RBI UL 2703 Installation Manual

Solar Mounng System

Installaon Guide

RBI Solar Versatile

Roof Mount Solution | RS-VS

Pitched Roof Mounng System

For Commercial & Residenal Solar PV Applicaons

UL 2703 Listed

for Bonding and Grounding

RBI Solar | 1292 Logan Circle NW | Atlanta, GA 30318 | 513-618-7240 | info@rbisolar.com

TABLE OF CONTENTS

UL 2703 Lisng Summary ��2

RBI Solar Warranty �� 2

Component Overview ��3

Applicable Roof Types �� 4

Flashing Method �� 4

Rail Support Locaons �� 7

Rail Design �� 8

Module Orientaon �� 8

Tools & Materials �� 9

RS-VS Layout �� 9

RS-VS Installaon �� 10

RS-VS Accessory Mounng Installaon �� 11

RS-VS Grounding �� 12

APPENDIX A: Alternave Grounding Methods �� 16

APPENDIX B: Module Maintenance �� 17

APPENDIX C: Addional Grounding Notes �� 18

UL 2703 LISTING SUMMARY

The enre RBI Solar Versale Roof Mount Soluon is UL 2703 Listed for Bonding and Grounding. Some components,

such as ashing and L-feet, are not in the ground path and therefore were not required under UL 2703 to be evaluated.

The evaluated components have pages marked by:

RBI SOLAR WARRANTY

Installaon instrucons and applicable building code must be followed or product warranty is void. RBI Solar will

not be responsible for any loss and/or liable for any claim resulng from installaons that are not in accordance

with installaon guide instrucons and/or applicable building code.

2RBI Solar RS-VS | IG 2017

COMPONENT OVERVIEW

The RBI Solar Versatile Roof Mount Solution provides a simple, fast, and cost-effective flush mounting solution for PV modules on pitched roofs.

• End clamps and mid clamps are designed for module frame thicknesses ranging from 30-50mm. Inventory and project planning are simplied with just one end clamp and two mid clamp part numbers. Clamps snap into place anywhere along the RS-VS rail.

• Bonding is simplied with integrated bonding mid clamp and splice connector.

• Installaon me is reduced with pre-assembled end clamps, mid clamps, splice connectors,

and L-feet.

• Installaon condence is improved with T-bolt alignment indicators on L-feet aachments.

• Strength and long-life are assured with 304 stainless steel hardware and 6000 series mill nish

aluminum alloy.

• Costs are reduced and rail aachment spans are increased with two oponal high strength-toweight rao rail designs.

A

B

A B C D

L-foot

Rail Splice End Clamp Mid Clamp

E

F

G

C

D

E

F

WEEB CCR2

Grounding Lug

G

3RBI Solar RS-VS | IG 2017

APPLICABLE ROOF TYPES

The RBI Solar RS-VS mounng system can be mounted to any roof type with the proper ashing method. Most code

compliant ashing methods are compable with the RBI Solar RS-VS system’s L-foot. The roof covering will dictate the

proper ashing method. Common roong types are:

Asphalt Shingle Standing-Seam Curved Tile Slate Tile Trapezoidal Membrane

The RBI Solar RS-VS mounng system carries a Class A Fire Rang under UL 1703 on steep-sloped roofs when used with

all Type 1, Type 2, and Type 3 modules per tesng performed by Intertek. It is important to check the following items

prior to installaon on the roof:

• Verify roof raer size, material, and span to ensure that the roof structure is sound and capable of supporng the addional load of the PV array within local climac condions (wind/snow loads).

• Measure roof surfaces and account for any obstacles such as chimneys, parapets, skylights, or roof vents.

• Conrm roof construcon, type, and condion is suitable to last the life of the product.

• Conrm that the roof is re resistant and rated for the applicaon.

• Account for any roof access areas and required municipal set-back distances following the local jurisdicon.

