kinetic K-RACK User manual

KINETIC SOLAR
K-RACK™
INSTALLATION GUIDE
Kinetic Solar Racking and Mounting
UL 2703, LTR-AE-001-2012 and TIL A-40 Listed
274725

Kinetic Solar K-Rack™
Installation guide
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1. Disclaimer
Limitation of Liability/Precautionary Measures
Kinetic Solar Racking and Mounting Inc. (henceforth referred to as ‘Kinetic Solar’) does
not install any components of its Racking and Mounting systems. Kinetic Solar does not
have any duty or responsibility for the safe and proper installation and/or maintenance of
its Racking and Mounting systems, including job site safety standards and procedures.
All installation work must comply with the applicable regional (Authority Having
Jurisdiction) and local regulations (including all applicable Building Codes) or other
national or international electrical standards and are the sole responsibility of the
purchaser, installer, contractor, and/or developer.
Kinetic Solar shall not be held responsible for damages of any kind, including but not
limited to bodily harm, damage to property, or injury. Kinetic Solar shall not be held
responsible for the proper compliance or non-compliance with the instructions detailed in
this manual including handling solar modules, solar racking, or system installation.
Before attempting to install, operate or service a Kinetic Solar system, all instructions
should be read and understood. Failure to follow or interpret these instructions/guidelines
may result in death, injury, or property damage.
In addition to the instructions provided in this guide, the module manufacturer’s mounting
guidelines must also be adhered to. It is the sole responsibility of the purchaser, installer,
contractor, and/or developer to ensure that a compatible module is used.
Please retain this manual for future reference. Kinetic Solar reserves the right to make
additions, deletions, and modifications to the content ofthis documentwithoutprior notice.
Geocel 4500 Roof Bonding Sealant, BES 925 Roof Bonding Sealant, or equivalent is
required for wind speeds above 40km/h when installed on pitched roofs.
This manual is only valid for the following Kinetic Solar Racking Systems: K-Rack
The instructions contained in this manual are exclusive to the products referenced. Use
of any other products in conjunction with the listed products is done at one’s own risk.
Failing to comply with the above may result in the warranty being voided.

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2. Table of Contents
1. Disclaimer................................................................................................................. 1
2. Table of Contents...................................................................................................... 2
3. List of Figures ...........................................................................................................3
4. Certification Details...................................................................................................5
5. Common System Features ....................................................................................... 5
5.1. Torque Specifications....................................................................................................................................5
5.2. Kinetic Product Configurations......................................................................................................................6
5.3. Components..................................................................................................................................................7
6. Bonding Path .......................................................................................................... 12
6.1. Traditional Grounding Path.........................................................................................................................12
6.2. Groundhog Rail Grounding Path.................................................................................................................15
6.3. Hat Rail Grounding Path.............................................................................................................................16
6.4. Grounding Path in Bifacial Rail....................................................................................................................17
6.5. Grounding Path in Ridge Rail......................................................................................................................19
6.6. Joiners........................................................................................................................................................20
6.7. Thermal Break............................................................................................................................................22
6.8. Grounding...................................................................................................................................................22
6.9. Bonding and Grounding Devices ................................................................................................................24
6.10. Removing Modules from an Array...............................................................................................................31
7. List of Compatible Modules..................................................................................... 32
8. Required Maintenance............................................................................................ 32
9. Pitched Roof Installation Instructions ...................................................................... 32
9.1. Layout Considerations.................................................................................................................................32
9.2. Install Roof Mounts.....................................................................................................................................35
9.3. L-Brackets / Rails........................................................................................................................................48
9.4. Bear Clamp…………………………………………………………………………………………………………………49
9.5. Rail Joiners.................................................................................................................................................49
9.6. Awning Mounts ...........................................................................................................................................49
9.7. Micro Inverters............................................................................................................................................50
9.8. Mount Solar Modules..................................................................................................................................51
9.9. Wire Management.......................................................................................................................................52
10. Venture Rail System............................................................................................ 53
10.1. O-Ring Cord Sealing Channel.....................................................................................................................53
10.2. Install Rails .................................................................................................................................................53
10.3. Mounting Modules.......................................................................................................................................53
10.4. Wire Management.......................................................................................................................................54
10.5. Micro-Inverter Mounts.................................................................................................................................55

