assembly instructions for precision rms -...

Install Confidence 1010 B Street, Suite 400 – San Rafael, CA 94901

415-925-9650 – www.sunlink.com

Assembly Instructions for Precision RMS

TABLE OF CONTENTS

Notices and Safety Precautions Pages 1‐2

Component and Tool Quick Reference Pages 3‐4

Sub‐Structure Installation Guidelines Pages 5‐7

Panel Assembly Guidelines Pages 8‐9

Panel Installation Guidelines 0

Grounding Recommendations Page 11

Appendix A – Tilt Access™ Page 12

Mid‐row Foot (straddles 2 Long Beams)

Yokes Spars

End Row Foot (flush with Long Beam end)

Long Beam

Angle Strut


REV 03.14.2014 Page 1

Notices and Safety Precautions

Read this document before beginning installation work. Plan for safe practice during any installation activity with respect to

hazards from tripping, falling, lifting, repetitive stress, and any overhead or electrical hazards. When working close to building roof

edges, consider protection options that reduce worker exposure to fall hazards. Refer to OSHA Sub‐Chapter 7, Group 1, Article 2.

Precision RMS is made from aluminum and steel alloys, recycled rubber, and fastened together with steel assembly hardware. In the

form used in SunLink components, these materials are considered to be non‐toxic. Metal components often have sharp edges.

Handle carefully! Wearing gloves is good practice.

This document is not prescriptive regarding safety and does not purport to address all the safety concerns that may arise with its

use. Contractors should become familiar with all applicable safety, health and regulatory requirements before beginning work.

Electrical safety notice – Any time a SunLink system contains two or more electrically interconnected modules, a shock hazard is

present. SunLink is a mechanical system and contains no “live” parts. Mechanical installers and electricians should coordinate in

order to ensure that all personnel are aware of electrical hazards.

Precedence – Precision RMS positions and secures photovoltaic modules. DC “stringing” and interconnection of the modules

requires placement of conduit, conduit fittings and combiner boxes. Nothing in this document is intended to limit the allocation of

rooftop space or to control crafts with respect to work precedence and coordination.

Build rate – Estimated mechanical installation rate (modules per day) for an array consisting of modules installed with a Precision

RMS and assuming a well‐equipped four‐person crew is on the roof and working 7.5 hours / day with full task interchangeability: 240

modules / day.

As‐built documentation process – On‐roof use and mark‐up of this document is good practice. Mark up and annotate the drawings

on a regular basis, noting completions, exceptions, dimensional inconsistencies, etc.

Field modifications – Unauthorized field modification of SunLink components or assemblies may affect SunLink warranty coverage.

Provide marked up drawings for SunLink’s review, comment and approval prior to attempting any field modifications.

Workarounds – Workers laying out or installing arrays on rooftops may encounter undocumented or unexpected obstacles requiring

workaround. Since PV arrays are intended to be primarily regular and repeating structures, workarounds should be noted on

working drawings. When a workaround affects the location of two or more modules at once, the supervisor should be advised and

the workaround should be evaluated and then completed in a manner that ensures that the remainder of the array is not affected.

Roof surface – All large flat roofs have pitch and undulation, jointed assemblies, and may also have level separations and parapets.

Various roof‐mounted fittings, air vent pipes and equipment such as HVAC or process equipment may also be encountered. The

precise location of many rooftop details is not known since such details are installed under conditions in which the worker or

contractor may have discretion regarding final location.

Fire Safe Roof – Precision RMS is to be mounted over a fire resistant roof covering rated for the application. Precision RMS is not

meant for sloped roofs where the slope is greater than .5in/ft ~2.3° ~7%.

Fit‐up – Precision RMS is a designed‐fit system and is assembled using fasteners and assembly bolt sets. Matching hole locations are

engineered to ensure long‐term reserve assembly strength and life cycle reliability. Since undulation and slope is required to ensure

roof drainage, SunLink incorporates features that allow the array to follow the roof contour. Some connections are adjustable and

can be modified to change the geometry. Changes made in the field should be documented and authorized by SunLink.


