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ADNOC, Dubai
I N S TA L L AT I O N G U I D E
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COMPANY REGISTERED NO: 06980029 COMPANY VAT NO: 996499723
Copyright Pavegen Systems Ltd, 2022. It is illegal to reproduce this document without the permission of the owner, Pavegen Systems Ltd
1 Company Registered no: 06980029 Company VAT no: 996499723
Copyright Pavegen Systems Ltd. 2020, it is illegal to reproduce this document without the permission of the owner, Pavegen Systems Ltd.
Contact:
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WC1H 8LS
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INTRODUCTION
This document describes the components and the assembly of our V3.5 system.
Any installation, maintenance, alteration, modification or adjustment must be performed by:
A Pavegen employee, representative, etc. or;
by an appropriate number of suitably qualified and experienced personnel, with prior written
approval of Pavegen; using reasonable skill and care.
The steps of the installation should be conducted in the order they are presented below.
CONTENTS
1. Installation Guide p 3
Components p 3-5
Tool List p 7
Installation Process p 8-14
2. Final Commissioning p 14
Pre Start Checks p 14
Testing Procedure p 14
3. Appendix p 15-24
Please use Metric quantities for accuracy.
For any further information or queries, please contact: hello@[Link] and +44 (0) 2033 977 279
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1. INSTALLATION GUIDE
COMPONENTS (INCLUDED IN SHIPMENT)
Top Surface
Full Tile Half Tile (Left) Full Tile (Right)
Sub-Frame
Pedestal GRP Mid-Sheet Joist
Joist Connector (Corner)
Pedestal Adjustment Tool Semi-Circular Support Pad Corner Support Pad
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Sub-Frame
Generator Spider Edge Spiders Corner Spiders
Triangular Rubber Sheet PCB Holder
Edge-Frames
1250mm 2 Pad Frame 1250mm 3 Pad Frame 865mm Frame
Corner Frame 1 Corner Frame 2
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Electrical
Devices Installed:
• Edge Device (NUC)
• Charge Controller
• Temperature Sensor
• Switch
Generator & PCB Electrical Cabinet
DC Bus Cable Flex Cable Connector
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Fixings
Locking Screw and Washer 13mm Pan Head (MX8) Generator Screw
Self-Tapping Screw
35mm Self-Tapping Screw
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Tool/Component List (Not Included in Shipment)
• Laser Level
• Spirit level
• Measuring Tape
• Impact driver/ Drill
- T25 head
- SQ3 head
- PZ2 head
• Angle grinder/circular saw
• Basic wiring tools: cutters, connectors, electrical tape etc.
• Laptop (with TeamViewer App installed), wireless keyboard and mouse
• HDMI Cable
Exploded Component View
Section View Edge Frame
GRP Midsheet
12mm
25mm
38mm
Joist
150mm
Pedestal
75mm
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INSTALLATION PROCESS
Joist Frame
1. Lay out the joist frame using the spacing shown
(see Appendix A).
2. The space between the first two joists should be
163mm. Each subsequent gap must be 385mm.
3. Joists are secured together using the Joist
Connectors provided and 13mm Pan Head Self-
Tapping Screws.
4. Check all joists to ensure they are properly
fastened.
5. Fix the Joist Perimeter to the outside edge of
the joist frame with the 13mm Pan Head Self-
Tapping Screw. **This is to close the gap
between the array and the surrounding flooring.
It will need to be cut down to for the frame to fit
inside the excavation.**
6. Place the completed joist frame into the
excavation.
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Pedestal Placement
1. Assemble all pedestals (see Pedestal Assembly.
mp4).
2. Set all pedestals to a base height of 75mm.
3. Clip the pedestals around the joist frame (max
600mm apart). They should be positioned so
that the frame is fully and evenly supported.
See Appendix C for guidance.
4. Mount the pedestals to the joists off-centre as
shown (below) to allow space for the pedestal
adjustment tool.
5. Some pedestal bases (especially around outside
edges) will need to be cut down to fit inside the
excavation.
Height Adjustment
1. Set up the laser level. Make sure the elevated
joist frame is level and that it is the correct height
with respect to the finished surface. See ‘Section
View’ (Page 6) for component measurements.
2. Individual pedestals may need to be adjusted
slightly with the Pedestal Adjustment Tool.
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Electrical Cabinet
1. Mount the electrical cabinet in the chosen location.
2. Install a mains power socket into the electrical cabinet.
3. Run ethernet cable into the electrical cabinet and connect to the Switch.
4. Connect the NUC to the Switch and also to power.
5. Run both DC BUS cables and both LED power cables from the array, through the conduit into
the electrical cabinet.
6. Connect the DC Bus cables to the Wago connectors (labelled DC Bus).
7. Connect HDMI cable from the screen into the NUC.
**THE ELECTRICAL CABINET SHOULD NOT BE MODIFIED WITHOUT PAVEGEN’S AUTHORISATION**
Example electrical cabinet shown below:
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GRP Mid-Sheets & Edge Frame
1. On the underside of each large GRP mid-sheet,
ensure that there is a PCB holder next to each of
the 5 generator holes.
