KB Racking BARN RACK 2.0 User manual

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: [phone]
Fax: [phone]
[email protected]
www.kbracking.com

Rev.1, Sep 2019 Page 2of 38
ANSI/UL 2703
BarnRack 2.0 is certified in compliance with ANSI/UL 2703 Standards for Mounting
Systems, Mounting Devices, Clamping/Retention Devices, and Ground Lugs for Use with
Flat Plate Photovoltaic Modules and Panels. This racking system may be used to ground
and/or mount any PV module complying with UL 1703 only when the specific module has
been evaluated for grounding and/or mounting in compliance with the included
instructions.
EVALUATED MODULES
BarnRack 2.0 has been tested with the following UL Listed modules:
Silfab SLAXXXM, SLAXXXP, SLGXXXP, SLGXXXM, SLA-X.
Canadian Solar CS3U-P, CS3U-MS, CS3K-P, CS3K-MS, CS6U-P, CS6K-P, CS6K-MS.
ETL CERTIFIED CLAMPS
BarnRack 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. The grounding continues
through the racking system to a grounding point or grounding lug.
NOTE: Grounding locations are dependent on the system configuration, detailed on Page
30.
Figure 1 –KB Konnect Clamp Family
CERTIFICATION

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Only qualified professionals should install solar modules, DC cabling, and any anti-
lightning safety devices.
KB Racking®components may have shifted during shipping. Take extra care when moving
and unpacking components.
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.
FALL SAFETY
While installing the PV system, proper safety equipment should be worn. 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 modules closer than 6.5ft (2m) to roof edges or skylights.
INSTALLER’S RESPONSIBILITY
It is the installer’s responsibility to:
Wear and correctly use proper safety equipment.
Ensure the correct type and quantities of parts have been delivered.
Inspect all components prior to installation.
Store parts in a secure, dry location prior to, and during installation.
Maintain proper rooftop drainage.
Mount the racking system over a fire resistant roof covering rated for the
application.
Ensure that the racking system is installed in accordance with the provided
instructions.
SAFETY

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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.
Keep Copper away from Aluminum components in a fashion that maintains a
minimum of ¼” separation.
Comply with all applicable building and fire codes that may supersede this manual.

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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
LAYOUT DIAGRAM................................................................................................................................................................................................ 11
SPACING DIAGRAM.............................................................................................................................................................................................. 12
KEY INSTALLATION TIPS....................................................................................................................................................................................... 14
ROOF ATTACHMENTS ............................................................................................................................................................................................ 16
RAIL ATTACHMENT ................................................................................................................................................................................................. 17
SPLICING RAILS.......................................................................................................................................................................................................... 18
SPLICE REQUIREMENTS ...................................................................................................................................................................................... 18
SPLICING RAILS ...................................................................................................................................................................................................... 18
THERMAL BREAKS .................................................................................................................................................................................................... 19
MICROINVERTER INSTALLATION..................................................................................................................................................................... 20
ALTERNATE INSTALLATION METHODS ....................................................................................................................................................... 22
INSTALLING MODULES .......................................................................................................................................................................................... 23
SHARED-RAIL CONFIGURATION..................................................................................................................................................................... 23
FULLY-RAILED CONFIGURATION.................................................................................................................................................................... 26
WIRE MANAGEMENT.............................................................................................................................................................................................. 28
CUTTING RAILS........................................................................................................................................................................................................... 29
GROUNDING & BONDING ................................................................................................................................................................................... 30
GROUNDING LUGS............................................................................................................................................................................................... 30
SHARED-RAIL CONFIGURATION..................................................................................................................................................................... 31
FULLY-RAILED CONFIGURATION.................................................................................................................................................................... 32
LABEL ATTACHMENT .............................................................................................................................................................................................. 33
COMPLETING INSTALLATION ............................................................................................................................................................................ 35
PRODUCT MAINTENANCE ................................................................................................................................................................................... 36
TECHNICAL SPECS..................................................................................................................................................................................................... 37
TABLE OF CONTENTS

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Figure 2 –System Overview
COMPONENTS
KB10 Series Rail
KB10 Series Splice
KB Konnect Mid Clamp
Barn Attachment†
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
SYSTEM OVERVIEW

