Required Materials:

• BAG A M5×12 Flat Head Socket Cap Screws (Qty: 8)
• Module Locators (Qty: 4)
• Aligner Brackets (Qty: 2)
• Loctite™ 248 thread locker

Required Tools:

• 3mm hex head (1/4" square drive for torque wrench or 1/4" quick release bit for torque driver)
• Torque wrench or driver set to 6 Nm (53 in-lbs)
• Flat work surface

Figure 1.1: Materials and tools staged for frame assembly

1. Stand the Aligner Brackets upright as shown, ensuring the 80mm fan recesses are facing away from each other
2. Place 2 Module Locator rails on top as shown
3. Verify countersinks at each end face upward
4. Confirm locating teeth for modules face inward towards each other
5. Install four M5×12 FHSCS (BAG A) into each corner of the frame
6. Apply a small amount of Loctite™ 248 to each fastener
7. Tighten only enough for the screw head to be flush—do not torque yet

Figure 1.2: Bottom rail assembly with aligner brackets

Figure 1.3: Countersink orientation detail

1. Flip the assembly over to access the opposite side
2. Place 2 Module Locator rails on top as shown
3. Verify countersinks at each end face upward
4. Confirm locating teeth for modules face inward towards each other
5. Install four M5×12 FHCS (BAG A) into each corner of the frame
6. Apply a small amount of Loctite™ 248 to each fastener
7. Do not tighten or torque these fasteners yet

Figure 1.4: Completed frame with top rails installed

1. Set torque driver or torque wrench to 6 Nm (53 in-lbs)
2. Rotate the assembly 90 degrees so it stands on edge
3. Ensure all 4 corners of the frame rest flat on the work surface
4. Apply downward pressure on the Aligner Bracket while torquing the fastener to 6 Nm
5. Repeat for all 8 fasteners of the frame assembly
6. Rotate and/or flip the assembly as necessary to access and torque all fasteners

Figure 1.5: Correct torquing technique with pressure applied

Quality control requires visual confirmation that all fasteners have been properly torqued with thread locker applied.

1. Use a permanent marker or paint pen to apply a witness mark to each torqued fastener
2. Mark should span from the fastener head to the surrounding material
3. Apply torque marks only after a fastener has been torqued to specification with Loctite™ applied
4. Verify all 8 frame fasteners are marked before proceeding

Figure 1.6: Proper torque marking technique

1. Slide modules into the frame from above as shown
2. Verify the red side (positive/cathode) is oriented correctly for your configuration
3. Populate according to required series/parallel configuration
4. Ensure modules seat fully into the locating teeth on the rails

Figure 2.1: Module insertion into frame

Figure 2.2: Module polarity identification

Gather Required Parts & Tools:

• BAG B M5×25 SHCS (2 per Module Retainer)
• Module Retainers (quantity/part dependent on segment length)
• 4mm ball-tip hex bit (1/4" square drive or 1/4" quick release bit)
• Loctite™ 425 (cyanoacrylate-based, safe for plastics)
• Torque driver set to 36 in-lbs (~4 Nm)

Figure 2.3: Module retainer materials and tools

1. Starting from one end, mate the module retainers by inserting the posts of the Module Retainer into the retention holes on the modules
2. Ensure retainer posts are fully seated in the module retention holes
3. Verify retainer alignment before installing fasteners

Figure 2.4: Retainer alignment with modules

Figure 2.5: Retainer posts properly seated

1. Apply a small amount of Loctite™ 425 to each fastener before inserting
2. Insert fasteners into the outermost vertical holes of each Module Retainer
3. Thread both fasteners before torquing either one to ensure proper alignment
4. Torque each fastener to 36 in-lbs (~4 Nm or 3 ft-lbs) within 2 minutes of Loctite™ application
5. Apply torque mark to the head of each fastener after torquing

Figure 2.6: Fastener installation in retainer

Figure 2.7: Torque mark on retainer fastener

Figure 2.8: Torquing retainer fastener

1. Repeat steps 2.3 and 2.4 for the remaining retainers on the current side
2. Rotate the assembly 180 degrees to access the opposite side
3. Repeat steps 2.3 and 2.4 for all retainers on the second side
4. Verify all retainers are installed and all fasteners are torque-marked

Figure 2.9: Module side without retainers

Figure 2.10: Completed module assembly with retainers

Required Parts:

• Radsok® Pin Mount (Qty: 2)
• Radsok® Pin (Qty: 2)

Required Materials & Tools:

