KB Racking AEROGRID User manual

INSTALLATION
MANUAL
KB Racking Inc.
1050 King St W Suite 03A104, Toronto,
ON M6K 0C7
Phone: [phone]
[email protected]
www.kbracking.com Version 02 – Feb 23

2
KB Racking Inc., 1050 King St. W., Toronto, ON, M6K 0C7 | 1 [phone] | [e-mail] | www.kbracking.com
Table of Contents
Introduction and Safety Overview…………………………………...3
Preparing for Installation……………………………………………..4
System Overview……………………………………………………..5
System Components………………………………………………….6
System Hardware………………………………………………….....7
Installation Tools……………………………………………………....7
QUICKSTART INSTALLATION GUIDE……………………………8
How to Begin Assembly.……………………………………………..9
How to Use Your Spacing Diagram………………………............10
How to Use Your Rail Table………………………………………...11
Installing Roof Protection Mats…………………………………….12
Installing Rails ……………………………………………………….13
Installing Splices……………………………………………………..14
Installing Bottom Supports………………………………………….15
Top Support Assembly………………………………………….......16
Installing Top Supports…………………………………………...…17
Installing Accessory Brackets………………………………………18
Ballast Tray Assembly……………………………………………....19
Installing Ballast Trays on Accessory Brackets…………………..20
Installing Ballast Trays on Supports……………………………….21
Installing Ballast Stones.…………………………………………....22
______________________________________________________________________________________
Installing PV Modules……………………………………………….24
Installing Windshields……………………………………………….25
Electrical Grounding…………………………………………………26
Installing ETL Certified Grounding Lugs……………………….....27
Completing the Installation………………………………………....28
Product Maintenance Information………………………………....28
APPENDIX A | SolarEdge Power Optimizer Install Guide ……....29
APPENDIX B | U-Anchor 2000 Series Install Guide………...…..30

BEFORE YOU BEGIN
Read all the instructions carefully prior to installation. Precautionary
measures must be taken to ensure a safe working environment.
Always observe all governing codes and ordinances.
FOR YOUR SAFETY
Only qualified professionals should install solar modules, DC cabling,
and any anti-lightning safety devices. Any loose components or
fasteners shall be retightened in accordance with these instructions.
If roof/building has a fall distance of 10ft (3m) or greater,
Appropriate safety measures must be taken (i.e, harnesses)
for installation of modules closer than 6.5ft (2m) to roof edges or
skylights.
KB Racking Inc. requires all arrays to be no closer than 3ft (0.9m),
unless otherwise stated, from a building’s roof edge to validate wind
load calculations and ensure the system is safely ballasted.
PPE –While installing the PV system, proper safety equipment should
be worn.
Unpacking –KB Racking components may have shifted during
shipping. Take extra care when moving and unpacking components.
OVERVIEW
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.
Modules – Racking system to be used with modules where
compatibility from the manufacturer has been approved.
Grounding – Racking system may be used to ground and/or mount a
PV module complying with UL1703 only when the specific module has
been evaluated for grounding and/or mounting in compliance with the
included instructions.
KB RACKING IS NOT RESPONSIBLE FOR ANY DAMAGES
INCURRED ONCE THE SHIPMENT HAS BEEN SIGNED FOR
AND RECEIVED.
3
______________________________________________________________________________________
Introduction and Safety Overview
KB Racking Inc., 1050 King St. W., Toronto, ON, M6K 0C7 | 1 [phone] | [e-mail] | www.kbracking.com

INSPECTIONS
Inspect the roof for damages prior to installation and record any
existing damage with a digital camera.
1. Clean the roof surface and remove all dirt and debris.
2. Ensure proper drainage on the roof. Water accumulations may
lower the load reserve of the rooftop and decrease lifespan.
3. Ensure the correct type and quantities of parts have been
delivered. Unbox all components and check for any damages.
If you have received damaged or missing parts, immediately notify
your KB Racking Project Manager.
Wear safety gloves when handling parts. Newly fabricated parts
may have sharp edges.
REFERENCE DOCUMENTS
Ensure you have the following documents prior to beginning the
installation.
I. Mat Quantities per Rail Table (Page 10)
II. Spacing Diagram – Provided separately
III. Layout Diagram – Provided separately
IV. Ballast Layout Diagram – Provided separately
V. Rail Table – Provided separately
4
Preparing for Installation
______________________________________________________________________________________
KB Racking Inc., 1050 King St. W., Toronto, ON, M6K 0C7 | 1 [phone] | [e-mail] | www.kbracking.com