FLASHING METHODS

Note: The components in this section were not evaluated by UL since they are not on the grounding path.

RBI Solar RS-VS Flashing Set with Lag Bolt

This code-compliant flashing set is used for residential or

Lag Bolt

commercial (wood structure) applications of asphalt shingles. This set can be purchased from RBI Solar with either black or mill finish flashing plates.

Flat Washer

Bonded Washer

RSA-CP-SQ

Square Adapter

EcoFasten GF1-BLK-0812

Flashing Plate

4RBI Solar RS-VS | IG 2017

FLASHING METHODS (CONTINUED)

RBI Solar RS-VS GF Flashing Set with Lag Bolt

This code-compliant flashing set is used for residential or commercial asphalt shingle applications. This set can be purchased from RBI Solar with mill finish flashing plates.

RBI Solar RS-VS Flashing Set with Hanger Bolt

5/16x6 Lag Bolt

Flat Washer

EcoFasten GF1-MILL-0812

Flashing Plate

This code-compliant flashing set is used for residential or commercial asphalt shingle applications. This set can be purchased from RBI Solar with mill finish flashing plates.

RBI Solar RS-VS Flashing Set with Simple Seal

This code-compliant flashing set is used for residential (wood frame) applications with metal roofs. This set uses a Ecofasten Simple Seal to provide water-tight penetration

at each attachment point. For commercial projects with steel purlins, project-specific steel screws must be locally sourced by the customer. RBI Solar has a Simple Seal Adapter Kit that includes all components shown, except for the screw.

Flange Nut

Hex Nut

Bonded Washer

EcoFasten F-111-A Adapter

5/16x6 Hanger Bolt

EcoFasten GF1-MILL-0812

Flashing Plate

Screw

Flat Washer

Bonded Washer

RSA-CP-SQ Square Adapter

EcoFasten Simple Seal

Bushing

5RBI Solar RS-VS | IG 2017

FLASHING METHODS (CONTINUED)

RBI Solar RS-VS Compatibility with S-5! Clamps

The RBI Solar RS-VS L-foot can attach to all S-5! products used in projects with standing seam and corrugated metal roof panels. Below are the common brackets used in the industry.

(30.00 mm)

1.50"

(38.00 mm)

0.90"

(23.00 mm)

1.18"

1.50"

(38.00 mm)

0.54"

(14.00 mm)

0.40"

(10.00 mm)

M8 holes centered on part

1.35"

(34.00 mm)

(47.00 mm)

1.00"

(25.00 mm)

1.86"

1.02"

(26.00 mm)

0.26"

(7.00 mm)

0.38"

(9.00 mm)

(23.00 mm)

VB-47

0.90"

2.88"

(73.00 mm)

0.54"

(13.00 mm)

M8-1.25 Threaded Hole

M10-1.5

=

Threaded Hole

2.00"

(51.00 mm)

Factory-Applied Butyl

S-5-U Mini VersaBracket-47 CorruBracket

Used for standing-seam

metal roong applicaons

Used for exposed fastener

metal roong applicaons

Used for corrugated metal

RBI Solar RS-VS Compatibility with Quick Mount PV

The RBI Solar RS-VS L-foot can attach to all Quick Mount PV flashing components.

0.77"

(20.00 mm)

1.00"

(25.00 mm)

0.83"

(21.00 mm)

2.67"

(68.00 mm)

0.50"

(13.00 mm)

roong applicaons

(25.00 mm)

0.50"

(13.00 mm)

1.68"

(43.00 mm)

(13.00 mm)

1.00"

0.50"

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RAIL SUPPORT LOCATIONS

Stress on the RBI Solar RS-VS rail is proporonal to the loading and the length of the rail between supports. Span is the center-to-center distance between RBI Solar RS-VS rail supports (L-feet). Canlever is the distance from the outermost L-foot support to the end of the rail. Canlever can not exceed 33% of the rated rail span. Download span charts on our company website to determine spans and canlevers for your specic applicaon.