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3. List of Figures
FIGURE 1 - TORQUE SPECIFICATIONS
5
FIGURE 2: INSERTING K-NUT INTO SIDE CHANNEL
7
FIGURE 3 - INSERTING K-NUT INTO TOP CHANNEL (END-CLAMP SHOWN)
8
FIGURE 4 - HAT RAIL NUT INSERTION PROCEDURE
9
FIGURE 5 CABLE MANAGEMENT OPTIONS (LEFT) CABLE RACEWAY, (MIDDLE) LOCK-ON
CABLE
TIE, (RIGHT) INTEGRATED CABLE MANAGEMENT
10
FIGURE 6 LOCK-ON CABLE TIE
10
FIGURE 7 INTEGRATED CABLE MANAGEMENT
10
FIGURE 8 CABLE RACEWAY INSTALLATION PROCEDURE
11
FIGURE 9 GROUNDING PATH DETAIL
12
FIGURE 10 COMPONENT COMPATIBILITY CHART
13
FIGURE 11 GROUNDING PATH OF CONVENTIONAL AND SHARED RAIL SYSTEMS
13
FIGURE 12 GROUNDING PATH FOR TOP AND SIDE MOUNTS
14
FIGURE 13 FIXED ANGLE GROUND MOUNT GROUNDING PATH (BOTTOM GROUND LUG
ATTACHMENT SHOWN)
15
FIGURE 14 ADJUSTABLE GROUND MOUNT GROUNDING PATH
16
FIGURE 15 STATIC GROUND MOUNT GROUNDING PATH
17
FIGURE 16 STATIC GROUND MOUNT GROUNDING PATH THROUGH TUBE-CLAMP
18
FIGURE 17 STATIC GROUND MOUNT GROUNDING PATH THROUGH RAIL JOINER
18
FIGURE 18 GROUNDING PATH FOR RIDGE RAIL
19
FIGURE 19 JOINER COMPATIBILITY
20
FIGURE 20 RAIL/JOINER AND TUBE U-CLAMP ASSEMBLY
21
FIGURE 21 LANDSCAPE RIDGE RAIL
21
FIGURE 22 BONDING CONDUCTOR REQUIREMENTS
22
FIGURE 23 GROUND LUG MOUNTING OPTIONS
23
FIGURE 24 INSTALLED GROUNDING LUG
24
FIGURE 25 BONDING AND GROUNDING DEVICES
24
FIGURE 26 MODULE REMOVAL PROCEDURE
31
FIGURE 27 UL 2703 DESIGN LOADS
32
FIGURE 28 LTR-AE-001-2012 DESIGN LOADS
33
FIGURE 29 CONVENTIONAL VS SHARED RAIL
34
FIGURE 30 FLASHING POSITIONING
36

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FIGURE 31 INSTALLING WITH 4IN SELF-DRILLING SCREWS 36
FIGURE 32 MEASURE AND PRE-DRILL 37
FIGURE 33 INSTALLING WITH 2IN SELF-DRILLING SCREWS 38
FIGURE 34 GEOCEL PROFLEX 39
FIGURE 35 CAULKING PATH 39
FIGURE 36 GEOCEL 4500 39
FIGURE 37 INSTALLED FLASHING (TRUSS MOUNTING SHOWN) 39
FIGURE 38 MOUNTING UNIVERSAL L MOUNT 40
FIGURE 39 HANGER BOLT VALLEY INSTALLATION 42
FIGURE 40 HANGER BOLT PEAK INSTALLATION 43
FIGURE 41 INSTALLING SQUARE ROOF MOUNT 44
FIGURE 42 LEFT- GIRAFFE MOUNT (SELF-DRILLING SCREWS SHOWN), RIGHT- RHINO MOUNT
(2” LAG BOLTS SHOWN) 45
FIGURE 43 INSTALLING STANDING L 46
FIGURE 44 QUONSET HUT MOUNT 47
FIGURE 45 MODULES MOUNTED ON A QUONSET HUT 47
FIGURE 46 INSTALLED RAILS 48
FIGURE 47 BEAR CLAMP 49
FIGURE 48 AWNING MOUNTS 50
FIGURE 49 END AND MID CLAMP POSITIONS IN CONVENTIONAL AND SHARED RAIL LAYOUTS 52
FIGURE 50 INTEGRATED CABLE MANAGEMENT 53
FIGURE 51 INTEGRATED CABLE MANAGEMENT 54