5
______________________________________________________________________________________
System Overview
______________________________________________________________________________________
KB Racking Inc., 1050 King St. W., Toronto, ON, M6K 0C7 | 1 [phone] | [e-mail] | www.kbracking.com
.

Rail, XX in
G00-GS-01-XX
Splice
G00-GS-02
Accessory Bracket
G00-GS-05
Top Support
GXX-GS-04
Ballast Tray, XX in
G00-GS-06-XX
Pull Clamp
G00-GS-08
Roof Protection Mat
G00-RBR-01
System Components
______________________________________________________________________________________
.
Bottom Support
GXX-GS-03
KB Racking Inc., 1050 King St. W., Toronto, ON, M6K 0C7 | 1 [phone] | [e-mail] | www.kbracking.com 6
COMPONENTS NOT TO SCALE
Windshield
GXX-GS-07

Installation Tools
System Hardware
______________________________________________________________________________________
______________________________________________________________________________________
o7/16” Hex Socket
o3/8” Hex Socket
oRatchet
oPower Drill
oTorque Wrench
oSafety Gloves
oSafety Glasses
oChalk Reel
oMeasuring Tape
oSpacer Sticks (Pre-cut wooden spacers)
.
KB Racking Inc., 1050 King St. W., Toronto, ON, M6K 0C7 | 1 [phone] | [e-mail] | www.kbracking.com 7
COMPONENTS NOT TO SCALE
1/4”-20 x 1 3/4” Hex Bolt
9111-1420-1340-SS0
1/4”-20 Hex Nut
9211-1420-SS0
1/4”-20 x 5/8” Hex Bolt
9111-1420-580-SS0
1/4” x 7/8” Washer
9350-1420-780-SS0

4. Place ballast stones on ballast trays.
5. Install modules on supports and fasten pull clamps to module
(Torque pull clamps between 80-90 in-lb).
6. Fasten windshield to supports studs (Torque windshield
between 110-120 in-lb).
INSTALLATION STEPS
1. Place rails on roof with assembled roof protection mats. Fasten rails
together with splice (Torque splice between 80-90 in-lb).
2. Set top support to the proper height using notch marks as a
reference. Click-in bottom and top supports on rails (Torque top support
between 80-90 in-lb).
3. Click-in accessory brackets on rails and fasten ballast trays to
accessory bracket and top support studs (Torque ballast trays between
110-120 in-lb).
______________________________________________________________________________________
Quickstart Installation Guide
KB Racking Inc., 1050 King St. W., Toronto, ON, M6K 0C7 | 1 [phone] | [e-mail] | www.kbracking.com 8

9
How to Begin Assembly
1. From the layout, use the N/S and E/W dimensions of your roof as
the ORIGIN (i.e., the beginning) of your installation. The corner of the rail
will be the origin point for assembling the module array.
TIP: During the assembly, begin with the origin and cascade outward in
the N/S and E/W directions simultaneously.
______________________________________________________________________________________
KB Racking Inc., 1050 King St. W., Toronto, ON, M6K 0C7 | 1 [phone] | [e-mail] | www.kbracking.com
Roof Perimeter
Origin
N/S
E/W

Your Spacing Diagram will indicate the following dimensions.
A. N/S SUPPORT SPACING (N/S distance between supports)
B. INTER-ROW SPACING (Inter-row distance between supports)
C. E/W RAIL SPACING (E/W distance between rails)
D. E/W INTER-COLUMN SPACING (E/W distance between columns
rails)
E. ROW SPACING (N/S distance between similar points)
F. ACCESSORY BRACKET SPACING (N/S distance between bottom
support and accessory bracket)
G. E/W MODULE SPACING(E/W distance between module and rails)
H. TOP SUPPORT SPACING (Top support slot height) – See page 16
TIP: Create spacer sticks for the first four dimensions listed.
SPACING DIAGRAM EXAMPLE:
Spacing diagrams are specific to each installation.
10
How to Use Your Spacing Diagram
______________________________________________________________________________________
KB Racking Inc., 1050 King St. W., Toronto, ON, M6K 0C7 | 1 [phone] | [e-mail] | www.kbracking.com

RAIL TABLE EXAMPLE:
Rail tables are specific to each installation. Above, where 4 modules are on a rail, install
two 96” rails, one 48” rail and one 24” rail as seen in the illustration below.
AeroGrid consists of 3 rail lengths including 96”, 48”, and
24”. Combinations of these rail lengths are used within an array
assembly. Refer to your Rail Table to determine rail quantities used
within each array.
NOTE: Modules on a rail column references the number of module
rows within a given array and the associated quantities of rail
combinations used.
11
_______________________________________________________________________________________
How to Use Your Rail Table
______________________________________________________________________________________
96” 24”48”
96”
4
231
KB Racking Inc., 1050 King St. W., Toronto, ON, M6K 0C7 | 1 [phone] | [e-mail] | www.kbracking.com

MAT QUANTITIES PER RAIL:
.
Roof protection mats are used as a protective layer between the rail
and roof surface to avoid any sharp edges from penetrating the roof.
1. Slot one end of the mat and push the other end around the rail until a
snap fit is achieved on the rail.
2. Space out the roof protection mats to install the following quantities
per rail length. Roof protection mats are to be spaced equidistant.
Space roof protection mats a max of 32 in apart.
12
Installing Roof Protection Mats
______________________________________________________________________________________
KB Racking Inc., 1050 King St. W., Toronto, ON, M6K 0C7 | 1 [phone] | [e-mail] | www.kbracking.com
Rail Length Number of Mats
96” 3
48” 2
24” 1
Roof protection mat slots
around rail edges.
Roof protection mat
snap fitted to rail

13
Installing Rails
1. Place down your first rail for an array. Refer to your Rail Table and
Layout Diagram for assembly orientation and origin.
2. Use your Spacing Diagram to obtain the E/W rail spacing.
3. Lay rails adjacent to each other. Use chalk lines or spacer sticks to
ensure adjacent rails are parallel to each other and equally spaced
apart. Complete the first row of rails of the array.
4. Continue installing rows and columns of rails as required. Use your
Rail Table and Layout Diagram to determine specific quantities and
combinations.
TIP: The rail within a column, beginning at the south edge will be 96’’.
48”, and 24” rails will be used in combination at the north edge of the
rail column.
______________________________________________________________________________________
Rail edges aligned
KB Racking Inc., 1050 King St. W., Toronto, ON, M6K 0C7 | 1 [phone] | [e-mail] | www.kbracking.com
Origin

14
Installing Splices
Splices are used to fasten two rails together. One splice is used per two
rails.
1. Place splice studs through rail holes. Splice stud will be situated
between rail walls as seen in the image below.
2. Place ¼” x 7/8" washer on top of each splice.
3. Fasten both ¼”-20 hex nuts to splice studs.
TORQUE BETWEEN 80-90 IN-LB.
______________________________________________________________________________________
KB Racking Inc., 1050 King St. W., Toronto, ON, M6K 0C7 | 1 [phone] | [e-mail] | www.kbracking.com
¼”-20 x 7/8” washer
Splice
Splice Stud
¼”-20 hex nut
Studs fitted through rail wall
¼”-20 hex nuts fastened
to splice studs

