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