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Core RMS

CORE RMS features a sturdy grid assembly that provides superior strength and load distribution for framed or laminate installations of 10° or less. The system was engineered to be very simple to install, while at the same time durable enough to withstand high loads and extreme conditions

LOAD DISTRIBUTION - The product’s signature design links both north-south rows and east-west panel sections to one another with strong structural components, dispersing loads across the total array and requiring less ballast in most instances.

INSTALLATION EFFICIENCY - To streamline installation, Core RMS features intelligent rails and clamps that auto-align and auto-space modules. The system also offers +/- 2.5° adjustability in both north-south and east-west directions. In addition, clamps provide integrated grounding to save time and reduce costs.

POWER DENSITY - Core RMS is configured according to latitude and customer preference with project-specific row spacing to optimize project density and/or energy production.

ROOF-FRIENDLINESS - Like all SunLink RMS products, Core RMS is designed with roof-friendliness in mind, often requiring zero penetrations. The system and ballast both sit on rubber feet made from recycled tires – each foot eliminating two tires from our landfills. These feet and pads may eliminate the need for slip sheets. The foot assemblies are also designed to absorb thermal expansion within the system.
Only 5 Primary Components
T E C H N I C A L S P E C I F I C AT I O N S
FRAMED LAMINATE
Average Distributed Weight 2.8-3.8 PSF (connected) / 3.5-6.0 PSF (ballasted, ASCE 7, 90 mph)
Tilt Angles 5° and 10° 2°, 5° and 10°
Roof Applications BUR; PVC; TPO; SMS; Most low slope roofs
Materials Galvanized (hot dip and G90) steel, recycled rubber, stainless steel
Grounding Fully integrated grounding. ETL listed to UL 2703.
Module Capability All major framed PV modules All major laminate (glass-glass) modules
Mechanical Installation Rates A four-person crew working a 7.5 hour day can install up to 270 modules/day. A four-person crew working a 7.5 hour day can install up to 400 modules/day.
Testing All SunLink roof-mount system designs are based on the results of extensive testing including: boundary layer wind tunnel tests; advanced structural analysis; UL testing; and seismic testing and analysis.
Warranty 15 years
Manufacturing Can be ARRA compliant.
Assembly Instructions for Core RMS
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.

Core 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 With AC modules powered by SolarBridge, there is no need to install either a central inverter or numerous detached microinverters to the racking system. The SolarBridge-enabled system is truly plug-and-play.

Electrical safety notice – Any time a SunLink systems 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 – Core 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 Core RMS and assuming a well-equipped four-person crew is on the roof and working 7.5 hours / day with full task interchangeability: 280 modules / day.

As-built documentation process – On-roof use and mark-up of this document and the drawings referred to in 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 – Core RMS is to be mounted over a fire resistant roof covering rated for the application. The system is not meant for sloped roofs where the slope is greater than .5in/ft.

Fit-up – Core 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. Line-up for final bolted connection typically involves light “bucking in” during assembly. A drift pin is a useful tool with which to align holes for cross-bolting.

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 Core RMS. All fasteners are stainless steel. For any assembly, finish initial bolted assembly to finger tight. Use of air-powered tools that do not incorporate means to limit applied torque may damage the head of fasteners and is not recommended.

NOTE: When installing Core 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. Core RMS primary assembly supports four modules mounted in portrait 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 Links and Rails.
E. Be careful of trip hazards, as Rail and Row Links present a trip hazard.

Component and Tool Quick Reference
COMPONENTS
CORE FOOT
(Recycled Rubber with Steel Reinforcement and, Galvanized Steel Studs)
RAIL
(Galvanized Steel)
LINK
(Galvanized Steel)
RAIL POST
(Galvanized Steel)
END CLAMP
(Stainless Steel)
LANDING PAD
(Stainless Steel)
CENTER CLAMP
(Stainless Steel)
BALLAST PAD
(Recycled Rubber)
Ballast Installation
BALLAST BASKET
(Stainless Steel)
Ballast Installation
BALLAST BRACKET
(Galvanized Steel)

Ballast Installation
HOOKS
(Stainless Steel)

Ballast Installation
T-CONNECTOR POST
(Galvanized Steel)

Connector Installation
SHAFT COLLAR
(Aluminum)

Connector Installation
T-CONNECTOR ROD
(Galvanized Steel)

Connector Installation
REQUIRED INSTALLATION TOOLS
¾" x 4" long (minimum) deep socket torque wrench for a 1/2-13 hex nut (e.g. Sunex 224XD or Snap-on SIML240) ¾" deep socket torque wrench for a ½-13 hex nut 3/16" hex allen head driver for a 5/16” button head cap screw
Cordless screwdriver with torque adjustment Rubber mallet Standard claw hammer
Measuring tape Chalk line


Part I Substructure Installation


Step 1 - Snap Chalk Lines
  • A. Use the SunLink layout drawings to measure and snap chalk lines for the edge of        each sub-array.
Step 2 - Lay out Feet on Chalk Lines
  • A. Place Foot assemblies in their correct locations on chalk lines.
         Note: Refer to your SunLink layout.
Step 3 – Install the Rail Posts into Feet
  • A. Move from north to south.

  • B. Insert threaded studs on the Foot through pre-punched holes in the Rail Post.

  • C.Orient Rail Posts so that the top tube slopes south.