15
Installing Bottom Supports
1. Mark 6” setback from rail edge along the south edge.
2. Seat bottom support on rail. Apply downward pressure on the
support with your hands until the click-in feature has engaged with the
rail. Support feet will rest flush along the rail.
3. Refer to row spacing within Spacing Diagram for placement of
remaining bottom supports along rail.
______________________________________________________________________________________
TIP: The support will create a click-in sound once the support is
engaged with the rail. The rail walls will compress inward until the
support are flush with the rail.
KB Racking Inc., 1050 King St. W., Toronto, ON, M6K 0C7 | 1 [phone] | [e-mail] | www.kbracking.com
Bottom support
6”
Support feet flush with rail
Pull clamp
Rail wall

16
Top Support Assembly
1. Refer to your Spacing Diagram to measure the top support height. .
Align the ¼-20 x 5/8” bolt to the proper notch mark on the top support
sleeve.
2. Fasten ¼”-20 x 5/8” bolt to the specified height.
TORQUE BETWEEN 80-90 IN-LB.
3. Ensure pull clamp is loosened, and clamp position is sitting as seen
in the image below.
______________________________________________________________________________________
KB Racking Inc., 1050 King St. W., Toronto, ON, M6K 0C7 | 1 [phone] | [e-mail] | www.kbracking.com
Top support connector
Top support sleeve
Pull clamp¼”-20 x 1.75”
¼”-20 x 5/8”
Clamp position
Notch Marks
Ballast tray stud
Windshield stud
Windshield hook

17
KB Racking Inc., 1050 King St. W., Toronto, ON, M6K 0C7 | 1 [phone] | [e-mail] | www.kbracking.com
Installing Top Supports
1. Refer to your Spacing Diagram for the N/S support spacing length
and mark setback.
2. Seat bottom support on the rail. Apply downward pressure on the
support with your hands until the click-in feature has engaged with the
rail. Support feet will rest flush along the rail.
______________________________________________________________________________________
TIP: The support will create a click-in sound once the support is
engaged with the rail. The rail walls will compress inward until the
support are flush with the rail.
Installed top down
Top support
Rail wall

18
Installing Accessory Brackets
1. Refer to your Spacing Diagram for accessory bracket spacing. Mark
distance on rail.
2. Click-in accessory bracket by applying downward pressure with foot
until the accessory bracket is clicked-in to rail.
3. Place second accessory bracket on adjacent rail.
______________________________________________________________________________________
TIP: the accessory bracket click-in feature will create a snap sound once
the support is engaged with the rail.
Accessory Bracket teeth snap
below rail flanges
KB Racking Inc., 1050 King St. W., Toronto, ON, M6K 0C7 | 1 [phone] | [e-mail] | www.kbracking.com

19
KB Racking Inc., 1050 King St. W., Toronto, ON, M6K 0C7 | 1 [phone] | [e-mail] | www.kbracking.com
Ballast Tray Assembly
Ballast trays are installed in the E/W directions to allow for ballast
stones to be placed over top.
Ballast trays along the north edge are continuous and overlap each
other (A-E). Ballast Trays along the south edge are discontinuous and
are placed every other rail column (A, C, E).
______________________________________________________________________________________
NOTE: In certain layouts, additional ballast trays may be required along
the south edge to allow for maximum ballasting in areas where 7+ large
ballast stones are required (additional ballast tray D).
Review Ballast Layout to verify where additional ballast trays are to be
installed if required.
Discontinuous
(no ballast tray)
Additional ballast tray (D)
(Project Specific)
Origin A
B
C
D
E
North edge
South edge
E/W Inter-column Spacing
E/W Rail Spacing

20
_______________________________________________________________________________________
Installing Ballast Trays on Accessory Brackets
1. Place ballast tray on top of accessory brackets, ensuring ballast tray
slots are aligned with press-fit nut.
2. Ensure ballast tray is spaced equally between rails.
3. Continue to place adjacent ballast trays in every other rail column.
4. Fasten ballast tray to accessory bracket with ¼”-20 x 5/8” bolt.
TORQUE BETWEEN 110-120 IN-LB.
Space ballast tray equally
on both sides of rail.
¼”-20 x 5/8” bolt fastened through
ballast tray slot onto accessory
clamp.
KB Racking Inc., 1050 King St. W., Toronto, ON, M6K 0C7 | 1 [phone] | [e-mail] | www.kbracking.com
Ballast Tray