NUT (S/S) GNM8820/GNM4196
K 3/8 SPRING NUT (S/S) A392-012
A
B
C
F
E
D
I
H
G
J
K

1 . S I T E L A Y O U T
A P A L T E R N A T I V E S © 2020
I N S T A L L A T I O N M A N U A L - 6
A . MARK LOCATIONS
Mark anchor post locations using
the provided post and row
spacing diagram. See Note:
A. . FLAT SIT ES
Drive posts with single-point,
starting at the east end. Use
location lasers or gps or string line
to keep in a straight line. Use
height lasers to ensure correct
depth, or story sticks if not
equipped. If using a story stick,
ensure measurements are taken
from the relative ground height,
and not a localized
nonconformance, ie. mole hills,
divets, rocks
B. . UNEV EN GR OUND
For sites with ungraded or rolling
topology, the string method
cannot be used. It is important to
ensure the posts are set to the
correct depths and the finished
system should appear to conform
to the landscape (fig. B). These
posts will need to be measured
individually from the ground to the
top to ensure they are at the
correct height.
In cases in which post locations
can not be marked on the ground
(uneven terrain), it is advised to
have the surveyor mark the
location of every post, rather than
just the beginning and end of
each row.
Note:
For medium to large projects, anchor locations should be
staked by a professional surveyor, who can stake out end
of row post locations to the highest precision.
CONFORM TO THE TERRAIN
Note on Squareness: Ensuring the squareness of the array from early in the project
is essential in preventing problems later into a build.
1. Make certain the eastern-most anchor set is exactly spaced and perpendicular
to the row.
2. After installing several anchor sets, measure out a distance (approx. 98 5/8 for
74" North/South spaced Anchors)in the east/west direction.
3. Now measure from that point to the first back anchor to create a triangle. The
distance should equal approx 123 5/16 for 74" North/South spacing. Deviations
from this indicate out-of-squareness, and should be remedied immediately.
B
2 . P O S T I N S T A L L A T I O N

A P A L T E R N A T I V E S © 2020
I N S T A L L A T I O N M A N U A L - 7
C. OBSTRUCTIONS
If an impassable object is
encountered at the desired post
location, it is best to relocate it 6-
8" east or west of the original
location (fig. C). You must also
move it's mating post.
Example: If you move a north
(tall) post, you must also move
the south (short) post (and vise
versa) in the same direction and
distance to ensure they properly
mate.
D. HEIGHT ADJUSTMENTS
When posts are driven at the
incorrect height, an adjustment
may need to be made. Tie a
string from one known good
height post to another, skipping
several. Use this line to determine
the correct height for the
enclosed posts. If the post is too
tall, the top may be cut off and a
new 13/32" drilled 1" from the top.
Alternatively, the post may be
turned clockwise to lower it or
counter-clockwise to raise it. This is
accomplished using a pipe
wrench or post adjustment rod or
lever(fig. D).
Note:
While it is very difficult to make
every post perfectly plumb and
at the correct height, care should
be taken to keep them within the
tolerances specified in the plans,
to ensure the system fits and
functions as intended (fig. E).
TURN ADJUSTMENT ROD TO ADJUST HEIGHT.
Example tolerances.
See plans for approved
tolerances
P O S T I N S T A L L A T I O N ( c o n ' t )
CLOCKWISE = LOWER THE POST
COUNTER-CLOCKWISE = RAISE THE ROST
LOWER
D
RAISE
E

1 . S I T E L A Y O U T
A P A L T E R N A T I V E S © 2020
I N S T A L L A T I O N M A N U A L -
8
A. CEE To Post
Attach the cee channels to the West side of the anchor
post using the listed hardware. (fig. A). Refer to prints for
exact location
1. N/S CEE CHANNEL
2. ANCHOR POST
3. 3/8"-16 SERRATED FLANGE NUT
4. 3/8"-16 x 2 3/4" SERRATED FLANGE BOLT
A. Strut To CEE
Based on modules clamping zone, place strut over specified hole in cee channel.
Insert bolt through the strut and cee channel holes.
Secure with channel nut (fig. B).
1. E/W STRUT
2. N/S CEE CHANNEL
3. 3/8"-16 CHANNEL NUT
4. 3/8 - 16 x 1" SERRATED FLANGE BOLT
1
2
3
4
Note: It is recommended to loosely
assemble hardware until final adjustments
have been made. Then go back through
and tighten all hardware.
1
2
3
4
NOTE: Cee channel will always bolt to the west
side of post to ensure correct orientation

4. A D J U S T I N G S T R U T S A N D T I L T
A P A L T E R N A T I V E S © 2020
I N S T A L L A T I O N M A N U A L - 9
A. TILT ADJU STM ENT
When installing the cee channel,
use the hole pattern that
corresponds to the desired tilt. After
installing one cee channel
correctly, install another several
posts further away. Ensure the tilt
angle, height, and plumb is correct
on both. String a line at the top and
bottom between the two, and use
these as a guide for proper
placement of the remaining cee
channel.
A. . FINE HEIGHT AD JUSTMENT
Sighting down a row, looking from
the east or west, look for
inconsistencies' in the heights of
the racking. Adjust the height by
removing the cee channel
hardware, adjusting the height,
and reattaching the hardware (fig.
B). To lower the cee channel, use a
hole closer to the bottom. To raise,
use a hole further from the bottom.
If more severe adjustments are
needed, refer to "Height
Adjustment" on page 7.
NOTE: HOLES IN CEE CHANNEL ARE NOMINAL
CONNECTION POINTS USE ADJACENT HOLES
TO ADJUST CEE FORWARDS AND
BACKWARDS USE CORRECT HOLE FOR THE
NEEDED TILT ANGLE