  • D. Alternate between short and tall Rail Posts.

  • E. Ensure each Rail Post has two ½” fasteners connecting it to a Foot.

Step 4 – Install Links
  • A. Moving from south to north, connect Links to Foot/Rail Post assemblies by inserting      pre-installed threaded bolts through pre-punched holes in the Link.

  • B. Alternate between Rail and Row Links. Rail Links go underneath the module, while       Row Links go in the row between modules.
          Note: One end of each Rail Link is marked with blue paint.

  • C.Position Links so that the open side of the channel faces the roof.
          Note: Occasionally, feet may not have Rail and/or Row Links. Intermediate feet (feet       not located at the end of a Rail) never have a Row Link, and may or may not have       Rail Links. Refer to your site specific SunLink layout for guidance as to where links       are required. See figure in Step 2 above for an example of Link placement.
Step 5 – Install the Rail
  • A.Connect columns of Feet with the large profile Rail.
         Note: The Rail sits on top of the Rail Post.

  • B. Align the 1/2” holes in the side of the Rail with the holes in the side of the Rail Post.
          Note: Every Rail has a Rail Post and Foot at each end. The outer holes on the Rail Post are always used at the end of the Rail, even at the edge of a sub-array.

  • C.Foot/Rail Post assemblies may be required in the middle or ⅓ span of the Rail. These may or may not have a Rail Link. Refer to your site specific SunLink layout for guidance as to where additional Feet and Links are required. See figure for an example of Rail placement.

  • D.At intermediate locations, align the oversized hole in the center of the Rail Post with the pre-punched 1/2“ holes in the Rail.
Step 6 – Install Link and Rail Fasteners
  • A. Fasten the Rail Post to the Foot by Installing two ½"-13 nuts per Foot.
    Note: An extra deep socket wrench (minimum length of 4") is useful when installing nuts where no Link is present.

  • B. Torque fasteners to 8-10 ft-lbs.
    Note: Check to ensure the rubber foot remains flat on the roof surface.

  • C.Install ½-13 x 4.5” hex bolt and nut on each end of the Rail.

  • D.Torque to 25-30 ft-lbs.
    Note: Whenever a Rail Post is attached in the middle of the Rail for extra feet, only one ½ x 4.5” hex bolt is required to connect the Rail Post to the Rail.
Step 7 – Install Ballast Hooks and Brackets
  • A.Assemble the Upper Hook into the Lower Hooks.

  • B. Refer to your SunLink custom layout for location of each basket.
    Note: Hook and Bracket sizes are the same for all basket sizes.

  • C.Install 4 Hooks in each Ballast Basket location by snapping the hook assemblies into the 5/16” diameter holes in each side of the Rail.
    Notes: The shorter “South Hooks” attach to the south rail, the longer “North Hooks” attach to the north rail.

  • D.Orient the Ballast Bracket so that the tabs face toward where the Ballast Basket will be placed.

  • E.Fasten Upper and Lower Hook assembly to the Ballast Bracket using two (2) 5/16-18”x5/8” cap crews.
    • Align the South Hook by connecting it to the hole found at the end of the Ballast Bracket.

    • Align the North Hook by connecting it to the hole in the Ballast Bracket directly underneath.

    Note: The Hooks go on the outside of the Ballast Bracket, opposite from where the ballast will be placed.
  • FTorque to 11-14 ft-lbs.
Step 8 – Install Ballast Baskets
  • A. Center the Ballast Bracket between the Rails.

  • B. Drop the Ballast Basket onto the Brackets by placing the wire rim between the Ballast Bracket tabs.

Step 9 – Install Ballast Pads
  • A. Place Ballast Pads INTO the Ballast Basket from above, centering them beneath where each stack of ballast blocks will be placed.
    Note: Make sure the bumps in the pads protrude past the wires at the bottom of the Ballast Basket.

Step 10 – Place blocks into Ballast Basket
  • A. Stack blocks inside the Ballast Basket centered squarely over the Ballast Pads.
    Note: Refer to your SunLink custom layout to determine how many blocks should be placed in each basket.

Step 11 – Install the T-Connector Post
  • A. MDetermine location of T-Connector Posts using the layout provided by SunLink.
    Note: The T-Connector Post is always located 9" off the center line of the adjacent Foot and centered between the Rails.

  • B. Attach the T-Connector Post to the roof using the appropriate hole pattern as directed by your SunLink layout.

  • C.Add flashing.

  • D.Actual attachment to the roof, as well as associated hardware is not determined nor supplied by SunLink.

Step 12 – Attach Shaft Collar
  • A. Slide a Shaft Collar onto each end of the T-Connector Rod.
Step 13 – Connect T-Connector Rod to Rails
  • A.Slide the T-Connector Rod through the 1.5” diameter hole in the south Rail, and then back it into the 1.5” diameter hole in the north Rail.
Step 14 – Attach T-Connector Rod to T-Connector Post
  • A. Align the slots of the T-Connector Rod with the slot in the T-Connector Post.

  • B. Slide two (2) more Shaft Collars over each end of the T-Connector Rod.

  • C. Ensure Shaft Collars are flush with the web of the Rail and tighten the set screw to 11-14 ft-lbs.

  • D. Secure the T-Connector Rod to the T-Connector Post using a ½-13 x 4” hex bolt, nut and 2 washers.

  • E. Torque to 20-25 ft-lbs.

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