Span Cantilever

Roof decking

Raer

RS-VS Rail

Outermost L-foot

Rail Supports Near Splice Connectors

Continuous runs of modules require the introduction of splice connectors at rail breaks. There must be one L-foot on one side of each splice connector. It does not necessarily have to be the closest rafter, just the one that makes sense for your particular layout.

Either location can be used

(the best application for layout)

≈3/8”

Splice Connector

Raer

Rafter spacing (typ. 24”)

7RBI Solar RS-VS | IG 2017

RAIL DESIGN

There are two sizes of 6063-T6 aluminum extruded rail designs available. The VS-R is an economical rail used for most applications. The VS-C rail is better suited for applications requiring longer spans or higher wind and snow loads.

Mill Finish Black Anodized

VS-R

VS-C

MODULE ORIENTATION

VS-R

VS-C

1�22”

(31 mm)

1�98”

(50.4 mm)

VS-R

1�22”

(31 mm)

2.36”

(60 mm)

VS-C

RBI Solar RS-VS Rails should run perpendicular to structural members. The orientation of the modules is dependent on the direction of the structure you are attaching to. Trying to run the rails parallel to the structural members limits the spacing between rails to the spacing of the structure. This makes it very difficult to clamp down on the module in the proper locations.

Portrait Orientation Landscape Orientation

• Residential wood construction

• Standing seam metal (using S-5!)

• Rafters/standing seams run N-S

• Rails run E-W

• Clamp down modules on long side

• Commercial construcon

• Standing seam metal (aaching to purlin)

Rafters/purlins/

standing seams

Modules

RBI Solar RS-VS Rails

RBI Solar RS-VS Clamps

RBI Solar RS-VS L-feet

• Purlins run E-W

• Rails run N-S

• Clamp down modules on long side

8RBI Solar RS-VS | IG 2017

TOOLS & MATERIALS

Required Tools for Mounting RBI Solar RS-VS assembly Recommended Tools & Materials

• Socket wrench

• Torque wrench , 0-10 ft-lbs

• 13 mm hex deep socket

Notes:

1. Do not use power tools for installaon when a torque value is required.

2. All hardware necessary for installaon is provided by RBI Solar.

RBI SOLAR RS-VS LAYOUT

5

• Cutoff saw (excess rail)

• Nail pry-bar (flashing beneath shingles)

• Drill bit - 1/4” (pilot hole)

• Digital laser stud finder

• Tape measure, level & chalk

Plan the layout of the components per the

dimensions below:

Approximately 2/3 to 3/4 of the module length (please

1

refer to module manufacturer’s specicaons)*

For L-foot spacing, please refer to the RBI Solar RS-VS

2

Design Guide. Note that at least one L-foot should be

4

placed near each splice connecon.

1

2

Most PV module manufacturers have specific

*

3

locations or zones where top-down clamps can be installed. Typically, this zone falls within 1/8 and 1/4 the length of the module.

In order to allow for thermal expansion in the

**

system, should not exceed 40 ft. or a run of 12

5

modules. After 12 modules (or 40 ft.), there must be a break in the rail without a splice.

1½” minimum to allow for end clamp aachment

3

4

Quanty of modules in the vercal direcon x (module

length + 0.75”)

5

Quanty of modules in the horizontal direcon x (module

Length + 0.75”) + 3”(min.)**

1/4 L

1/8 L

L

4”

1.5”

1”

9RBI Solar RS-VS | IG 2017

RBI SOLAR RS-VS INSTALLATION

A

Step 1.t Flashing & L-feet

Select and install the proper code-compliant ashing per the manufacturer’s instrucons. Aach L-feet to ashing components.

A

B

A

Step 2. Rails

Aach the rails to the L-feet using the pre assembled T-bolts and nuts. To ensure the T-bolts are

B A

aligned properly, make sure the line on the end of the T-bolt is perpendicular to the rail. Tighten T-bolt to 10 -lbs.