REV 03.14.2014 Page 2

Notices and Safety Precautions

Roof life and care – The service life of any roof is contingent upon care for the roof especially during equipment installation on a

roof. Avoid concentrated loads on the roof. Never drag SunLink components into place. Instead, elevate the component, and then

move it manually or with a cart. Locate it and then place it “on spot.” To ensure roofing system warranty continuation, work with

roofing system installation contractors to ensure roofing system – array compatibility.

WARNING! Single‐ply roofs are not damage tolerant. Avoid accumulation of metal fines that result from drilling or sawing metal

components. Metal fines embedded in the soles of shoes can damage single‐ply roofs.

Fasteners – All required fasteners are furnished with Precision RMS. All fasteners are stainless steel. For any assembly, finish initial

bolted assembly to finger tight. Refer to the Installation Manual for detailed information on application and required torque on all

fasteners. Use of air‐powered tools that do not incorporate means to limit applied torque may damage the head of fasteners and is

not recommended.

Final inspection – Visually inspect assembled SunLink arrays, roof‐mounted or ground supported. The suggested process consists of

a row‐by‐row walk‐through and then a perimeter walk‐around, after mechanical assembly, before electrical completion. Report any

distortion in the assembly to SunLink. Array substructure supports should be in full contact with the roof or the ground. Any

indication of uneven distribution of weight should be evaluated and corrected before continuing with electrical finishing.

NOTE: When installing Precision RMS, unless otherwise noted on the layout drawings, the recommended practice is to allow for up to

4 inches of array movement on the roof. Movements can be caused by thermal effects, roof vibrations, earthquakes, and wind

storms. It is also recommended to install a service loop for all electrical wiring entering or leaving the array, and for any wiring that

crosses between two unconnected structural components within the array.

.

GENERAL PROCEDURE NOTES

A. Precision RMS primary assembly supports up to 4 modules in landscape orientation, and arranged edge to edge in the East‐

West direction. A standard assembly consists of 4 framed modules arranged on a single panel.

B. At the end of every work day ensure all components are securely attached. Temporary ballast (i.e. sandbags) may be

required to secure the system to the roof during the installation process to prevent movement or damage due to wind.

C. For all handling of components, wear gloves.

D. Be careful of pinch hazards, especially when installing panel assemblies.

E. Be careful of trip hazards. Beams, especially the Long Beam, present a trip hazard.

COMPONENTS

Ass

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sembly I

03.14.2014

LATERAPart # 64

STRUT BPart # 64

EXTRUDEPart # 68

Instructi

(Long Beam

AL LINK ‐0005‐001

BRACKET ‐0004‐001

D WASHER 8‐0001‐001

ons for

Part # 63‐000

B

Precisio

PRE‐ASSEM1‐XXX, Yoke Pa

RUBBER FOOFoot ‐ Pa

Foot Bracket –

Part #

BALLAST BASKBasket Part

67‐0002‐001 (1Bracket Pad Par

200 lb

on RMS

MBLED LONG Bart # 64‐0001‐0

OT & FOOT BRArt # 62‐0001‐0– Part # 62‐00

SPAR# 61‐0001‐XXX

ET, BRACKETSt # 67‐0001‐001 (16”) 67‐0003‐00Part #67‐0004‐001rt # ‐ 67‐0006‐001

bs

P

BEAM001, Angle Stru

ACKET001 002‐001

S & PADS12”) 01 (24”)

400 lbs

Part I - Su

ut Part # 64‐00

P

Part #6

CONPost

Part # 66

b-Structur

003‐XXX)

PIVOT BLOCKart # 64‐0002‐

MODULE CLI# 68‐0001‐0018‐0002‐001 (1/

NNECTOR ASSEt, Deck, Purlin B60‐00001 thro

Page 3

re Installat

K‐001

P (5/16”) /4”)

