KB Racking ReziRack 2.0 User manual
Rev.1, Sep 2019 Page 2of 42
ANSI/UL 2703
ReziRack 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
ReziRack 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
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. 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
34.
Figure 1 –KB Konnect Clamp Family
CERTIFICATION
Rev.1, Sep 2019 Page 3of 42
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
Rev.1, Sep 2019 Page 4of 42
▪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.
Rev.1, Sep 2019 Page 5of 42
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 ................................................................................................................................................................................................... 11
DEFINE RAIL SPAN .................................................................................................................................................................................................................. 11
CREATE SPACING DIAGRAM................................................................................................................................................................................................ 12
LAYOUT DIAGRAM.................................................................................................................................................................................................................. 16
KEY INSTALLATION TIPS .......................................................................................................................................................................................................... 18
SHINGLE ATTACHMENTS......................................................................................................................................................................................................... 20
RAIL ATTACHMENT .................................................................................................................................................................................................................... 21
SPLICING RAILS ............................................................................................................................................................................................................................ 22
SPLICE REQUIREMENTS......................................................................................................................................................................................................... 22
SPLICING RAILS........................................................................................................................................................................................................................ 22
THERMAL BREAKS....................................................................................................................................................................................................................... 23
MICROINVERTER INSTALLATION......................................................................................................................................................................................... 24
ALTERNATE INSTALLATION METHODS............................................................................................................................................................................ 26
INSTALLING MODULES ............................................................................................................................................................................................................. 27
SHARED-RAIL CONFIGURATION........................................................................................................................................................................................ 27
FULLY-RAILED CONFIGURATION ....................................................................................................................................................................................... 30
WIRE MANAGEMENT................................................................................................................................................................................................................. 32
CUTTING RAILS............................................................................................................................................................................................................................. 33
GROUNDING & BONDING....................................................................................................................................................................................................... 34
GROUNDING LUGS................................................................................................................................................................................................................. 34
SHARED-RAIL CONFIGURATION........................................................................................................................................................................................ 35
FULLY-RAILED CONFIGURATION ....................................................................................................................................................................................... 36
LABEL ATTACHMENT................................................................................................................................................................................................................. 37
COMPLETING INSTALLATION ................................................................................................................................................................................................ 39
PRODUCT MAINTENANCE....................................................................................................................................................................................................... 40
TECHNICAL SPECS ....................................................................................................................................................................................................................... 41
TABLE OF CONTENTS
Rev.1, Sep 2019 Page 6of 42
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
SYSTEM OVERVIEW
Rev.1, Sep 2019 Page 7of 42
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
Size
Fastener
Torque
[N-m]
Torque
[ft-lb]
M6
M6 Serrated Flange Bolt
8.3
6.1
M8
M8 T-Bolt
22
16.2
5/16”
5/16” Hanger Bolt
23
17
Rev.1, Sep 2019 Page 8of 42
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).
•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 Shingle
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
Rev.1, Sep 2019 Page 9of 42
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. Consequently,
Rails are shared between modules.
Figure 4 –Shared-Rail Portrait Configuration
Figure 5 –Shared-Rail Landscape Configuration
INSTALLATION CONFIGURATIONS
Rev.1, Sep 2019 Page 10 of 42
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 11 of 42
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:
Assess site conditions
→
Define Rail span
→
Create Spacing Diagram
→
Draw
Array Layout
ASSESS SITE CONDITIONS
The site must be assessed to determine variables that will affect anchor spacing. Always
consult with your local AHJ if conditions are uncertain.
DEFINE RAIL SPAN
KB Racking provides tables that specify maximum spans applicable for each installation.
Spans are dependent on site conditions –double check this information before
proceeding.
Figure 8 –Sample Span Tables
PRE-INSTALLATION
Rev.1, Sep 2019 Page 12 of 42
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
Attachment Spacing†
N/S Spacing: Module Length
OR
Width + 0.76” (dependent on orientation)
E/W Spacing: Refer to span tables (Page 11)
Module Height
Refer to Page 8 for limitations on module height.
Clamp Distance
Refer to module manufacturer instructions for guidelines on clamping distance.
Clamping Distance is measured from the module edge to middle of the clamp.
Module Spacing
N/S Spacing: 0.76”
E/W Spacing: Refer to module manufacturer instructions
†
Attachment Spacing is measured from any point on the shingle attachment to the same point on the next
Rev.1, Sep 2019 Page 13 of 42
To calculate the area of your array, use the following formula:
N/S Dimension [in] = (
Module Length OR Width
x
No. of Modules
) + (0.76 x (
No. of Modules
+1)) + 1.18
E/W Dimension [in] = (
Module Length OR Width
x
No. of Modules
) + (
Module Spacing E/W
x (
No. of Modules
-1)) +
(
Rail Length Past Module
x 2)
Rev.1, Sep 2019 Page 14 of 42
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
Attachment Spacing†
N/S Spacing: Dependent on clamping distance
E/W Spacing: Refer to span tables (Page 11)
Inter-Row Attachment
Spacing N/S
Distance between attachments between module rows; Fully-Railed
configuration only
Clamp Distance
Refer to module manufacturer instructions for guidelines on clamping distance.
Clamping Distance is measured from the module edge to middle of the clamp.
Module Spacing
N/S Spacing: Dependent on row spacing
E/W Spacing: 0.76”
†
Attachment Spacing is measured from any point on the shingle attachment to the same point on the next
Rev.1, Sep 2019 Page 15 of 42
To calculate the area of your array, use the following formula:
N/S Length [in] = (
Module Length OR Width
x
No. of Modules
) + (
Module Spacing N/S
x (
No. of Modules
-1))
E/W Length [in] = (
Module Length OR Width
x
No. of Modules
) + (
0.76
x (
No. of Modules
+1)) + (
Rail Length Past
Module
x 2)
Rev.1, Sep 2019 Page 16 of 42
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.
Figure 11 –Sample Layout Diagram
Rev.1, Sep 2019 Page 17 of 42
INSTALLATION
Rev.1, Sep 2019 Page 18 of 42
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 –Installation Direction
ORDER OF INSTALLATION
The general order of installation is:
Shingle 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
Rev.1, Sep 2019 Page 19 of 42
L-FOOT ORIENTATION
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.
Figure 13 –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 14 –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 15 –Integrated End Clamp (
Left
), KB Konnect Clamp with End Block (
Right
)
Rev.1, Sep 2019 Page 20 of 42
1
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.
Refer to Appendix for detailed shingle
attachment installation instructions.
NOTE: Figure 16 is for reference only.
Figure 16 –Chalk Lines on Shingle Roof
2
Refer to Shingle Attachment Installation
Manual for detailed install instructions.
NOTE: Bolt from L-Foot to Roof shall be
conformed with manuafacturer’s installation
manual
Figure 17 - Shingle Attachment
SHINGLE ATTACHMENTS
Table of contents
Other KB Racking Rack & Stand manuals