Step 3. Splice Connectors

B

C

Splice connectors are required to connect rails together. Slide a splice connector in the rst rail unl the head of the rivet stops the splice connector.

C

Slide the end of the second rail over the splice

B

connector unl the rivet head stops it. There will be a

C

B

slight gap between rails for thermal expansion.

Important: At least ONE L-foot must be installed close to each IB splice connector. See RBI Solar RS-VS Layout for additional information.

B

C

8 .-lbs.

B

10 .-lbs.

B

Step 4. End Clamps

Snap the end clamp onto the rail as shown.

D

Secure the modules by ghtening clamp to 8 -lbs.

Important: DO NOT apply additional anti-sieze to the clamps.

D

B

Step 5. WEEB-CCR2

E

s l i d e u n d e r  r s t m o d u l e l e a v i n g e n o u g h r o o m f o r t h e

F

mid clamp to snap above.

Place the WEEB-CCR2 over the top of rail and

BE

Step 5. Mid Clamp

Snap the mid clamp onto the rail over the WEEB-CCR2. Slide the next module against the mid

F

clamp and ghten to 10 -lbs.

Important: DO NOT apply additional anti-sieze to the clamps.

BF

F

10RBI Solar RS-VS | IG 2017

RBI SOLAR ACCESSORY MOUNTING INSTALLATION

As part of the UL 2703 Listing, any type of flat plate (common to most microinverters and power

optimizers) can be bonded to the rest of the system provided that the plate meets the requirements listed

below. After installing the provided hardware, tighten to 10 ft-lbs.

M8-1.25 304 SS serrated flange nut (torque to 10 ft-lbs)

5/16” 304 SS flat washer 1.5” OD

0.12” thick

Flat plate (common to microinverters/power optimizers; 5052-H32 aluminum; 2mm thick)

Burndy 304 SS WEEB-CCR2

M8x1.25 x 20mm 304 S T-bolt w/ nylon patch

11RBI Solar RS-VS | IG 2017

RBI SOLAR RS-VS GROUNDING

Rail-to-GEC Grounding at Ends (tighten to 10 ft-lbs)

NOTES:

• Only one lug per module row required

• See Appendix A for alternate grounding method

M8-1.25 304SS serrated flange nut

6-14 AWG, Cu, solid or stranded

WEEB-Lug-8.0 (ghten to 7 -lbs on copper wire)

WEEB-8.0

M8-1.25x20mm 304SS T-bolt w/ nylon patch

12RBI Solar RS-VS | IG 2017

RBI SOLAR RS-VS GROUNDING (CONTINUED)

Rail-to-Rail Grounding at IB Splice (tighten to 10 ft-lbs)

NOTES:

The WEEB-Bonding Jumper 8.0 provides the bond from rail to rail. The VS Splice Connector is not bonded

to the system.

M8-1.25x20mm 304SS

T-bolt w/ nylon patch

WEEB-8.0

Bonding Jumper 8.0

M 8 - 1 . 2 5 3 0 4 S S

serrated flange nut

13RBI Solar RS-VS | IG 2017

RBI SOLAR RS-VS GROUNDING (CONTINUED)

Module-to-Module and Module-to-Rail Grounding at IB Mid Clamp (tighten to 10 ft-lbs)

NOTE:

The end clamp and mid clamp connectors are not bonded to the system. The WEEB-CCR2 is what properly

bonds the modules to the rail.

M8-1.25x40mm 304SS hex head bolt

RBI Solar mid clamp top plate

M8-1.25 304SS square nut with Nyplate coating

RBI Solar mid clamp connector

WEEB-CCR2

Module frame

14RBI Solar RS-VS | IG 2017

RBI SOLAR RS-VS GROUNDING (CONTINUED)

WEEB clip bonds the microinverter/ power optimizer

flat plate to rail.

WEEB clip and Bonding Jumper bond one rail to another

rail across the splice connector.