EMBLYBases ‐ ugh 00004

tion


REV 03.14.2014 Page 4

Part I - Sub-Structure Installation

TILT ACCESS™ PROP Part # 69‐0007‐001

LOCATOR JIG

FASTENERS/TORQUE (FT LBS)*no torque/static

Part Number Fastener Description Panel Assembly Long Beam Assembly

Foot Connector Lateral Link Ballast

09‐00001‐01 Hex Flange Nut 1/4‐20 * 09‐00002‐01 Hex Flange Nut 5/16‐18 15‐20 15‐20 30‐35 30‐3509‐00004‐01 Hex Head Cap Screw 3/4‐10 x 1.75 30‐40 09‐00005‐01 Hex Nut 3/8‐16 35‐40 30 09‐00008‐01 Flat Washer for 3/4 Screw * 09‐00121‐01 Carriage Bolt 5/16‐18 x 0.75 * * 09‐00126‐01 Roll Pin 3/16 x 1.75 * 09‐00127‐01 Lock Washer 3/8 * * 09‐00132‐01 Distorted Thread Hex Locknut 5/16‐18 9‐11 09‐00133‐01 Hex Bolt 5/16‐18 x 2.0 9‐11 09‐00139‐01 T‐Stud 5/16‐18 x 1.0 * *09‐00140‐01 Hex Bolt 3/8‐16 x 1.5 35‐40 30

09‐00145‐01 Button Head Cap Screw

5/16‐18 x 1.0 9‐11

09‐00146‐01 Button Head Cap Screw

1/4‐20x1.0 5‐6

REQUIRED INSTALLATION TOOLS

Minimum six (6) saw horses (e.g. Stanley 11012 ‐

32” high, 4” long, 29” wide) ½” wrench Torque wrench

Cordless screwdriver with torque adjustment

9/16” socket 3/16” allen drive

9/16” wrench 1/2” socket with drill attachment Ratchet

Ass

REV 0

Step 1

AB

C

Step AB

CD

E

Fh

Step

A

Fh

Step 4

ABN

sembly I

03.14.2014

1 – Assemble FoA. Center theB. Insert the

cavity. C. Rotate bot

2 – Attach MidA. Locate MidB. Insert 2 3/

Bracket hoNote: boltspositioned

C. Lock washeD. Insert 2x 3

Bracket hoE. Lock Extru

Note: Ensugrooves on

Fasteners: (4x)hex nuts, (4x) 3

3 – Attach EndA. Align Foot

using by inbolts into ssides.

Fasteners: (2xhex nuts, (2x) 3

4 – Layout RowA. Mark lines B. Layout rowNote that the n

Instructi

oot and Attach e Long Beam onlower flange o

th sides inward

d‐Row Feet. d‐Row Foot bet8‐16 x 1.50” heoles. s should be leftd on the roof foers and nut. /8‐16 x 1.50” holes with Extrudded Washer anure grooves on n Foot Bracket. 3/8‐16 x 1.50”3/8 lock washe

d Row Foot. Bracket with e

nserting two (2slots, placing E

) 3/8‐16 x 1.503/8 lock washe

ws of Foot Beaon roof to gui

ws of Foot Beamnorth‐side Yoke

ons for

to Long Beam. n Foot bases. f the Foot Brac

d to clamp to L

tween two Lonex head bolts i

t loose until ther roof followin

hex head boltsded Washers ond nut. Extruded Was ” hex head bolrs, and (4x) Ex

end of Long Bex) 3/8‐16 x 1.5Extruded Wash

0” hex head bors, and (2x) Ex

am Assembliesde Foot layoutm assemblies. e has an Angle

Precisio

ckets into Foot

ong Beam.

ng Beams. nto round Foo

e foot is g.

into slotted Foon both sides.

sher engage

ts, (4x) 3/8‐16 truded Washe

am and attach50” hex head ers on both

lts, (2x) 3/8‐16truded Washe

s t.

Strut attached

on RMS

t

ot

oot

rs

h

6 rs.

d.

F

Ro

Ho

P

Foot

ound

oles

Foot Beam As

Part I – Su

Slotted

Holes

ssemblies

b-Structur

Long Beam

Foot

d

s

Extruded

washers

Page 5

re Installat

t Bracket

Align to

end.

