KB Racking Inc.
One Atlantic Ave., Suite 106, Toronto ON M6K 3E7
714 W Olympic Blvd. Suite 936, Los Angeles CA 90013
Phone: 1-888-661-3204
Fax: 647-933-5375
info@kbracking.com
www.kbracking.com Revision NW-06 | Jan 2016
I N S T A L L A T I O N M A N U A L
IMPORTANT
Always observe all governing codes
and ordinances.
For Reference Only – Images and
diagrams used in this manual are for
reference only. Your project will have
specific documents and dimensions
(provided separately).
Secure & Dry Storage – Store parts in
a secure, dry location during installation.
Wet storage stains are prevented by
sufficient ventilation and protection from
moisture.
Roof Flooding – Ensure proper rooftop
drainage. Constant submersion of PV
supports in water may damage parts.
Consult with a KB Racking® Project
Manager if this is the case.
Check Parts – Ensure the correct type
and quantities of parts have been
delivered.
Damaged Parts – If you have received
damaged parts, immediately notify your
KB Racking
®
Project Manager.
Fire Rating - Racking system is to be
mounted over a fire resistant roof
covering rated for the application
Grounding - Racking system may be
used to ground and/or mount a PV
module complying with UL1703.
Modules – Racking system to be used
with modules where compatibility from
manufacturer has been approved
FOR YOUR SAFETY
While installing the PV system, proper
safety equipment should be worn.
⚠
DANGER
Only qualified professionals should
install solar panels, DC cabling, and
any anti-lightning safety devices.
Seulment les professionels qualifié
devrait installer les panneaux solaires,
les fils CC, et les dispositifs de sécurité
contre la foudre.
⚠
CAUTION/ATTENTION
KB Racking
®
components may have
shifted during shipping. Take extra care
when moving and unpacking
components.
Les composants de KB Racking
®
peuvent ont déplacé au cours du
transport. Prendre des précautions
supplémentaires lorsque vous déplacez
et déballage les composants.
BEFORE YOU BEGIN
Read all instructions carefully and
completely.
KB RACKING
®
IS NOT RESPONSIBLE FOR ANY
DAMAGES INCURRED ONCE SHIPMENT HAS BEEN
SIGNED FOR AND RECEIVED.
2
Table of Contents
System Overview .......................................................................................................... 3
Parts Supplied by KB Racking® ................................................................................. 3
Tools and Equipment Required for Installation ........................................................... 3
Preparing for Installation ............................................................................................... 5
How to Use Your Layout Diagram ................................................................................. 5
How to Use Your Spacing Diagram ............................................................................... 6
Installing Hook Profile ................................................................................................... 7
Installing Rails ............................................................................................................. 11
Installing Panels .......................................................................................................... 13
Grounding and Cable Management ............................................................................ 13
Installing ETL Certified Grounding Lugs ...................................................................... 14
Tyco Grounding Lug ................................................................................................. 14
Ilsco Grounding Lug ................................................................................................. 15
Completing the Installation .......................................................................................... 18
Product Maintenance Information ............................................................................... 18
3
System Overview
Parts Supplied by KB Racking®
Tools and Equipment Required for Installation
□
B00
-
01
E-
62
BarnRack Rai
l
□
B00
-
02
E-XX
Roof Hook
□
B00
-
04B
Splice
Pl
ate
□
C0
2
-xxE
Module Middle Clamp
□
C0
2
-xxE
Module End Clamp
□
M8 T-Bo
lt
Lag Bolt/TEKS S
cr
ew
□
M8 Serrated Flange N
ut
□
Sealing Washer [Not
evaluated to UL2703
Requirements]
□
TORX T40-Bit / 3/16” Allen Bit Tip
□
13mm Hex Socket
□
Safety Gloves
□
Safety Glasses
□
Power Drill
□
Adapter-Bits for Drill/Ratchet
□
Torque Wrench
4
⚠
PLEASE READ THE FOLLOWING
⚠
If roof/building edge has a fall distance of 10ft (3m) or greater,
Appropriate safety measures must be taken (i.e. harnesses) for
installation of panels closer than 6.5ft (2m) to roof edges or skylights.
Distance from gas lines and electrical equipment
Solar panels should be a minimum of 3ft (0.9m) away, unless otherwise
stated. Failure to comply could result in an inspection failure requiring the
system to be dismantled.
Distance from rooftop hatches and/or doorways
Solar panels should be a minimum of 5ft (1.5m) away, unless otherwise
stated.
