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Related Manuals for KB Racking ReziRack 2.0
Summary of Contents for KB Racking ReziRack 2.0
- Page 1 INSTALLATION MANUAL KB Racking ® Inc. 1 Atlantic Ave., Suite 210, Toronto ON M6K 3E7 117 E. Colorado Blvd., Pasadena, CA 91105 Varsovia 36, Col. Juárez, Interior 731, Cuidad de México, 06600 Phone: 1-888-661-3204 Fax: 647-933-5375 info@kbracking.com www.kbracking.com...
- Page 2 • Canadian Solar CS3U-P, CS3U-MS, CS3K-P, CS3K-MS, CS6U-P, CS6K-P, CS6K-MS. ETL CERTIFIED CLAMPS ReziRack 2.0 uses ETL Certified KB Konnect Clamps to secure PV modules to the system. The KB Konnect Clamps feature protruding screws that pierce the module frame providing a bonding connection between adjacent module frames.
- Page 3 Seulement les professionnels qualifié devrait installer les panneaux solaires, les fils CC, et les dispositifs de sécurité contre la foudre. Les composants de KB Racking peuvent ont déplacé au cours du transport. Prendre des ® précautions supplémentaires lorsque vous déplacez et déballage les composants.
- Page 4 ▪ 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. ▪...
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Page 5: Table Of Contents
TABLE OF CONTENTS SYSTEM OVERVIEW ............................................6 COMPONENTS ............................................6 TOOLS REQUIRED ............................................7 TORQUE VALUES ............................................7 SYSTEM LIMITATIONS ..........................................8 INSTALLATION CONFIGURATIONS ......................................9 SHARED-RAIL CONFIGURATION ......................................9 FULLY-RAILED CONFIGURATION ....................................... 10 PRE-INSTALLATION ............................................ 11 PREPARING FOR INSTALLATION ......................................11 ASSESS SITE CONDITIONS ........................................ -
Page 6: System Overview
SYSTEM OVERVIEW Figure 2 – System Overview COMPONENTS KB10 Series Rail KB10 Series Splice KB Konnect Mid Clamp Shingle Attachment with Black Galva Flashing L-Foot † KB Konnect End Clamp † Project-specific component may appear different KB Konnect End Clamp Variations (Integrated End Clamp, KB Konnect Mid Clamp with End Block) are shown Rev.1, Sep 2019 Page 6 of 42... -
Page 7: Tools Required
TOOLS REQUIRED □ 3/16” Allen Bit Tip OR 5mm Hex Drive □ Torque Wrench □ 13mm Hex Socket □ Cordless Drill □ Tape Measure □ Spirit Level □ Safety Gloves □ Portable Band/Reciprocating Saw □ Safety Glasses □ Jigs NOTE: Refer to Appendix A for tools required for shingle attachment TORQUE VALUES Torque Torque... -
Page 8: System Limitations
SYSTEM LIMITATIONS Limitations that govern the installation of the ReziRack 2.0 system are listed below: • For Shared Rail installations, the centre of each KB Konnect Clamp must be placed at minimum 4” from the module edge. • Any given rail must contain a minimum of two Rail spans (i.e. three anchor connections to the roof). -
Page 9: Installation Configurations
INSTALLATION CONFIGURATIONS The versatility of ReziRack 2.0 allows it to be installed in both Shared-Rail and Fully-Railed configurations depending on your project requirements. NOTE: The selected configuration must adhere to the mounting instructions provided by your module manufacturer. SHARED-RAIL CONFIGURATION Shared-Rail configurations feature three Rails per two rows of modules. -
Page 10: Fully-Railed Configuration
FULLY-RAILED CONFIGURATION Fully-Railed configurations feature two Rails per row of modules. Figure 6 – Fully-Railed Portrait Configuration Figure 7 – Fully-Railed Landscape Configuration Rev.1, Sep 2019 Page 10 of 42... -
Page 11: Pre-Installation
PRE-INSTALLATION This section provides recommendations on designing arrays for your ReziRack 2.0 system. Review each step carefully before installation. PREPARING FOR INSTALLATION Use the guidelines below to plan your layout. Always ensure layouts are compliant with local AHJ requirements. The following is a general order of planning, prior to installation:... -
Page 12: Create Spacing Diagram
CREATE SPACING DIAGRAM Once the below dimensions have been determined, enter them into the provided Spacing Diagram template. SHARED-RAIL Figure 9 – Sample Shared-Rail Spacing Diagram To finalize your Shared-Rail Spacing Diagram, you will need to determine the following dimensions: DIMENSION HOW TO CALCULATE/DETERMINE N/S Spacing: Module Length... - Page 13 To calculate the area of your array, use the following formula: N/S Dimension [in] = Module Length OR Width No. of Modules No. of Modules ) + (0.76 x ( +1)) + 1.18 E/W Dimension [in] = Module Length OR Width No.