End of

sub array

tion

Ass

REV 0

Step

A

B

C

D

E

F

Nloye

sembly I

03.14.2014

5a – AssembleA. Mount the

a. Enbr

b. Pusl

B. Place the Balign with tthe Long B

C. Consult yofor each Ba

D. Bolt each Bbolts.

E. Load the resymmetric

Fasteners: (2x)

Note: Ballast paocations are fixyour SunLink laeach basket.

Instructi

e and Install Bae Ballast Brackengage vertical racket ush the Ballastots. Ballast Pads intthe wires and Beam) is indicat

ur SunLink layoallast Basket asBallast Basket t

equired numbecally on both si 5/16 x 1.00” t

avers should bxed and panelsayout to load th

ons for

allast Basket (iet to the Ballaswires with the

t Bracket up to

to the Ballast Bthe orientationted on the pad

out to determissembly. to the Long Be

er of ballast pades of the pant‐studs; (2x) 5/

e loaded only as have been inshe appropriate

Precisio

if applicable)st Basket. e 6 clips on the

engage the 6

Baskets. The pan N‐S (parallel d.

ine the locatio

eam with two t

avers . 16‐18 flange n

after Foot stalled. Followe ballast weigh

on RMS

v‐

ads to

n

‐

uts

w t in

P

Ballast

Basket

200 l

400 lb

380

Ballast

Bracket

Part I - Su

lb basket 12” x 1

b basket 12” x 12

lb basket 8”x16

b-Structur

Ballast

12” ballast pave

2” ballast pavers

” ballast pavers

Page 6

re Installat

t Pad

ers

s

tion


REV 03.14.2014 Page 7

Part I - Sub-Structure Installation

Step 5b – Install Connectors (if applicable)

A. Consult your SunLink layout to determine the location for each Connector.

B. Attach Connector arm between Connector post and Long Beam using (2x) 3/8‐16 x 1.50” bolts; (2x) 3/8‐16 nuts.

Fasteners: (2x) 3/8‐16 x 1.50” hex head bolts; (2x) 3/8‐16 nuts; (1x) 3/4‐10 x 1.75” head cap screw; (1x) 3/4 washer Note: The connector should be installed after panels are assembled.

Connector

Arm Long Beam

Connector

Post

Ass

REV 0

Note:set upStep 3 PREP

AB

NpcNU

Step 1

A

*S

Step

A

BNaCHMafF

sembly I

03.14.2014

: If you are recep two saw horse3.

STEP – PrepareA. Lay out sawB. Distance b

approximaNote: Placing pprovides a largcomponents. Note: Folding tUse 2 folding ta

1 – Position MoA. Position m

approxima*Refer to SunLiSpacing varies

2– Attach SpaA. Start by fas

ends are flB. Space inteNote: Module Cand modules, aCaution: Verify MHint: For easierModule Clips toagainst Clips anfasteners.l Fasteners: For

a. 5/16 v5/16‐15/16‐15/16 M

b. 1/4 ve1/4‐201/4‐201/4 M

Instructi

iving prepanelizes to hold the p

e Saw Horses w horses as shetween first anately 12” shorteplywood sheetser work surfac

ables can be uables for 3x1, 3

odules on Saw Hmodules on sawately 0.50” gapink layout for edepending on p

rs to Modules stening end mush and squarrnal modules sClips will force and provide groModule Clip is enr fastener asseo Module framnd rotate them

each module yversion 18 x 1.00” butt18” flange nut Module Clip ersion 0 x 1.00” butto0 flange nut odule Clip

ons for

ized modules fropanel assemblie

own. nd last saw hoer than Spar bes on the saw hoce for holding t

sed in place of3 folding tables

Horses w horses, leavin* between moexact module gpanel size.

odules to Spare. so spacing is evalignment betounding. ngaged with spambly, loosely ae first, then pla

m into place. Fin

you will need (

ton head cap sc

on head cap scr

Precisio

om SunLink, es and skip to

rse should be eing used. orses ools and

f saw horses. s for 4x1.

