ASSEMBLY INSTRUCTIONS FOR SUNLINK PV MODULE ROOF MOUNT SYSTEM

TABLE OF CONTENTS
Notices and safety General procedure notes Installation materials and tools Part diagrams Elevation Views Assembly sequence Tilt bracket assembly and installation Substrate assembly Panel assembly: 4x1 & 3x1 General module to spar grounding Tilt Access Feature Panel installation Lateral link assembly Wind deflector assembly Ballast pan installation Connector installation Spar field drilling Page 13 Page 17 Page 18 Page 19 Page 21 Page 22 Page 28 Page 32 Page 34 Page 2 Page 4 Page 5 Page 5 Page 7 Page 9 Page 10 Page 12

Assembly instructions for SunLink roof mount system- Rev L

Page 1 of 38

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. The SunLink Roof Mount System (RMS) is made from aluminum alloy, fastened together with stainless steel assembly hardware. Aluminum alloy components are manufactured per ASTM B209 and ASTM B221. 5052-H32 is used for sheetmetal components, and tempered 6000 series alloys are used for extruded components. In the forms used in SunLink, 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 panel 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 The SunLink RMS positions and secures photovoltaic modules. DC stringing and interconnection of the modules requires placement of conduit, conduit ttings 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 commercial-class modules installed with a SunLink RMS and assuming a well-equipped four-person crew is on the roof and working 7.5 hours / day with full task interchangeability: > 120 modules / day. As-built documentation process On-roof use and mark-up of this document and the drawings and printed matter 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 modications Unauthorized eld modication of SunLink components or assemblies may affect SunLink warranty coverage. Provide marked up drawings for SunLinks review, comment and approval prior to attempting any eld modications. Work arounds Workers laying out or installing arrays on rooftops may encounter undocumented or unexpected obstacles requiring a work around. Since PV arrays are intended to be primarily regular and repeating structures, work arounds should be noted on working drawings. When a work around affects the location of two or more modules at once, the supervisor should be advised and the work around should be evaluated and then completed in a manner that ensures that the remainder of the array is not affected. Roof surface All large at roofs have pitch and undulation, jointed assemblies, and may also have level separations and parapets. Various roof-mounted ttings, 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 nal location. Fire Safe Roof The SunLink RMS is to be mounted over a fire resistant roof covering rated for the application. The SunLink RMS is not meant for sloped roofs where the slope is greater than 1 :12 (7 or 12%).

Assembly instructions for SunLink roof mount system- Rev L

Page 2 of 38

Fit-up SunLink is a designed-t 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 nal 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 roong system warranty continuation, work with roong system installation contractors to ensure roong system array compatibility. WARNING! Single-ply roofs are not damage tolerant. Avoid accumulation of metal nes that result from drilling or sawing metal components. Metal nes embedded in the soles of shoes can damage single-ply roofs. Fasteners All required fasteners are furnished with the SunLink RMS. All fasteners are 18Cr-8Ni stainless steel. For any assembly, nish initial bolted assembly to nger tight. Refer to the Installation Manual for detailed information on application. Button-head cap screws (BHCS) are precision, low-prole fasteners. Use of air-powered tools that do not incorporate means to limit applied torque may damage the head of these 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 substrate 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 nishing.

Assembly instructions for SunLink roof mount system- Rev L

Page 3 of 38

GENERAL PROCEDURE NOTES

A. The SunLink system assembles modules into panels as follows: 4x1 4 modules assembled into one panel 3x1 3 modules assembled into one panel 2x1 2 modules assembled into one panel B. Tilt brackets Tilt brackets are multi-function SunLink assemblies. Together with longitudinal links, tilt brackets make up the SunLink roof substrate. Tilt brackets enable free-standing array support and allow for mechanical anchoring. Tilt bracket bases can be adapted to any roof type. Tilt bracket covers set the array angle of incidence, connect SunLink panels to the substrate subsystem and establish array row spacing. Tilt brackets are congured for easy eld assembly and are shipped in two parts. Tilt bracket covers are shipped in a semiformed condition and need final forming to be completed on-site and are then attached to the tilt bracket bases. This minimizes on site storage and reduces shipping and handling bulk. Assembly time for tilt bracket is about 10 seconds. The assembly process is worker friendly. As is true for any precision assembly, a light touch works best. Do not over-bend the tilt bracket cover.