Distance between arrays
Unless otherwise stated, solar arrays should be spaced a minimum of 4ft
(1.2m) from each other, E/W, with a minimum 1ft (0.3m) gap ever 15 to
16 modules to allow emergency crews easy access between arrays.
5
Preparing for Installation
1
2
Ensure the surface of the roof is clear of debris and obstacles that may impair
the installation of the system or the performance and safety of the installation
team.
Check and count that all parts and their desired quantities have arrived in the
proper fashion.
How to Use Your Layout Diagram
1
2
Note the following items on your project specific Layout Diagram:
NORTH ARROW DIMENSIONS LEGEND
ARRAY NUMBERS ROOF STRUCTURES SUPPORTS
From your layout, use the N/S and E/W dimensions at a corner of your roof
as the ORIGIN (i.e. the beginning) of your installation.
Figure 1 - Sample Layout Diagram
6
How to Use Your Spacing Diagram
1
2
Your Spacing Diagram will indicate the following important dimensions:
ROW SPACING (Distance between Hook rows, along corrugation)
COLUMN SPACING (Dist. between Hook columns, across corrugation)
PANEL SPACING (Distance between panel columns)
Record the above numbers and do not confuse them.
Figure 2 - Sample Spacing Diagram
7
Installing Hook Profile
1
Using the engineering drawings provided, mark the hook locations ensuring
that they line up with the roofing ribs and the underlying purlin members.
Figure 3 - Detailed View of System Components
IMPORTANT
The roof hooks are meant to be positioned on top
of the rib profile in order to remove them from the
water causeway when it rains.
These hooks are also meant to be fastened into the
purlin of the roof structure.
8
2
3
4
At the indicated locations, pre-drill a hole through the sheet metal to create a
path for the fastener, as shown in Figure 4 - Predrill Sheet Metal.
When fastening into thick metal purlin, it may be necessary to additionally
predrill the path through the purlin for the screw.
Figure 4 - Predrill Sheet Metal
For wood structures, as well as metal, use the appropriate screws along with
sealing washers to penetrate the roof and fasten into the purlin below. The
respective screws and washers will be provided, depending on the roof
structure.
It is critical that hooks supporting the same column/row of modules should be
oriented in opposite directions to better distribute the forces on the system
and create less stress on the modules. See Figure 5 - Hook Orientation
Option 1 and Figure 6 - Hook Orientation Option 2 next page.
9
Figure 5 - Hook Orientation Option 1
Figure 6 - Hook Orientation Option 2
IMPORTANT
The hook profiles and hanger bolts must be
spaced according to the engineering drawings and
never at a greater spacing than as indicated.
Please refer to Figure 7 on the following page to
see the sample engineering drawing and specified
dimensions.
10
5
Figure 7 - Sample Engineering Drawing
Fasten the hooks to the roof, ensuring a water tight seal with the rubber
sealing tape. The roof hook must not make direct contact with the metal
roofing. Use water resistant caulking where necessary to eliminate to
possibility of leaks.
Figure 8 - Fasten hook profile
11
Installing Rails
1
2
3
The T-Bolts provided are used to connect the rails to the hook profiles.
Feed the T-Bolt through the hook profiles' allotted slot as shown in Figure 8
below. Then position the rail above it and feed the head of the bolt through the
rail slot.
Figure 9- Fastening the Rails
Figure 10 - Fit T-Bolt to Rail
When the M8 serrated nuts are fastened to the T-Bolts, as shown in Figure 9
above, the bolt head provides a locking mechanism on the inside of the rails
allowing the nut to be fastened effectively.
IMPORTANT
Due to the spacing of the ribs, the hook profiles
and therefore the rail position may vary slightly
from the engineering drawings provided. It is
important to keep in mind that each pair of rails
running up the column/row of modules should be
spaced exactly as the indicated spacing on the
engineering drawing and not further apart.
12
4
Each rail comes in 6.2 meter [20.34 ft] lengths. Rails can easily be cut to the
required length when necessary.
When securing two rails together, splice plates are used at the end of each rail
and fastened together using the provided bolts and serrated nuts. Make sure to
secure splice plates on the underside of the rails.
Figure 11 - Splice Plate Rail Connectors
13
Installing Panels
1
2
Begin at an array corner. Position it to its respective set of rails. If possible,
start at the bottom of the roof and work your way up.
Along the array edge, click end clamps (C02-xxE) into supports. When
clamped, the KB Konnect Clamp should appear centered on the support.