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TOOLS REQUIRED
□3/16” Allen Bit Tip OR 5mm Hex Drive
□Torque Wrench
□3/16” Hex Drive
□Cordless Drill
□13mm Hex Socket
□Spirit Level
□Tape Measure
□Portable Band/Reciprocating Saw
□Safety Gloves
□Safety Glasses
□Spacing Sticks
□Jigs
TORQUE VALUES
Size
Fastener
Torque
[N-m]
Torque
[ft-lb]
M6
M6 Serrated Flange Bolt
8.3
6.1
M8
M8 Serrated Flange Bolt
22
16.2
M8
M8 T-Bolt
22
16.2

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Limitations that govern the installation of the BarnRack 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).
Splices can be used between two Rails only when each Rail has at least two spans.
A thermal break of at least 1.75” must be included for every 80 feet of spliced
Rail.
Modules must not be installed across thermal breaks.
Maximum Rail cantilever is ⅓of maximum span and must not exceed 3 feet.
The system must have an appropriate method of direct-to-earth grounding in
accordance with current standards.
The maximum clearance between roof and bottom of module is 8”.
Sufficient clearance must be maintained between the module frame and roof, in
accordance with module manufacturer instructions.
NOTE: A Rail span is defined as a section of Rail that runs between two adjacent Roof
Attachments.
The image below shows an example of a Rail with two spans (i.e. with three anchor
connections to the roof).
Figure 3 –Rail Spans
SYSTEM LIMITATIONS

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The versatility of BarnRack 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. Consequently,
Rails are shared between modules.
Figure 4 –Shared-Rail Portrait Configuration
Figure 5 –Shared-Rail Landscape Configuration
INSTALLATION CONFIGURATIONS

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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

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This section reviews the supporting documents that are included with your BarnRack 2.0
system. Study each document prior to installation.
LAYOUT DIAGRAM
Figure 8 –Sample Layout Diagram
Layout Diagrams contain plans for all arrays in your project.
Note the following items on your project-specific Layout Diagram:
□NORTH ARROW
□DIMENSIONS
□LEGEND
□ARRAY NUMBERS
□ROOF STRUCTURES
□THERMAL BREAKS
Array Origin: From your layout, use the N/S and E/W dimension at a corner of your roof
as the origin of your installation (see details A and B in Figure 8).
PRE-INSTALLATION

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SPACING DIAGRAM
Figure 9 –Sample Spacing Diagram
Your Spacing Diagram will indicate the following dimensions:
□ BARN ATTACHMENT SPACING N/S (Distance between attachments, along
corrugation)
□ BARN ATTACHMENT SPACING E/W (Distance between attachments, across
corrugations)
□ INTER BARN ATTACHMENT SPACING N/S (Distance between attachments
between module rows; Fully-Railed configuration only)
□ MODULE SPACING (Distance between modules)
□ MODULE HEIGHT (Clearance between module and roof)
NOTE: Ensure measurements are taken from the centre-to-centre or edge-to-edge
points as indicated in your project-specific Spacing Diagram.

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INSTALLATION

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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 10 –Installation Direction
ORDER OF INSTALLATION
The general order of installation is:
Roof Attachments → Rails → Modules → Grounding and Bonding
RAIL HEIGHT ALIGNMENT
When laying Rails, ensure adjacent Rails maintain the same height off the roof. Use a jig
to consistently position the Rail at the same height.
THERMAL BREAK
A thermal break of at least 1.75” must be included for every 80 feet of spliced Rail. Thermal
breaks are identified in your Layout Diagram.
RAIL SPACING
Care must be taken to ensure the Rails are positioned as per the Spacing Diagram. Use
the slots on the L-Foot to adjust Rails ±½”as needed. Failure to comply with the specified
dimensions will result in poor alignment between the racking system and module. Use a
jig to help position the Rails correctly.
KEY INSTALLATION TIPS

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L-FOOT ORIENTATION
L-Feet must sit as perpendicular as possible to the roof surface. This is controlled by
properly installing the roof attachment. An improperly installed L-Foot will prevent proper
installation of BarnRack 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.
Figure 11 –L-Foot Orientation
LOCKING T-BOLT
The M8 T-Bolt features an indicator which confirms engagement with the Rail. When
securing the T-Bolt, ensure the indicator remains in the vertical position.
Figure 12 –Vertical Position showing Engagement
KB KONNECT END CLAMP VARIATIONS
At array ends, modules that are 40mm (1.57”) in thickness will use Integrated End Clamps.
Other module thicknesses will use KB Konnect Clamps with End Blocks matching the
module thickness.
Figure 13 –Integrated End Clamp ( Left ), KB Konnect Clamp with End Block ( Right )