C. TILT ACCESS is a unique feature to SunLink that lets you ip the panels up and out of the way. During installation do not leave panels unattended in the tilt up position. Do not place panels in locked tilt up position if winds exceed 15mph. D. Temporary ballast 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. E. Safety For all day handling of aluminum components, wear gloves. Be careful of pinch hazards, especially when lowering panels onto tilt brackets

Assembly instructions for SunLink roof mount system- Rev L

Page 4 of 38

REQUIRED INSTALLATION MATERIALS AND TOOLS

Minimum six (6) saw horses (e.g. Stanley 2 way adjustable saw horses, 32 high, 4 long and 29 wide. Stanley part number 11012) 2. Torque wrench 3. Cordless screwdriver with torque adjustment 4. Rubber mallet 5. 1/2 wrench 6. 9/16 wrench 7. 1-1/8 wrench 8. Hex bit drivers - 3/16, 5/32, 7/32 9. Drift pin 10. Wire cutters 11. Pliers 1.

PART DIAGRAMS
Spar (aluminum extrusion) Longitudinal link (aluminum extrusion) Anchor block (aluminum extrusion)

Lateral link (aluminum extrusion)

Pivot block (aluminum extrusion)

Clamp block (aluminum extrusion)

Tilt bracket base (aluminum sheetmetal)

Tilt bracket cover (aluminum sheetmetal)

End row tilt bracket cover (Aluminum sheetmetal)

Assembly instructions for SunLink roof mount system- Rev L

Page 5 of 38

PART DIAGRAMS
East wind deflector (aluminum sheetmetal) West wind deflector (aluminum sheetmetal) End East deflector (aluminum sheetmetal)

End West deflector (aluminum sheetmetal)

End disc (aluminum extrusion)

Deflector clip (Stainless steel)

Drill jig

Long link clamp (stainless steel)

Z Clamp Arm (stainless steel)

Ballast pan (aluminum sheetmetal)

Flashable post anchor (FPA) (machined/welded aluminum)

Assembly instructions for SunLink roof mount system- Rev L

Page 6 of 38

(note tilt brackets are transparent for clarity)

ELEVATION VIEW OF 5 SYSTEM

PV Module End Disc Pivot block

Clamp block

Wind deflector

Spar

Anchor block

Tilt bracket

Long Link

Tilt bracket

North end row tilt bracket

(note tilt brackets are transparent for clarity)

ELEVATION VIEW OF 10 SYSTEM

Clamp block PV Module Pivot block End Disc Lateral link

Wind deflector

Spar

Anchor block

Long Link End row tilt bracket (smaller size than tilt bracket)

Tilt bracket

End row tilt bracket (smaller size than tilt bracket)

Assembly instructions for SunLink roof mount system- Rev L

Page 7 of 38

(note tilt brackets are transparent for clarity)

ELEVATION VIEW OF 15 SYSTEM

Clamp block PV Module Lateral link Spar Anchor block

Wind deflector

Pivot block End disc

Long link End row tilt bracket (smaller size than tilt bracket)

Tilt bracket

End row tilt bracket (smaller size than tilt bracket)

(note tilt brackets are transparent for clarity)

ELEVATION VIEW OF 20 SYSTEM

Clamp block PV Module Pivot block End disc Spar Lateral link Anchor block

Wind deflector

Long link End row tilt bracket (smaller size than tilt bracket)

Tilt bracket

End row tilt bracket (smaller size than tilt bracket)

Assembly instructions for SunLink roof mount system- Rev L

Page 8 of 38

ASSEMBLY AND INSTALLATION SEQUENCE

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Assemble tilt bracket bending jig. Assemble tilt brackets. Install tilt brackets and longitudinal links on roof. Lay out modules and spars on saw horses. Attach clamp blocks to spars. Attach modules to spars. Install grounding screws Attach pivot blocks and anchor blocks to spars. Attach panels to tilt brackets. Hook up module leads. Attach lateral links. Attach wind deflectors on north rows. Install end discs. Install ballast pans and/or connector post assemblies.

