KB Racking BarnRack Installation guide

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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KB Racking BarnRack Installation guide

KB Racking BarnRack Installation guide

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