2. Lay down GRP mid-sheets on top of the joist
frame using Appendix E as a guide.
3. The GRP sheets should overhang the edge
of the joist frame by 6mm on each side and the
pilot holes on the edge of each GRP sheet
should line up with the ridge in the centre of the
joists.
4. Ensure that the DC bus cables coming from the
electrical cabinet are visible and accessible.
5. Lay out the Edge Frames on the outer edge of
each GRP sheet using Appendix F as a guide.
6. Line up the edge frame with the GRP mid-sheet,
then secure the edge frames into the mid-
sheet using 35mm Self-Tapping Screw. The
screw will secure the frame, mid-sheet and the
joist together.
7. When securing the Corner Frame pieces,
position the Corner Support Pads in place
first.
8. The top of the edge frame should now be the
same height as the final adjacent floor surface.
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Fitting & Connecting Generators
The generators are connected in a “daisy chain topology” (in parallel electrically), with the first and
last generators connected to the charge controller via the DC Bus cables - see example illustration
below.
1. Pull one DC Bus cable up through the first generator hole and one through the last (see
diagram above).
2. Starting at the first hole, connect the short cable from a generator to the DC Bus cable via
a Flex Cable Connector.
3. Reach into the hole and clip the generator’s PCB to the PCB Holder on the underside of the
GRP. Place the generator into the hole and rotate approx 90 degrees, lining up the pilot
holes.
4. Connect the long cable from the first generator to the short cable on the next generator.
5. Repeat step 3.
6. Continue this process, connecting all generators.
7. At the last generator, connect the short cable to the other DC Bus cable via a Flex Cable
Connector. The circuit is now complete.
8. Fasten the generators to the GRP mid sheet with 2x Generator Screws using the guide
holes provided.
***Do not test or depress any generators until they are connected to the charge controller***
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GRP Mid-sheet Finishing, Support Pads and Rubber Sheets
1. Finish securing the GRP sheets to the joists via the guide holes, using 35mm Self-
Tapping Screw.
2. Position all the Semi Circular Support Pads - they should not be secured down.
3. Lay rubber pads between generators where the tiles will be laid. Use the
Appendix H) as a guide.
4. Attach rubber spiders to the tops of all generators and support pads - use
Appendix H for a guide to placement.
Fit Tiles
1. Ensure the rubber generator protector ring is in position on top of each generator.
2. Lay tiles according to Appendix K
3. Fix tiles with Locking Screw and Washer. Over-tightening may cause the screw head to
break.
4. Check that the tiles are level and seated properly.
13
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Software Installation & Testing
1. The Pavegen team will now need to connect to the NUC (Edge Device) and remotely test
the system. The NUC will need to be connected to the internet.
2. Turn on the screen and the NUC. Connect a wireless mouse and keyboard to the NUC.
3. TeamViewer will open automatically. Ensure the green “ready’ dot (which signifies
successful connection) is visible at the bottom of the window.
4. This could take a few hours. Pavegen will notify you once the update has finished.
5. Once the NUC is turned on, the software should appear on the screen automatically
within 30-60 seconds. Contact Pavegen for any troubleshooting.
6. Step on every generator 3-4 times. Check that steps are registering on the screen.
2. FINAL COMMISSIONING
PRE-START CHECKS
Mechanical Tests
• Check gradient/fall of top surface-angle and direction
• Check all tiles are seated correctly
• Check all tile retention screws are present, seated correctly and tightened to the
recommended torque.
Electrical Tests
• Check for electrical shorts by conducting a continuity test with a multimeter. Depress a
generator then probe across the DC bus terminal which connects to the Charge Controller.
• Check Charge Controller is properly labelled and secured, with all the covers on.
• Check NUC is secured and protected.
• Check cables are labelled and tidy.
TESTING PROCEDURE
Mechanical Tests
• Check the free movement and feel of all generators. Measurements of performance are
carried out in the Electrical Test.
Electrical Tests
• Electrical testing is monitored remotely by the Pavegen team via the Mindshpere platform. A
person on site will need to assist in this by taking steps on the array.
14
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3. APPENDIX
• Appendix A - Joist Layout
• Appendix C - Pedestal Layout
• Appendix D - DC Bus Layout
• Appendix E - GRP Layout
• Appendix F - Edge Frame Layout
• Appendix G - Generator Layout
• Appendix H - Support Pad, Rubber Spider and Mat Placement
• Appendix J - Full Tile Layout
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Appendix A - Joist Layout
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Appendix C - Pedestal Layout
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Appendix D - DC Bus Layout
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Appendix E - GRP Layout
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Appendix F - Edge Frame Layout
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Appendix G - Generator Layout
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Appendix H - Support Pad, Rubber Spider and Rubber Mat Placement
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Appendix J - Full Tile Layout
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