Assembly instructions for SunLink roof mount system- Rev L

Page 9 of 38

Parts Used Tilt bracket cover Tilt bracket base Long link 3/8-16 x 2.25 HHCS 3/8-16 Hex nut

TILT BRACKET ASSEMBLY AND INSTALLATION

Step 1. Tilt bracket jig assembly

Before beginning assembly of the tilt brackets a bending jig must first be made which will ease assembly. (10 degree system shown) The bending jig is made as follows; take two tilt bracket covers and bend them over a longitudinal link (refer to Step 2), being careful not to over bend. Attach the tilt bracket cover to the tilt bracket base as shown in step 3 below. Attach a longitudinal link between the two tilt brackets as shown below using two (2) 3/8-16 x 2.25 HHCS and 3/8 Hex nuts, (note: longitudinal link is only attached to the upper hole in the tilt brackets when used as jig). The bending jig is now ready to be used.

Longitudinal link

Tilt bracket cover

Step 2. Bend tilt bracket covers Lay a tilt bracket cover over the longitudinal link and bend the sides of the cover inwards, being careful not to over bend. The tilt bracket cover will have a little spring back.

Assembly instructions for SunLink roof mount system- Rev L

Page 10 of 38

Step 3. Create tilt bracket cover and base assembly Attach the tilt bracket cover to the tilt bracket base. Center the tilt bracket cover over the tilt bracket base and pinch the legs of the tilt bracket cover until the slots in the cover clear the locking tabs in the base. Allow the cover to expand with the locking tabs of the base engaging with the slots in the cover. Push down on the center of the cover to complete engagement of tabs. Ensure all locking tabs are engaged properly.

Pinch slightly
Pinch cover and align locking tabs with slots

Release
Release and engage locking tabs, push cover down to complete engagement

Assembled tilt bracket

Assembly instructions for SunLink roof mount system- Rev L

Page 11 of 38

Parts Used Tilt bracket cover Tilt bracket base Long link 3/8-16 x 2.25 HHCS 3/8-16 Hex nut 3/8 Flat washer

SUBSTRATE ASSEMBLY
Step 1. Create the substrate

Set up tilt brackets at desired location and attach longitudinal links between tilt brackets as shown below. Use four (4) 3/8-16 x 2.25 HHCS, eight (8) 3/8 flat washers and four (4) 3/8 hex nuts to attach the longitudinal link to the tilt brackets. Use a washer on each side of the tilt bracket. Do not fully tighten the nuts. Repeat for second column of tilt brackets.

Assembly instructions for SunLink roof mount system- Rev L

Page 12 of 38

Parts Used Spars Clamp blocks 5/16-18 x 1.25 BHCS 3/8-16 x 2.25 HHCS 3/8-16 Hex Nut Mounting fasteners: 5/16-18 x .625 BHCS 5/16 Hex flange nut Or -20 x .625 BHCS Or -20 Hex flange nut

(4x1 panel system shown)

PANEL ASSEMBLY

4x1 and 3x1 Panel Assembly:

Step 1. Saw horse preparation

Lay out saw horses as shown, distance between first and last saw horse should be approximately 12 shorter than spar being used. A spar can be set on ground beside saw horses and used as guide. Note: It may be helpful to place plywood sheets on the saw horses to provide a larger work surface for holding tools and components.

Orient and lay spars on either side of the saw horses

Step 2. Module and Spar Preparation Spars are used as the main component of the panel assemblies. Modules are affixed directly. Lay modules face down with an approximate module to module gap of 1.25. Lay two (2) spars on top of the edges of the modules. Orient modules such that junction boxes are in same direction for all modules.

Orient spars PV Module

Spar

Saw horse

PV Module

Assembly instructions for SunLink roof mount system- Rev L

Page 13 of 38

Step 3. Clamp blocks The clamp blocks are used to provide equal spacing between modules. Install three (3) clamp blocks per 4x1 spar and two (2) clamp blocks per 3x1 spar and 1 clamp block per 2x1 spar using one (1) 5/1618 x 1.25 BHCS per clamp block. Leave clamp blocks loose.