Figure 12 - Snapping the clamp in position
Figure 13 - Final Assembly
Figure 14 - Fastening the clamps
⚠
IMPORTANT
Strong winds can lift panels. Solar panels cannot
be left unsupervised without all FOUR (4) KB
Konnect clamps torqued in place.
14
3
4
5
For end clamps only, insert the end clamp blocks (C01-xxE) to balance clamp
in place, (see example, Figure 5).
Place the next solar panel in the row. Click middle clamps (C02-xxE) into
mounting slots on the supports, (see example, Figure 6).
Secure the first panel in the row. Tighten the end clamps and middle clamps
with a standard drill or torque wrench.
Torque to 8.3Nm (6.1ft-lb).
Figure 15 - Use Standard Drill
(Image for reference only – EkonoRack model shown)
Figure 16 - Use Torque Wrench
(Image for reference only – EkonoRack model shown)
IMPORTANT
End clamp blocks provided by KB Racking
®
are
designed to match your solar module thickness.
This ensures the clamp sits flat. If end clamps do
not sit flat, you have the incorrect block.
Notify your builder immediately.
IMPORTANT
Each solar panel requires FOUR (4) clamps.
15
6
7
8
Continue placing panels for your first row. Tighten the middle clamps as panels
are installed.
At the end of the row, secure the end clamp with the end clamp block.
Begin the next row. Repeat steps 1-7 until all panels are installed.
⚠
IMPORTANT
To prevent damage to solar panel and clamp, do
not exceed recommended torque setting above.
Do not use hammer drills, impact drivers, or long
allen keys.
⚠
IMPORTANT
When securing clamps, ensure panels do not
slide and fall off roof. It is recommended that at
least 2 installers install the first panel in each row.
IMPORTANT
KB Konnect clips are designed for single use only.
If clips are removed for maintenance purposes, please
re-install using new KB Konnect clip.
16
Grounding and Cable Management
1
2
3
Panels can be cabled as they are installed. Install grounding wires across
each continuous row, once per rail extensions.
Insert uninsulated grounding wire into each grounding lug.
Each continuous row of panels is grounded once on the end of the rails
IMPORTANT
When bonded, any one panel OR group of panels
can be removed without disrupting the bonding
path.
17
Installing ETL Certified Grounding Lugs
Tyco Grounding Lug
1
2
Screw threaded post of grounding lugs (not provided) into the frame of the
rails of Each Row. Tighten the hex washer nut.
Torque to: 2.82Nm (2.1ft-lb).
Insert #6 AWG – RW75 uninsulated copped ground wire into wire slot.
Tighten hex nut. Torque to: 5.08Nm (3.75ft-lb).
IMPORTANT
For the purpose of electrical bonding, one
grounding lug is required per row. DO NOT
exceed 20 panels in the E/W directions (per row),
respectively. Panels may be installed in
landscape or portrait orientation.
Maximum Series Fuse Rating: 30 Amps
Fig. 15 - Grounding Lug Schematic (Tyco model, 2058729-1, shown as an example)
18
Ilsco Grounding Lug
1
2
IMPORTANT
For the purpose of electrical bonding, one
grounding lug is required per row. DO NOT
exceed 20 panels in the E/W directions (per row),
respectively. Panels may be installed in
landscape or portrait orientation.
Maximum Series Fuse Rating: 30 Amps
Insert #6 AWG – RW75 uninsulated copped ground wire into wire slot.
Tighten the bolt. Torque to: 5.08Nm (3.75ft-lb).
Fasten grounding lugs (not provided) onto the frame of the rails of Each
Row. Tighten the bolt.
Torque to: 5Nm (3.69ft-lb).
Grounding Lug Schematic (Ilsco model, SGB-4, shown as an example)
19
⚠
PLEASE READ THE FOLLOWING
⚠
Keep Copper away from Aluminum components in a fashion that
maintains a minimum of ¼” separation.
⚠
PLEASE READ THE FOLLOWING
⚠
The bonding path for grounding is a result of the interconnection of all
components within each individual row; modules, clamps, and rails.
During scheduled maintenance, the removal of modules, or other
components must be carefully and methodically considered.
At all times, the array must be interconnected to the grounding lug (as
well as during maintenance).
⚠
PLEASE READ THE FOLLOWING
⚠
Installer is responsible for and shall provide an appropriate method of
direct-to-earth grounding in accordance with the latest edition of the
Canadian Electrical Code Part 1, CSA 22.1 Safety Standard for Electrical
Installations or the National Building Code, including NEC 250:
Grounding and Bonding, and NEC 690: Solar Photovoltaic Systems.
Please refer to your local Building and Electrical Codes.
20
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