ng odules. gap spacing.

rs and ensure

ven. tween Spars

ar channel. assemble ace Spar nally tighten

4x) of each.

crew

rew

on RMS

Module

e Clip

PPart II - Pa

Spar

Page 8

nel Assemmbly

Ass

REV 0

Step

A

NXsB

C

D

E

Ncac

F

F5

sembly I

03.14.2014

3 – Spar CompA. Consult yo

Bracket anNote: There areX1 value, and esheet SL0 of layB. With the p

horizontal of the spar

C. Slide 5/16‐the north S

D. Insert Strunut.

E. Repeat stelocator jig

Note: do not uscarriage bolts. access for slidinchannels.

F. Each panePivot BlockStrut Brack

Fasteners: (4x)5/16‐18 flange

Instructi

ponent Assembur SunLink layond Pivot Block le two jigs for eeast jig set to Xyout for X1 andpanel assemblysurface, place r.

‐18 x 0.75” carSpar and align t Bracket and f

eps B, C and D osetting to posi

se T‐studs for tT‐studs are useng carriage bol

l assembly reqks. Repeat stepket and Pivot B 5/16‐18 x 0.75nuts.

ons for

bly out for the corocations. each panel ID –X3 value. See pad X3 values. y module‐side‐dsupplied locat

riage bolt fromthe bolt to thefasten with 5/1

on south Spar ition the Pivot

this operation ied only where lts from the en

uires 2 Strut Bps A‐E to insertBlock. 5” carriage bol

Precisio

rrect Strut

– west jig set toanel ID table o

down on a tor jig at the en

m each end of e fixture point.16‐18 flange

using the sameBlock.

in place of there is no

nds of the

rackets and 2 t the second

lts and (4x)

on RMS

o on

nd

e

P

Angle Ssh

art II – Pa

Strut and Pivot Bhould be aligned

Page 9

nel Assem

Block .

mbly

Ass

REV 0

Step 1

A

B

C

D

F(

Step 2A

B

C

D

E

F

G

FfNW

sembly I

03.14.2014

1 – Attach PaneA. Hold pane

drop Pivot B. Ensure tha

cross bolt. Note: Cautengaged.

C. Rotate panStrut Brack

D. Lock panel5/16‐18 x 2

Fasteners: (2x)2x) flange nut

2 – Attach LaterA. Consult yo

location foB. Check gap

Shift panelC. Insert (2x)

channels. D. While hold

18x 1.0” t‐E. Visually ali

Lateral LinF. Hold the La

panels andthe outer t

G. Attach (2x)studs; atta

Fasteners: (4x)flange nut, (2x)Note: Ensure thWasher engage

Instructi

el Assemblies tol assembly vertBlocks into Yo

at the pivot blo

tion. Make sure

nel assembly dkets into Anglel assembly with2.00” hex head 5/16‐18 x 2.005/16‐18.

ral Links. ur SunLink layoor each Lateral between panel column if the 5/16‐18x 1.0”

ding the Laterastuds in Lateragn the t‐studs k slots. ateral Link midd attach (2x) 5/t‐studs. ) Extruded Wach (2x) 5/16‐1 5/16‐18 x 1.00) Extruded Washat the groovese with grooves

ons for

o Foot Beam Astically as showokes. ock fully engage

e Pivot Block is

ownward and e Struts. h two Angle Std bolt/nut pair0” hex head bo

out to determiLink. els are 1.0” +/‐gap is off. t‐studs in adja

l Link insert (2al Link holes. in spar channe

dspan to the ad/16‐18 flange n

shers to the in8 flange nuts. 0” t‐stud, (4x) sher. s in the Extruds on the Lateral

Precisio

ssemblies. wn and

es the

s fully

guide

rut (2x) s. olt, and

ine the

0.5”.

acent spar

x) 5/16‐

els to the

djacent nuts to

ner t‐

5/16‐18

ed l Link.