- Page 14 FULLY-RAILED Figure 10 – Sample Fully-Railed Spacing Diagram To finalize your Fully-Railed Spacing Diagram, you will need to determine the following dimensions: DIMENSION HOW TO CALCULATE/DETERMINE N/S Spacing: Dependent on clamping distance † Attachment Spacing E/W Spacing: Refer to span tables (Page 11) Inter-Row Attachment Distance between attachments between module rows;...
- Page 15 To calculate the area of your array, use the following formula: N/S Length [in] = Module Length OR Width No. of Modules Module Spacing N/S No. of Modules ) + ( -1)) E/W Length [in] = Module Length OR Width No.
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Page 16: Layout Diagram
LAYOUT DIAGRAM NOTE: Ensure that rafter locations are identified before proceeding. • Use a drawing of the roof to plan your layout. • Overlay rafters on this drawing. • Using your Spacing Diagram, draw your layout. • Identify the point of origin on your Layout Diagram. This is the point where the first shingle attachment will be placed. - Page 17 INSTALLATION Rev.1, Sep 2019 Page 17 of 42...
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Page 18: Key Installation Tips
KEY INSTALLATION TIPS INSTALLATION ORIGIN Each array in your layout diagram will have a point of origin. The installation of every array MUST begin at the origin. INSTALLATION DIRECTION It is recommended that installations start at the bottom of the roof, working up. Figure 12 –... - Page 19 L-Feet must sit as perpendicular as possible to the roof surface. This is controlled by properly installing the shingle attachment. An improperly installed L-Foot will prevent proper installation of ReziRack 2.0. Always rotate and orient the L-Feet as shown in the figure below. This is recommended to keep the installation consistent throughout the array.
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Page 20: Shingle Attachments
SHINGLE ATTACHMENTS Use your Layout Diagram to determine and mark the location of the first shingle attachment. Draw chalk lines in the E/W and N/S directions to determine the locations of the other shingle attachments. Use the Spacing Diagram as an aid. Figure 16 –... -
Page 21: Rail Attachment
RAIL ATTACHMENT Refer to your Layout Diagram to determine the arrangement of Rails for each array. Multiple rail lengths may be required. See Page 33 for instructions on cutting Rails. Figure 18 – Sample Layout Diagram Install Rails onto L-Feet by aligning the T-Bolt slot on the Rail with the L-Foot slot. -
Page 22: Splicing Rails
SPLICING RAILS The ReziRack 2.0 system uses a Splice to connect two Rails end-to-end. SPLICE REQUIREMENTS • Adjacent Rails being spliced must be at the same height off the roof. Use a jig to maintain consistent Rail height throughout the array. -
Page 23: Thermal Breaks
ReziRack 2.0. A thermal break of at least 1.75” must be included for every 80 feet of spliced Rail in ReziRack 2.0 arrays. Thermal Breaks are identified in your Layout Diagram. NOTE: Do not install modules across/over thermal breaks. Figure 24 – Thermal Break Rev.1, Sep 2019... -
Page 24: Microinverter Installation
MICROINVERTER INSTALLATION This section provides guidance on installing microinverters to your ReziRack 2.0 system. KB Racking ® can provide a mounting kit containing the following components to mount a microinverter weighing less than 5kg: • Accessory Bracket • M8 Serrated Flange Bolt •... - Page 25 Install the microinverter onto the Accessory Bracket using M6 Serrated Flange Bolts and Nuts. Torque to 9.5Nm (7.0 ft-lb). Figure 27 – Securing Microinverter to Accessory Bracket Rev.1, Sep 2019 Page 25 of 42...
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Page 26: Alternate Installation Methods
ALTERNATE INSTALLATION METHODS Alternate microinverter installation methods are shown below: Fully-Railed Configuration Only Module Mounting ( Microinverters are mounted to the module frame using slots on the underside of the module. Figure 28 – Microinverter Mounted to Module (Fully-Railed Configuration Only) Alternate Rail Mounting: Microinverters can be mounted to the top of the Rail using M8 bolts and nuts. -
Page 27: Installing Modules
INSTALLING MODULES SHARED-RAIL CONFIGURATION Module installation begins at the array origin (Page 16), or corner location. It is a continuous installation process that sees adjacent modules being installed up, then across. This may also require some adjustment to Rail positioning. A correctly installed system will have modules evenly seated on Rails, and KB Konnect Clamps in full-contact, flush, and correctly spaced on modules. - Page 28 Secure the first module onto each Rail with KB Konnect (KBK) Clamps. Use your Spacing Diagram to locate the Clamp locations relative to the module edge. Click-in and secure End Clamps at array edges first. The centre of each KB Konnect Clamp must be placed at least 4”...