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1
Install Barn Attachments onto roof
corrugations. Use your Spacing Diagram to
obtain spacing dimensions.
Consistent spacing is important; use a
spacing stick or jig to aid installation.
Refer to Appendix for detailed Barn
Attachment installation instructions.
Figure 14 –Barn Attachment Installation
Figure 15 –Barn Attachment Spacing
2
Install L-Feet onto Barn Attachments, short
leg resting on the Attachment.
Rotate and orient the L-Feet as shown in
Figure 16. Additionally, ensure L-Feet are
perpendicular to the roof surface.
Use the provided M8 Bolt to hand-tighten
the L-Feet to the Barn Attachments.
Figure 16 –L-Foot Placement
3
Fasten the L-Feet to the Barn Attachments.
Torque to 22Nm (16.2 ft-lb).
Figure 17 –L-Foot Attachment
ROOF ATTACHMENTS

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1
Refer to your Layout Diagram to determine
the arrangement of Rails for each array.
Multiple rail lengths may be required.
See Page 29 for instructions on cutting Rails.
Figure 18 –Sample Layout Diagram
2
Install Rails onto L-Feet by aligning the T-Bolt
slot on the Rail with the L-Foot slot.
Raise the Rail to the height specified in the
Spacing Diagram. Ensure this height is kept
consistent throughout the array.
For each Rail, fasten L-Feet closest to the Rail
ends first, followed by the remaining L-Feet.
NOTE: Use a jig to consistently position the
Rail at the same height off the roof.
Figure 19 –T-Bolt through Slot on L-Foot
3
Use the provided T-Bolt and M8 Serrated
Flange Nut to secure the Rail to the L-Feet.
Torque to 22Nm (16.2 ft-lb).
Figure 20 –Fastening Rail to L-Foot
4
Double-check Rail alignment based on
Spacing Diagram dimensions.
NOTE: The L-Feet feature a slot to allow ± ½”
adjustment on the Inter-Rail/Rail Spacing.
Figure 21 –Rail Spacing/Spacing Diagram
RAIL ATTACHMENT

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The BarnRack 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.
Each Rail being spliced must span across a minimum of three (3) anchor points
(i.e. two spans).
SPLICING RAILS
1
Install Splices between two adjacent Rails.
Do not place any gaps in between.
The Splice must be evenly spaced on each
Rail.
T-Bolts are inserted into each Rail, rotating
to the locked position (Page 14). Guide the
T-Bolts through the slots on the Splice.
Figure 22 –Placing Splice between Rails
2
Secure the installation with an M8 Serrated
Flange Nut, ensure the T-Bolt indicator
remains vertical.
Torque to 22Nm (16.2 ft-lb).
Figure 23 –Securing Splice to Rails
SPLICING RAILS

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Aluminum components experience thermal expansion/contraction due to temperature
cycles. To prevent damage from thermal expansion, thermal breaks must be included, as
specified below. Failure to comply with this instruction can result in damage to the
BarnRack 2.0.
A thermal break of at least 1.75” must be included for every 80 feet of spliced Rail in
BarnRack 2.0 arrays. Thermal Breaks are identified in your Layout Diagram.
NOTE: Do not install modules across/over thermal breaks.
Figure 24 –Thermal Break
THERMAL BREAKS

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This section provides guidance on installing microinverters to your BarnRack 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
M8 T-Bolt
M8 Serrated Flange Nuts
NOTE: Some microinverters require the use of a star washer or other components to
complete grounding requirements. Please follow instructions set by your microinverter
manufacturer. KB Racking®can provide star washers if requested.
NOTE: The maximum microinverter weight that can be mounted with the KB
Microinverter Kit is 5kg.
1
Install the Accessory Bracket onto the Rail
using the provided T-Bolt and M8 Serrated
Flange Nut.
Orient the Accessory Bracket as shown in
Figure 25.
While securing the Accessory Bracket with a
M8 Serrated Flange Nut, ensure the T-Bolt
remains in its locked position (Page 14).
Torque to 22Nm (16.2 ft-lb).
NOTE: Accessory Brackets should be used on
every mounting point on the microinverter.
Figure 25 –Securing Accessory Bracket to Rail
Figure 26 –Placing Microinverter on Accessory Bracket
MICROINVERTER INSTALLATION