Spar

Module Clamp block

Assembly instructions for SunLink roof mount system- Rev L

Page 14 of 38

Step 4. Attach modules to spars Attach modules to spars in the orientation shown below. Depending on module and mounting hole diameter, use either four (4) 5/16-18 x .625 BHCS or four (4) 1/4 20 x .625 BHCS with corresponding flange nuts per module. Spars with .28 mounting holes use 1/4 screws and spars with .34 holes use 5/16 screws. Leave nuts loose. Once all bolts and nuts are installed, verify that the clamp block flanges are positioned flush over each module and square with the spar. Tighten all bolts to 11-14 ft lbs using cordless screwdriver. Ensure cordless screwdriver is set to the correct torque. During this process make sure the spars are seated, with no gaps, against the outside of the PV module frames.

Step 5. Install pivot blocks to spars Install two (2) pivot blocks onto the first spar. It may be necessary to lightly tap the pivot block into place using a rubber mallet. Attach pivot blocks to spar using 3/8-16 x 2.25 HHCS, two (2) per pivot block. Tighten to 16-20 ft lbs.

Pivot block Spar

Pivot block

Spar

Side view of pivot block and spar.

Assembly instructions for SunLink roof mount system- Rev L

Page 15 of 38

Step 6. Install the anchor blocks Install two (2) anchor blocks onto the second spar. Rotate anchor block so that grooved surface is facing modules. Attach anchor blocks to spar using two (2) 3/8-16 x 2.25 bolts and 3/8 hex nuts. Tighten to 16-20 ft lbs. Note: Depending on movement of panels on site, the anchor blocks can be attached to the tilt brackets first. The anchor blocks would then be attached to the spar after the panel is installed on the tilt brackets.

Anchor block

Assembly instructions for SunLink roof mount system- Rev L

Page 16 of 38

General Module to Spar Grounding Recommendations

Please refer to General Module to Spar Grounding Recommendations Rev A

Assembly instructions for SunLink roof mount system- Rev L

Page 17 of 38

TILT ACCESS FEATURE

TILT ACCESS is a unique feature to SunLink that lets you ip the panels up and out of the way. This enables access to the underside of the modules during installation and routine maintenance. To use the TILT ACCESS feature: 1. 2. 3. Remove both 3/8-16x2.25 HHCSs from the Anchor Block/Tilt Bracket assemblies and one from each of the Pivot Block/Tilt Bracket assemblies (reference below image for exact hole locations). Lift the sub-assembly (4x1 and 3x1) up to 100 degrees. To hold the modules in position align the provided locking holes on the Tilt Bracket with the locking holes on each Pivot Block. Place one 3/8-16x2.25 HHCS into the locking holes on each of the two tilt brackets.

Note: TILT ACCESS feature is allowed without additional support in wind speed less than 15mph.

Assembly instructions for SunLink roof mount system- Rev L

Page 18 of 38

Parts Used Assembled panel Substrate End disc 3/8-16 x 2.25 HHCS 3/8-16 Hex nut 3/8 Flat washer

PANEL INSTALLATION

Step 1. Attaching the panel to the substrate Attach the assembled panel to the installed tilt brackets. Orient the assembled panel up 90 and guide the pivot blocks into the tilt brackets on the south side.

Step 2. Attaching the anchor blocks to the substrate Rotate the panel down and guide the anchor blocks into the north side tilt brackets. Install two (2) 3/8-16 x 2.25 HHCS with a 3/8 flat washer into each anchor block and attach a 3/8 flat washer and 3/8 hex nut on each bolt. Do not tighten. Install two (2) 3/816x2.25 HHCS with 3/8 flat washers into each pivot block and fasten with 3/8 flat washers and nuts. Once all bolts are installed and panels are in correct position tighten all eight (8) mounting bolts to 16-20 ft lbs.

Assembly instructions for SunLink roof mount system- Rev L

Page 19 of 38

Step 3. Installing end disc to substrate Install end disc into open end of each tilt bracket located on the south side of each SunLink column. Secure end disc with one (1) 3/8-16 x 2.25 HHCS with two (2) 3/8 flat washers and one (1) 3/8 hex nut. Tighten to 16-20 ft lbs.