5. S T R U T J O I N I N G
A P A L T E R N A T I V E S © 2020
I N S T A L L A T I O N M A N U A L - 10
A. STRUT - TO - STRUT CONNECTIONS
Join adjacent East/West struts together using a Strut-To-Strut splice and the appropriate hardware (4 sets for each
splice)(fig. D)
1. 3/8"-16 x 1" SERRATED FLANGE BOLT
2. E/W STRUT
3. SPLICE
4. 3/8"-16 SERRATED FLANGE NUT
1
2
3
4
NOTE: Ensure that the stress exerted on the struts will be
dispersed by staggering the splice locations in an
East/West direction (ie. not in a straight line, see figure
on pg. 14). When all the struts in a row have been
added, tightened down, modules installed, and
endstops are locked down. The ends of the struts can
be trimmed.
D

6. M O D U L E I N S T A L L A T I O N
A P A L T E R N A T I V E S © 2020
I N S T A L L A T I O N M A N U A L - 11
A. LAYOUT
Tie a string from the first to the last North/south strut at
the location you would like the top edge of the lower
row of panels to be. This ensures the panels will line up,
even if the struts are slightly off. You can also mark the
location of the mid/end clamps on the side of the
panels with a pencil or china marker.
B. INITIAL CLAMPING
Place the first module at the East end, line the top edge
with the string, and loosely clamp the struts with two end
clamps, lock washers, and spring nuts on the outside, and
two mid clamps, lock washers, and spring nuts on the
inside. Ensure the first module aligns with the line.
[B] M8 X 70mm Bolt (Stainless) A381-006
[H] M8 LockWasher (Stainless) A387-002
[7] End-Clamp (Aluminum) N/A
[5] Mid-Clamp (Aluminum) A337-175
[J] M8 Spring Nut (Galvanized) GNM8820/GNM4196
B
H
7
J
5

7 . A D D I T I O N A L M O D U L E S
A P A L T E R N A T I V E S © 2020
I N S T A L L A T I O N M A N U A L - 12
A. SETTING PANELS
Continue setting panels by sliding
the next module on top the first,
using two mid-clamps
(unfastened) between the panels
as temporary spacer blocks.
Align the edges of the panel to
the one below it. Add two more
mid clamps, lock washers, and
spring nuts. Ensure it is parallel to
the first, and continue installing in
this fashion, going one-by-one,
bottom to top. Use the string on
top and a straightedge on the
bottom to keep them square. For
the West most module, install two
end clamps to finish.
B. ST RUT END TRIMMING
Once all glass is set and the layout is acceptable, you can
trim the ends. If the Strut-To-Strut connection splices have
been staggered as mentioned in the earlier note, the ends
of the row will be uneven and unsightly. To remedy,
measure the distance of the shortest strut (least amount of
overhang) to the North/South strut. Using this
measurement, mark the other three struts and trim off the
excess (fig. C) using a portaband. Do this to both the East
and West ends. If required for the project, spray galv the
cut ends. Dispose of the cut-off pieces.
8
6
4
2
7
5
3
1

8 . C A B L E B R A C I N G
A P A L T E R N A T I V E S © 2020
I N S T A L L A T I O N M A N U A L - 13
Each set of anchor posts get multiple sets of cable
braces to limit movement and reduce fatigue. There is a
solid brace between each set of North/South posts and
a single cable brace between each East/West set of
posts. See prints for instructions for placement. Cable
braces are not used to induce static tension, like trusses
of a bridge, but instead only keep the posts from
spreading and moving about.
A. Spread the clamp apart, slide around the post,
and recompress it.
B. Next, insert the loop of the cable into the gap on
the clamp and start bolt. Adjust clamp height and
orientation, and then tighten bolt.
1. UPPER ANCHOR POST
2. CABLE BRACE
3. BRACE CLAMP
4. HARD BRACE
5. CLAMP BOLT
6. LOWER ANCHOR
Note: Ensure that the clamp is aligned with its intended
direction and the bolt is facing inwards, for aesthetic
purposes.
C. Continue installing the
remaining cables in the same
manner and according to the
bracing layout.
Note: Make sure each brace is
taught by adjusting it up or
down the post. Cables should
have no noticeable slack
1
2
3
4
5
6

I N F O R M A T I O N & C O N T A C T
A P A L T E R N A T I V E S © 2020
I N S T A L L A T I O N M A N U A L - 14
AP Alternatives, LLC
20-345 County Road X
PO Box 326
Ridgeville Corners, OH 43555
Office [phone]
Fax [phone]
www.apalternatives.com
www.readyracksolar.com
Revision Details
Edition: 5
Date: 01/30/2020