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4. Certification Details
The system has been evaluated to UL 2703 and TIL A-40 for Grounding/Bonding and
Mechanical Loading. The largest module tested with this system was 2384 mm x 1303
mm in size. This racking system may be used to mount and ground PV modules equal
to or smaller than 2384 mm x 1303 mm (or equivalent area) in size. Please see Kinetic
Solar’s List of Compatible Modules Revision 7 for more details.
5. Common System Features
5.1. Torque Specifications
Custom L
3/8”
20 (27.12)
Fall Restraint
Clay Tile Roof Mount
Tube U-Clamp
Figure 1 - Torque Specifications
Product
Fastener Size
Torque ft-lbs (N-m)
Lay-In Ground Lug (Nut and Bolt)
#8
N/A
L-Brackets / Angled L-Brackets
5/16”
12 (16.27)
Giraffe Mount (Excluding Roof Mounting Hardware)
Rhino Mount (Excluding Roof Mounting Hardware)
Quonset Hut Mount
Ridge Rail Mount
Toepedo Clamp
Flashing Kit (Excluding Roof Mounting Hardware)
Mid-Clamp / End Clamp
Joiner
Top Mount - Micro Inverter Mounting Kit for Bifacial Rail
Top Mount - Micro Inverter Mounting Kit for Rapid1 Rail
Standing-L/BearClamp
Hanger Bolts (Excluding Lag Screw Portion)
Flashing Kit Base Plate
4” Base Plate (Excluding Roof Mounting Hardware)
Hat Rail Micro Inverter Mount
Conduit Clamp / Toe Clamp
Conduit Attachment Bracket for Flashing Kit
Top of Rail Accessory Clamp
Grounding Lug (to rail)
Kinetic Rail Jumper Kit (to rail)
U-Bracket Clamp
Grounding Lug (to wire)
3 (4.07)
Kinetic Rail Jumper Kit (to wire)
Rodent Guard Clamp
N/A
Rodent Guard Clip
N/A
Mesh Stud Nut for Bifacial Rail
N/A
End Cap
N/A

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5.2. Kinetic Product Configurations
Product Category
Components
M-Type
(For use with mill finish aluminum rail only)
KJS2-MM
KHGLUG-M
KMWCxxxx-MM
KECxxxx-MM
KHMNS-MM
KHMNL-MM
KHMNT-MM
KHMTB-MM
A-Type
(For use with anodized rail or mill finish rail)
KJS2W-MA
KJS2W-BA
KJS2W-CA
KBRJ-MA
KBRU-MA
KHGLUG-A
KMWCxxxx-BA
KMWCxxxx-CA
KECxxxx-BA
KECxxxx-CA
KHMNS-MA
KHMNL-MA
KHMNT-MA
KHMTB-MA
G-Type
(For use with galvanized steel only)
KHGLUG-G
KMWCxxxx-G
KECxxxx-G
KAGMM-G
5.2.1. Understanding Kinetic SKUs
The following SKU suffixes are used:
-MM
Mill finished component for use with mill finish rail only
-M
For use with mill finish rail only
-MA
Mill finish component for use with anodized rail or mill finish rail
-CA
Clear anodized component for use with anodized rail or mill finish rail
-BA
Clear anodized component for use with anodized rail or mill finish rail
-A
For use with anodized rail or mill finish rail
-G
For use with galvanized rail

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KJS2-MA
Example
Kinetic Joiner - Mill Finish for Anodized Rail or Mill Finish
Rail
5.3. Components
5.3.1. Kinetic Nut (K-Nut)
The Kinetic Nut (K-Nut) [KHNTS-M or KHNTS-A] is a common component utilized in
many Kinetic products.
5.3.1.1. Inserting K-nut into side channel
If attaching a component to the side channel of the rail such as an L-Bracket follow the
steps shown in Figure 2.
1. At a 30° angle insert the L-Bracket with the K-Nut at the top of the slot.
2. Rotate into position so that the entirety of the K-Nut ends up inside the channel.
3. Drop into place. The inserted component should sit in place and easily slide
back and forth in the channel.
Figure 2: Inserting K-Nut into Side Channel

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5.3.1.2. Inserting K-Nut into top channel
If attaching a component to the top channel of the rail such as an End or Mid Clamp,
follow the steps shown in Figure 3
1. At a 30° angle insert the clamp assembly with the clamp held at the top of the
bolt. Ensure that the K-Nut is positioned at the lowest point on the bolt so that
there is clearance to pivot the clamp into an upright position.
2. Rotate into position so that the entirety of the K-Nut is inside the top channel of
the rail.
3. Drop into place. The inserted component should easily slide back and forth in
the channel see Figure 3 B.
Figure 3 - Inserting K-Nut into Top Channel (End-Clamp shown)
5.3.1.3. K-Nut Tightening Procedure
For components utilizing the K-Nut, check to ensure that the K-Nut is properly seated in
the channel and that its sides are parallel to the length of the rail.