- Page 29 Completely secure the first module. Use a 3/16” Allen Bit/5mm Hex Drive, tighten all Clamps with a standard drill or torque wrench. Torque to 8.3Nm (6.1ft-lb). NOTE: To prevent damage to module and KBK Clamp, do not exceed recommended torque setting above. Do not use hammer drills, impact drivers, or Figure 34 –KB Konnect Clamp + End Block Installed long Allen keys.
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Page 30: Fully-Railed Configuration
FULLY-RAILED CONFIGURATION Module installation begins at the array origin (Page 16), or corner location. It is a continuous installation process that sees adjacent modules being installed across, then up. This may also require some adjustment to Rail positioning. A correctly installed system will have modules evenly seated on Rails, and KB Konnect Clamps in full-contact, flush, and correctly spaced on modules. - Page 31 Place the next module in the row, as shown in Figure 38. If no module is directly adjacent in the row, completely install the first module with four (4) KBK End Clamps. Click-in secure Clamps between modules. The adjacent module must be in place before completely installing the KBK Mid Clamp.
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Page 32: Wire Management
WIRE MANAGEMENT As modules are being installed, tuck wires into the wire management slot of the KB10 Series Rails. Figure 41 – Wires Routed through Channel As an added measure, MC4 connectors must be securely zip tied to the Rails. Figure 42 –... -
Page 33: Cutting Rails
CUTTING RAILS This section will serve as a guide to cutting Rails on ReziRack 2.0. Shared-Rail Installations: Measure 6.5” or greater from the End Clamp/Integrated End Clamp (as shown in Figure 44), and mark this distance. Fully-Railed Installations: Measure 4” or greater from the End Clamp Block/Integrated End Clamp (as shown in Figure 45), and mark this distance. -
Page 34: Grounding & Bonding
• At all times, the array must be interconnected to the grounding lug (as well as during maintenance). GROUNDING LUGS Only ETL Certified Grounding Lugs may be used to ground KB Racking ® systems. Examples of ETL Certified Grounding Lugs are: •... -
Page 35: Shared-Rail Configuration
SHARED-RAIL CONFIGURATION Shared-Rail Installations require one grounding point per array. Figure 46 – Shared-Rail Grounding Scheme Fasten grounding lug to the Rail. Torque as per manufacturer requirement. Figure 47 is for reference. Figure 47 – Grounding Lug Placement Insert #6 AWG – RW75 uninsulated copper ground wire into grounding lug. -
Page 36: Fully-Railed Configuration
FULLY-RAILED CONFIGURATION Fully-Railed Installations require one grounding point per row of modules. Figure 49 – Fully-Railed Grounding Scheme Fasten grounding lug to one Rail per row of modules. Torque manufacturer requirement. Figure 50 is for reference. Figure 50 – Grounding Lug Placement Insert #6 AWG –... -
Page 37: Label Attachment
LABEL ATTACHMENT Certification labels (Figure 52) must be visibly displayed on every array. Mark the appropriate quarter and year of assembly using a 1-hole punch. For a system being installed in April 2021, punch Q2 2021. For each array, a certification label must be pasted to at least one Rail carrying a grounding lug. - Page 38 POST-INSTALLATION Rev.1, Sep 2019 Page 38 of 42...
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Page 39: Completing Installation
COMPLETING INSTALLATION For each array, ensure the following items are checked off: SHINGLE ATTACHMENT Are shingle attachments installed as per manufacturer instructions? L-FEET Are L-Feet perpendicular to roof surface? Are L-Feet correctly torqued? RAILS Are Rails securely fastened to L-Feet? Are T-Bolts correctly torqued? Is a thermal break included, as specified in the manual? Are thermal breaks free of modules? -
Page 40: Product Maintenance
PRODUCT MAINTENANCE To maximize life span and ensure peak performance, KB Racking recommends routine ® maintenance checks. The following checks should be completed every 6 months to maintain the system’s integrity. • Remove debris from rooftop that can damage modules or stop solar absorption. -
Page 41: Technical Specs
TECHNICAL SPECS REZIRACK 2.0 – TECHNICAL SPECS Distribution Load 1.5 – 3 lbs/ft Inclinations Flush Wind Speed Up to 190mph Material 6000 series aluminum Module Type All standard size framed PV modules Wire Management Built into KB10 Rail Orientation Landscape, Portrait Rail Length 10’, 20’... - Page 42 APPENDIX...