End disc

End row tilt bracket cover (South row)

Assembly instructions for SunLink roof mount system- Rev L

Page 20 of 38

Parts Used Assembled panel Lateral link 3/8-16 x 2.25 HHCS 3/8-16 Hex nut

LATERAL LINK INSTALLATION

Lateral links are used to provide connection in the E/W direction and are an important component in the overall design of the SunLink RMS. Lateral links are located between panels where shown on layout drawing. Step 1. Attaching the lateral link to the spar Insert the lateral link within the spar channel of each panel and align mounting holes. Install two (4) 3/8 - 16 x 2.25 HHCS through spar and lateral link (2 each end) and attach four (4) 3/8 hex nuts. Tighten to 16-20 ft lbs.

Spar Lateral link

Lateral link assembly

Assembly instructions for SunLink roof mount system- Rev L

Page 21 of 38

Parts Used Assembled panel E and W Deflectors Deflector clips 5/16-18 x 1 HHCS 5/16-18 Hex flange nut 5/16-18 x .625 BHCS

WIND DEFLECTOR ASSEMBLY

Wind deflectors are installed on the North end of each SunLink column. Wind deflectors are also required when transitioning from a 3x1 to a 4x1 or where a module is omitted. See layout drawing for wind deflector locations.

North row wind deflectors

All panels use two (2) wind deflectors per panel (1 East deflector and 1 West deflector). Wind deflectors are attached to the back of the spar and to the end row tilt bracket covers. Step 1. Installing deflectors to North row spar Install deflector mounting hardware to spars on North row. Install 5/16-18 x 1 HHCS with 5/16 flange nuts into each .344 hole on the back leg of the spar, quantity varies depending on module type and whether a 4x1, 3x1 or 2x1 is being used. Torque to 14 -16 ft lbs. Note: this step can be done when the panels are being assembled during the panel assembly process if the panel is being used for the North row.

5/16-18 Hex flange nuts

Wind deflector

5/16-18 x 1 HHCS

Hardware

Exploded side view showing deflector attachment (Anchor blocks removed for clarity)
Assembly instructions for SunLink roof mount system- Rev L

Page 22 of 38

Step 2. Attach E/W deflectors to spars Attach east and west deflectors to spar using 5/16-18 flange nuts. Orient the deflectors such that the end tabs are facing out and are at the center of the 4x1, 3x1 and 2x1 panel. Torque to 14-16 ft lbs.

East wind deflector

West wind deflector

End tabs of deflectors

Assembly instructions for SunLink roof mount system- Rev L

Page 23 of 38

Step 3. Attach deflector clips to end row tilt brackets Attach deflector clips to end row tilt brackets using two (2) 5/16-18 x .625 BHCS per deflector clip. Torque to 11 to 14 ft lbs.

Deflector clip goes over lip on deflector

Side view of deflector to tilt bracket assembly

Assembly instructions for SunLink roof mount system- Rev L

Page 24 of 38

Step 4. Connect E/W deflector tabs Connect east and west deflector end tabs at center of panel using 5/16-18 x .625 BHCS with flange nuts, quantity varies between 0 and 4 depending on system. Torque to 11-14 ft lbs.

Side view of north row assembly (10 system)

Assembly instructions for SunLink roof mount system- Rev L

Page 25 of 38

End wind deflector

End wind deflectors are used when transitioning from a 3x1 to a 4x1 or when a module is omitted due to an obstruction. The end wind deflector is attached using the anchor block and lateral link holes. Step 1. Remove anchor block and spar fasteners Remove the two 3/8-16 x 2.25 HHCS anchor block to spar mounting screws on the side of the spar where the end wind deflector will be mounted. Remove the upper anchor block to tilt bracket 3/8-16 x 2.25 HHCS with washers and hex nut. Set fasteners aside.

Remove these three (3) fasteners

Step 2. Attach end wind deflector Attach the end wind deflector to the back of the spar. Install the two anchor block to spar mounting screws through the end wind deflector mounting holes. Insert two (2) 3/8-16 x 2.25 HHCS with 3/8 hex nuts removed in step 1 through the two mounting holes at the end of the end wind deflector and into the lateral link holes on the spar. Torque to 14 -20 ft lbs.