on RMS

t‐stud + flange nu

ut

Part

Rota

t‐stud extruded wa

flange n

t IV – Pane

te

+ asher + nut

Page 10

el Installat

Angle StBolts

Drop and engage

0

tion

rut

Ass

REV 0

The P

mod

To pr

acco

Revis

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for sl

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1

2

3

sembly I

03.14.2014

Precision RMS

ules certified

i. Reduc

depen

ii. Reduc

iii. Reduc

revent unnec

rdance with l

sion (for the U

ision RMS is t

loped roofs w

NOTE: GROUN

nding the Continding Lugs A. Identify gro

end of arraB. Fasten groC. Torque to D. Run solid c

through lufollows: #1#6 AWG, 3

Note: Do not coaluminum FootNote: Only one

Qty/Lug

1

1

1

Instructi

S grounding m

under UL STD

cing groundin

ndent on layo

cing installati

cing overall c

essary risk of

ocal codes, o

US) or the Can

to be mounte

where the slop

NDING HARDW

inuous Array Us

ounding locatiay. unding lug as s11‐14 ft‐lbs. copper equipmg binding screw10 AWG, 20in l35 in. lbs. onnect copper t Bracket. lug is required

Part Name

Hex Flange

WEEB Lug

Carriage Bo

ons for

method confo

D 1703. The b

ng lugs from 1

out)

on time

ost of system

f fire, electrica

or in the absen

nadian Electr

ed over a fire

pe is greater t

WARE NOT SU

sing Direct Buria

on on north or

shown.

ment ground cow and torque abs, #8 AWG, 2

wire directly to

d per continuou

e

e Nut 5/16‐18

8.0, 1.60” x 0.71”

olt 5/16‐18 X .75”

Precisio

orms to UL SU

benefits of th

1 per PV mod

m

al shock or pe

nce of local co

ical Code CSA

resistant roof

than 1 ½”:12”

UPPLIED BY S

al

r south

onductor as 5 in. lbs.,

o

us array.

” x 0.47”

”

on RMS

UB 2703 and i

e Precision R

ule to 1 per c

ersonal injury

odes, with th

A C22.1 ‐ Late

f covering rat

” (7° or 12%).

UNLINK***:

Part

is certified by

MS Groundin

continuous Pr

y, all wiring an

he National El

est Revisions a

ted for the ap

.

V – Groun

y ETL for use w

ng include:

recision RMS

nd grounding

ectrical Code

and local cod

pplication. Pre

Part Number (Pa

SunLink: 09‐0000

Wiley: 30020111

SunLink: 09‐0012

ding Reco

with all photo

array. (contin

g must be don

e, ANSI/NFPA

es and ordina

ecision RMS i

ack Qty) [Or Equi

02‐01

1

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Page 11

mmendatio

ovoltaic

nuous array

ne in

No. 70‐Lates

ances.

s not meant

ivalent Part]

2

1

ons

t

Ass

REV 0

Step 1assem Step 2panel

Step 3

Step 4

A

B

C

D

Nu

***Impanefastetorqu

sembly I

03.14.2014

1 – Remove Latmbly to be lifted

2 – Remove hexl assembly.

3 – Lift Panel As

4 – Engage Tilt AA. Insert Ang

Access ProB. Insert hex

Tilt Access fastening t

C. At the top screw throand the ho

D. Fasten wit

Note: Do not leunsupervised.

mportant: whels are fastenedners that wereued to specifica

Instructi

teral Links fromd.

x head bolts fro

ssembly.

Access Prop. le Strut into thop. head bolt just Prop and intothe matching nend, insert a 5

ough the hole iole in the Strut h a 5/16 flange

eave Tilt Access

en Tilt Access Pd down permae left loose foration.***

ons for

either side of t

om Angle Struts

he bottom end

removed throthe Angle Stru

nut finger tight5/16 button hen the Tilt AcceBracket. ed nut.

s engaged

Props are remoanently, all yokr tilt‐up need t

Precisio

the panel

s to free

of Tilt

ugh the ut, . ead cap ss Prop

oved and ke to be

on RMS

Appeendix A – T

Page 12

Tilt Access

2

s™

assembly instructions for precision rms -...

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