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5.3.2. Steel Nut
When installing Mid or End Clamps onto the Hat Rail, follow the steps shown below:
Figure 4 - Hat Rail Nut Insertion Procedure
a) Insert bent end of Nut into wide portion of slot at a 30° angle.
b) Insert nut fully into slot.
c) Drop into place.

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5.3.3. Cable Management Options
Figure 5 Cable Management Options (Left) Cable Raceway, (Middle) Lock-On Cable Tie, (Right) Integrated Cable
Management
5.3.3.1. Lock-on Cable Tie
Unlike traditional cable ties, the Rail Locking Cable Tie
(KCMT-1) connects directly to Rail instead of wrapping
around it; extending the life of the Cable Tie by reducing
stress points.
Figure 6 Lock-on Cable Tie
5.3.3.2. Integrated Cable Management
The rail itself provides a channel which may be used to secure cables in
certain scenarios. Simply press the cable into the grooves at the top of
the cable management channel along the length which you would like
to secure. A maximum of two cables can be secured this way using the
channel.
Figure 7 Integrated
Cable Management

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5.3.3.3. Cable Raceway
The Cable Raceway may be attached to the cable management channel or the side
channel. The same method of installation can be used for both. Cable Raceway Kits
include a sufficient number of segments to cover the indicated length or span between
L-Brackets.
Sold in kits of 16”, 24”, 32”, & 48”
1. Hang the Cable Raceway segment on the bottom edge of the side channel of the
rail. Lay cables into Cable Raceway segment.
2. Rotate Raceway segment until it snaps into top edge of side channel of rail
Figure 8 Cable Raceway Installation Procedure

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6. Bonding Path
6.1. Traditional Grounding Path
Figure 9 Grounding Path Detail
The grounding path through the main bonding components is shown above. The rail
shown is the Rapid Rail, however this bonding path is consistent for the Venture Rail,
Ground Hog Rail, Hat Rail, Bifacial Rail and Ridge Rail. The module bonding is
achieved through the Mid-Clamp. If anodized rail is to be used, then the A-Type of
Kinetic Mid-Clamps and Ground Lugs must be used in order to penetrate the anodized
coating of the rail and provide adequate bonding. If mill finished rail is to be used, then
the M-Type of components or A-Type may be used. Similarly, if bonding is to be
achieved through the rail joiner, the correct rail joiner must also be used. For anodized
rail, either the KJS2-MA, KJS2-BA or KJS2-CA must be used. For mill finish rail, either
the KJS2-MM, KJS2-MA, KJS2-BA or KJS2-CA may be used.

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Rail
Component
Mill Finish Aluminum Rails
M-Type or A-Type
Black Anodized Aluminum Rails
A-Type only
Clear Anodized Aluminum Rails
A-Type only
Hat Rail
G-Type only
Figure 10 Component Compatibility Chart
Conventional Rail
One ground lug is required per row of
modules. KHGLUG-A must be used on
anodized rail
Shared Rail
One ground lug is required per array.
KHGLUG-A must be used on anodized rail
Figure 11 Grounding Path of Conventional and Shared Rail Systems

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Grounding can be achieved with side and top mounts through the use of a ground lug
attached to the Mounting Kit or directly to the rail.
Figure 12 Grounding Path for Top and Side Mounts (Mill Finish Shown)

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6.2. Groundhog Rail Grounding Path
Figure 13 Fixed Angle Ground Mount Grounding Path (Bottom Ground Lug Attachment Shown)
Grounding can be achieved on the Groundhog Rail through the use of a ground lug
(KHGLUG-M) for mill finish rails or (KHGLUG-A) for anodized rails. The ground lug can
be positioned at either the top or the bottom of the rail.

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6.3. Hat Rail Grounding Path
Figure 14 Adjustable Ground Mount Grounding Path
Grounding can be achieved on the Hat Rail through the use of a ground lug (KHGLUG-
G) attached to the Mounting Kit or directly to the Hat Rail.

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6.4. Grounding Path in Bifacial Rail
Grounding can be achieved on the Bifacial Rail through the use of a ground lug
(KHGLUG-M) for mill finish rails or (KHGLUG-A) for anodized rails. The ground lug can
be positioned at either the top or the bottom of the rail.
Figure 15 Static Ground Mount Grounding Path

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Figure 17 Static Ground Mount Grounding Path through Tube-Clamp
Figure 16 Static Ground Mount Grounding Path through Rail Joiner

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6.5. Grounding Path in Ridge Rail
Grounding can be achieved on the Ridge Rail through the use of a ground lug
(KHGLUG-M) for mill finish rails or (KHGLUG-A) for anodized rails.
Figure 18 Grounding Path for Ridge Rail