End wind deflector

Assembly instructions for SunLink roof mount system- Rev L

Page 26 of 38

Step 3. Reattach anchor blocks to spar Reinstall upper anchor block to tilt bracket fastener removed in step 1 through the end tab on the end wind deflector. Torque to 16 20 ft lbs.

Note: East end wind deflector shown, procedure is the same for West end wind deflectors.

May need to field modify deflector Add west end deflector Drill two holes in spar

If this module is omitted, cut spars and deflector approximately 6 from tilt bracket cover
Array section showing east end wind deflector on a 4x1 and east and west deflectors on a 3x1

Assembly instructions for SunLink roof mount system- Rev L

Page 27 of 38

Parts Used Ballast pan 14 gauge SS wire

BALLAST PAN INSTALLATION

One method of hold down for the SunLink RMS is ballasted. SunLink has various methods for ballasting the RMS which make use of commonly available pavers. Ballast pans are available in 3 different sizes, 12, 16 and 24. The 12 and 24 ballast pans are designed to work with 12 x 12 x 2 (nominal) pavers weighing 24 lbs each. The 16 ballast pan is designed to work with 16 x 8 x 2 (nominal) pavers, weighing 18 lbs each. 14 gauge (.08) stainless steel wires are tied to each side of the ballast pan are used to secure the pavers to the pan. Length of wire required will depend on ballast pan and number of pavers used, for example a 24 ballast pan with 8 pavers would require approximately 6 of wire per pan. 9 of wire is provided per pan for worst case. Note: A suitable waterproof adhesive can be used in place of the wire ties. Use adhesive to attach the pavers to the ballast pan and to attach pavers to pavers. Step 1. Place ballast pans Place ballast pan over longitudinal link and keep pan close to the North row tilt bracket cover.

Longitudinal Link

Ballast Pan

DIMENSION A B C D
Assembly instructions for SunLink roof mount system- Rev L

12 BALLAST [IN] 27.7 12.00 28.3 6.0

16 BALLAST [IN] 35.3 16.0 37.0 8.0

24 BALLAST [IN] 27.7 24.0 29.3 12.0

Page 28 of 38

Step 2. Placing ballast Lay required number of pavers onto ballast pan. Place pavers as close as possible to long link.

4 pavers double stacked

Push pavers toward long link

Other paver layout options

16

16

24

12

16 ballast pan with 4 pavers

24 ballast pan with 4 pavers

Assembly instructions for SunLink roof mount system- Rev L

Page 29 of 38

Step 3. Placing tie down wire Loop wire though hole on side of ballast pan and twist it around itself (two twists minimum) to secure.

Hole in ballast pan Wire through hole and twisted around itself
Step 4. Affixed tie down wire Pull wire taut and loop through hole on other side of ballast pan and secure by twisting wire around itself (two twists minimum)

Wire pulled taut and secured each end

Assembly instructions for SunLink roof mount system- Rev L

Page 30 of 38

Step 5. Installing multiple tie down wires Repeat steps 3 and 4 for second wire.

Note: Alternate single wire attachment method for 4 pavers high or fewer: Loop wire through holes on one side of ballast pan. Remove slack and loop ends through opposite side of ballast pan. Twist wire around itself (two twists minimum) to secure.

Assembly instructions for SunLink roof mount system- Rev L

Page 31 of 38

Parts Used Flashable Post Anchor (FPA) Z-clamp arm (ZCA) Long link clamp -10 x 1.5 HHCS Flat Washer 5/16-18 x .625 BHCS 5/16 Hex flange nut

CONNECTOR INSTALLATION

One method of hold down for the SunLink RMS is physically connecting it to the roof. The advantages of a connected SunLink RMS is reduced connector counts. Connectors are installed when extra attachment is required to attach the SunLink system to roofing with minimum penetration. Step 1. Install Flashable Post Anchor (FPA) Attach flashable post anchor (FPA) to roof and add flashing.

Mounting screws (Roof attachment hardware determined and supplied by others) FPA Backer board to bring connector base flush with deck Determined and supplied by others Section of roof with roofing material removed to allow direct access to substrate

FPA with flashing installed Determined and supplied by others

Assembly instructions for SunLink roof mount system- Rev L

Page 32 of 38

Step 2. Install Z-Clamp Arm (ZCA) to long link Connect Z clamp arm to long link using long link clamp and four (4) 5/16 x .625 BHCS with 5/16 flange nuts. Do not tighten nuts. Step 3. Install ZCA to FPA Connect Z clamp arm to FPA and secure with 3/4 -10 x 1.5 HHCS and flat washer. Tighten to 30-40ft lbs. Tighten 5/16" nuts on long link clamp to 11-14 ft lbs.

Z-clamp arm

Flashable post anchor

Long link clamp

Assembly instructions for SunLink roof mount system- Rev L

Page 33 of 38

SPAR FIELD DRILLING

REQUIRED INSTALLATION MATERIALS AND TOOLS 1. 2. 3. 4. 5. Spar drill jig 13/32 metal cutting drill bits (minimum 2 per job) 9/16 wrenches or sockets Vise-grip pliers clamps (2) see Mcmaster-Carr Part # 5105A14 as example. Cordless screwdriver with torque adjustment

Refer to layout drawing to determine if spar field drilling is required for system. When a column of 4x1 transitions to a 3x1 (or vice-a-versa) the tilt bracket of the of 3x1 that does not line up with the 4x1 column needs to be attached to the spar of the 4x1. To do this, two 13/32 holes have to be drilled in the 4x1 spar to allow attachment of either a pivot block or anchor block (which block to use depends on whether the 3x1 is to the north or south of the 4x1). This pivot block or anchor block will then be attached to the tilt bracket of the 3x1.

South

South

3x1 to the north of a 4x1 (connect to 4x1 using anchor block)

3x1 to the south of a 4x1 (connect to 4x1using pivot block)

Note: It is best to drill the spars before attaching them to the modules, but they can also be drilled in place.

Assembly instructions for SunLink roof mount system- Rev L

Page 34 of 38

Method A Drilling the spar before assembly. Determine which side of the 4x1 spar needs the extra mounting holes before beginning. Step 1. Lining up spars Lay a 3x1 and 4x1 spar back to back and align one set of anchor/pivot block holes on the 3x1 with the matching holes on the 4x1.

3x1 spar

4x1 spar

Align holes

Side view
Step 2. Affix spars together Clamp and bolt spars together to maintain alignment.

Assembly instructions for SunLink roof mount system- Rev L

Page 35 of 38

Step 3. Affix drill jig Connect the drill jig to the 3x1 spar at the second pivot/anchor block location. Tighten thumbscrew to secure the drill jig to the spar.

Drill jig

Step 4. Drill spar Using the drill jig as a guide, drill two 13/32 holes through 4x1 spar. Debur edges on both sides.

Assembly instructions for SunLink roof mount system- Rev L

Page 36 of 38

Method B drilling spars after system is mounted on roof. Step 1. Connecting using an anchor block When connecting on north side using an anchor block: Use anchor block as a guide to ensure that the drill jig is in the correct location. Push drill jig into spar until it stops. Secure drill jig to spar using jig thumb screw. Drill two 13/32 holes in 4x1 spar. Debur edges on both sides.

Drill jig 4x1 North side spar

Tilt bracket of 3x1

Drill jig thumbscrew

Anchor block used as guide

Assembly instructions for SunLink roof mount system- Rev L

Page 37 of 38

Step 2. Connecting using a pivot block When connecting on south side using an anchor block: 4 x1 panel may need to be rotated up to gain access to inside of lower spar. Use anchor block as a guide to ensure that the drill jig is in the correct location. Push drill jig into spar until it stops. Secure drill jig to spar using jig thumb screw. Remove anchor block, Drill two 13/32 holes in 4x1 spar. Debur edges on both sides. Note: Anchor block is only used as a guide, a pivot block will be used to connect the 3x1 tilt bracket to the 4x1 spar.

4x1 south side spar

Anchor block used as guide

Drill jig

Drill jig thumbscrew

Assembly instructions for SunLink roof mount system- Rev L

Page 38 of 38