• Loctite™ 248 thread locker
• 7/8" open end wrench
• 5/8" deep well socket
• Torque wrench set to 15 ft-lbs (20 Nm)

Assembly Steps:

1. Apply a small amount of Loctite™ 248 to the threads of the Radsok® pin
2. Thread the pin into the Radsok® Pin Mount as shown
3. Hold the Pin Mount with the 7/8" wrench and torque the Radsok® Pin to 15 ft-lbs (~20 Nm) using the 5/8" deep well socket
4. Repeat for the second Radsok® Pin Mount assembly

Figure 3.1: Radsok® components

Figure 3.2: Radsok® pin installation

Gather the Following:

• BAG C M6×16 HHS (Qty: 2)
• BAG E M6 HD Safety Washer (Qty: 2)
• Completed Radsok® Pin Assemblies from previous step
• Loctite™ 248 thread locker
• 10mm socket
• Torque wrench set to 6 Nm (53 in-lbs)

Figure 3.3: Tightening Radsok®

Figure 3.4: Completed Radsok® pin assembly

1. Place the M6 washer (BAG E) on the M6×16 HHS (BAG C)
2. CRITICAL: Ensure washer is oriented properly! The "cup" side should face the part, not the screw head
3. Apply a small amount of Loctite™ 248 to the threads of the fastener
4. Position the Radsok® Pin Assembly over the module terminal as shown
5. Insert the hex head fastener through the open hole in the Radsok® Pin Assembly
6. Thread fastener into the busbar connector of the module
7. Torque the fastener to 53 in-lbs (6 Nm)
8. Apply torque mark to the fastener
9. Repeat for the opposite end of the assembly

Figure 3.5: Radsok® assembly next to module

Gather the Following:

• 2-Hole Busbar (per connection)
• BAG D M6×12 HHS (2 per busbar)
• BAG E M6 HD Safety Washer (2 per busbar)
• Loctite™ 248 thread locker
• 10mm socket
• Torque wrench set to 6 Nm (53 in-lbs)

Figure 3.6: Radsok® installation

1. Place a washer (BAG E) on each fastener (BAG D)
2. CRITICAL: Ensure washer orientation is correct! Cup side faces the part, not the fastener head
3. Apply a small amount of Loctite™ 248 to the threads of each fastener
4. Place the busbar over the desired position between modules
5. Maintain firm hold on the busbar while inserting fasteners through both holes
6. Thread both fasteners into the busbar connectors before releasing the busbar
7. SAFETY: Threading both fasteners before release reduces the risk of busbar rotation causing a short circuit
8. Torque each fastener to 53 in-lbs (6 Nm)
9. Apply torque marks to both fasteners
10. Continue with remaining busbars, working systematically from one end

Figure 3.7: Radsok® tightening

Figure 3.8: Radsok® torque mark

Continue installing busbars systematically along the module string, following the procedure established in Step 3.5.

1. Work methodically from one end of the assembly
2. Verify correct series/parallel configuration at each connection point
3. Maintain consistent torque values and apply torque marks to all fasteners
4. Double-check polarity before installing each busbar

Figure 3.9: Busbar hardware

1. Visually inspect all busbar connections for proper seating
2. Verify all torque marks are present and properly applied
3. Check that all spring lock washers are properly oriented
4. Confirm series/parallel configuration matches design specifications

Figure 3.10: Busbar installation

Required Parts:

• Mending Brace
• BAG F M5×12 Low Profile SHCS (Qty: 2)
• Loctite™ 248 thread locker

Required Tools:

• 3mm hex head (1/4" square drive or 1/4" quick release bit)
• Torque wrench or driver set to 5 Nm (44-50 in-lbs)

Figure 4.1: Mending brace components

1. Position adjacent segments on the base plate with appropriate spacing
2. Place the Mending Brace over the mating holes on adjacent Aligner Brackets
3. Apply a small amount of Loctite™ 248 to the threads of each fastener
4. Thread one fastener through each hole in the Mending Brace into the M5 threaded holes of the Aligner Brackets
5. Thread both fasteners before applying torque to either fastener
6. Torque each fastener to 44 in-lbs (5 Nm)
7. Apply torque marks to both fasteners
8. Repeat for additional mending braces as required by segment count

Figure 4.2: Mending brace installation

1. Verify all fasteners are properly torqued and marked
2. Check alignment of adjacent segments
3. Ensure structural rigidity of mending brace connections
4. Inspect for any gaps or misalignment between segments

Figure 4.3: Torque mending plate

Figure 4.4: Complete mending plate assembly w/ torque mark