WEEB clip bonds both modules to the rail.

WEEB clip bonds the rail to the lug. The solid copper

wire provides the ground connection.

15RBI Solar RS-VS | IG 2017

APPENDIX A: ALTERNATIVE GROUNDING METHODS

Dynobond Module Jumper Installation

The module jumper can bond one row of modules to another row of modules without the need of addional

grounding lugs and copper wire. The teeth on the clamps bite into the module frame penetrang the anodized

surface. It requires no tools and can slide on either the long or short side of the module frame. For SolarWorld

modules, the module jumper must be installed on the short side of the module frame.

Alternate Rail-to-GEC Grounding at Ends

Aside from the WEEB-Lug-8.0, the Ilsco GBL-4DBT lug can be used as an approved grounding lug.

10-32 304 SS hex nut

No. 10 304 SS star washer

0.196” drilled hole in RBI Solar VS-R Rail

Tin-coated copper Ilsco GBL-4DBT lug

No. 10 304 SS split lock washer

10-32x0.75 304 SS HH bolt

(tighten to 35 in-lbs)

Ilsco DE-OX oxide inhibitor

¼-28 304 SS set screw (tighten to 35 in-lbs)

10-14 AWG, Cu, solid 4-8 AWG, Cu, stranded

16RBI Solar RS-VS | IG 2017

APPENDIX B: MODULE MAINTENANCE

Bonding Path when Removing a Module

When removing a solar module for module maintenance, the system must stay properly grounded. If the

module has a mid clamp securing it to the rail, the WEEB-CCR2 will keep the module bonded to the ground

path. If the module does not have a mid clamp securing it to the rail, then grounding lugs and copper wire will

need to be used in order to ensure all modules are properly grounded.

Module

Temporarily

Removed

Step 1. Drill Hole

Drill a 0.196” hole in the side of the rail using a #9 drill bit and attach an Ilsco GBL-4DBT lug to the wall of the rail.

Step 2. Lug

Attach an Ilsco GBL-4DBT lug to the grounding hole of the module frame. Tighten to 35 in-lbs.

Step 3. Copper Wire

Connect a copper wire from the lug in the rail to the lug in the module frame. Tighten to 35 in-lbs.

NOTES:

1. It is important to periodically inspect the installed system for loose components, loose fasteners, and

corrosion. If any corroded parts are discovered, the aected parts must immediately be replaced.

17RBI Solar RS-VS | IG 2017

APPENDIX C: ADDITIONAL GROUNDING NOTES

The RBI Solar RS-VS mounng system may be used to ground and/or mount a PV module complying with UL

1703 only when the specic module has been evaluated for grounding and/or mounng in compliance with the

included instrucons.

In order to maintain the Lisng for bonding, Listed (ZODZ) or R/C(ZODZ2) wire management device(s) must be

assembled according to the manufacturer’s instrucons.

The RBI Solar RS-VS is a non-separately derived system that is listed under UL 2703 and was evaluated with the

modules listed in the table below. The max fuse rang is 30A, which covers most modules.

Table 1. UL 2703 Approved Modules

Module Manufacturer Module Series

SolarWorld

Hyundai

Sunmodule Plus, SW xxx Mono (33mm frame) where xxx is 275 to 300 Sunmodule SW xxx XL Mono (33mm frame) where xxx is 320 to 350 Sunmodule Pro-Series, SW xxx Poly (33mm frame) where xxx is 250 to 260 Sunmodule Protect, SW xxx Mono (33mm frame) where xxx is 275 to 280

HiS-MxxxRG where xxx is 250 to 260 HiS-SxxxRG where xxx is 260 to 270 HiS-SxxxRW where xxx is 255 to 265

HiS-MxxxMG where xxx is 230 to 250 HiS-SxxxMG where xxx is 245 to 265

18RBI Solar RS-VS | IG 2017

RBI UL 2703 Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual