kinetic K-RACK User manual

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

Kinetic Solar K-Rack™
Installation guide
Page 1of 37
27 May 2019
1. Disclaimer
Limitation of Liability/Precautionary Measures
Kinetic Solar Racking and Mounting Inc. (Kinetic Solar) does not install any components
of its Racking and Mounting systems. Kinetic Solar Racking and Mounting does not
have any duty or responsibility for 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 and local regulations or
other national or international electrical standards and are the sole responsibility of the
installer, contractor and/or developer.
Kinetic Solar Racking and Mounting shall not be held responsible for damages of any
kind, including but not limited to: bodily harm, damage to property or injury. Kinetic
Solar Inc. 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 these instructions/guidelines may
result in death, injury or property damage.
Space rails according to module manufacturer’s specifications
Solar module width and/or length will determine the exact rail spacing. (Please refer to
the module manufacturer’s specifications)
Please retain this manual for future reference. Kinetic Solar reserves the right to make
additions, deletions and modifications to the content of this document without prior
notice.
Geocel 4500 Roof Bonding Sealant, BES 925 Roof Bonding Sealant or equivalent is
required for wind speeds above 40km/h when installing 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.

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2. Table of Contents
1. Disclaimer.................................................................................................................1
2. Table of Contents .....................................................................................................2
3. List of Figures...........................................................................................................3
4. Certification Details...................................................................................................4
5. Common System Features.......................................................................................4
5.1. Torque Specifications...................................................................................................................................4
5.2. Kinetic Product Configurations .....................................................................................................................5
5.3. Components.................................................................................................................................................6
6. Bonding Path..........................................................................................................11
6.1. Traditional Grounding Path.........................................................................................................................11
6.2. Groundhog Rail Grounding Path ................................................................................................................13
6.3. Hat Rail Grounding Path.............................................................................................................................14
6.4. Joiners........................................................................................................................................................15
6.5. Thermal Break............................................................................................................................................15
6.6. Grounding...................................................................................................................................................15
6.7. Bonding and Grounding Devices................................................................................................................17
6.8. Removing Modules from an Array ..............................................................................................................20
7. List of Compatible Modules ....................................................................................21
8. Required Maintenance............................................................................................21
9. Pitched Roof Installation Instructions......................................................................22
9.1. Layout Considerations................................................................................................................................22
9.2. Install Roof Mounts.....................................................................................................................................24
9.3. L-Brackets / Rails .......................................................................................................................................30
9.4. Rail Joiners.................................................................................................................................................30
9.5. Micro Inverters............................................................................................................................................30
9.6. Mount Solar Modules..................................................................................................................................31
9.7. Wire Management ......................................................................................................................................32
10. Venture Rail System............................................................................................34
10.1. O-Ring Cord Sealing Channel....................................................................................................................34
10.2. Install Rails.................................................................................................................................................34
10.3. Mounting Modules ......................................................................................................................................34
10.4. Wire Management ......................................................................................................................................34
10.5. Micro-Inverter Mounts.................................................................................................................................35

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3. List of Figures
FIGURE 1 - TORQUE SPECIFICATIONS 4
FIGURE 2: INSERTING K-NUT INTO SIDE CHANNEL 6
FIGURE 3 - INSERTING K-NUT INTO TOP CHANNEL (END-CLAMP SHOWN) 7
FIGURE 4 - HAT RAIL NUT INSERTION PROCEDURE 8
FIGURE 5 CABLE MANAGEMENT OPTIONS (LEFT) CABLE RACEWAY, (MIDDLE) LOCK-ON CABLE TIE, (RIGHT)
INTEGRATED CABLE MANAGEMENT 9
FIGURE 6 LOCK-ON CABLE TIE 9
FIGURE 7 INTEGRATED CABLE MANAGEMENT 9
FIGURE 8 CABLE RACEWAY INSTALLATION PROCEDURE 10
FIGURE 9 GROUNDING PATH DETAIL 11
FIGURE 10 COMPONENT COMPATIBILITY CHART 12
FIGURE 11 GROUNDING PATH OF CONVENTIONAL AND SHARED RAIL SYSTEMS 12
FIGURE 12 FIXED ANGLE GROUND MOUNT GROUNDING PATH (BOTTOM GROUND LUG ATTACHMENT SHOWN) 13
FIGURE 13 ADJUSTABLE GROUND MOUNT GROUNDING PATH 14
FIGURE 14 JOINER COMPATIBILITY 15
FIGURE 15 BONDING CONDUCTOR REQUIREMENTS 16
FIGURE 16 GROUND LUG MOUNTING OPTIONS 16
FIGURE 17 BONDING AND GROUNDING DEVICES 19
FIGURE 18 MODULE REMOVAL PROCEDURE 20
FIGURE 19 UL 2703 DESIGN LOADS 22
FIGURE 20 LTR-AE-001-2012 DESIGN LOADS 22
FIGURE 21 CONVENTIONAL VS SHARED RAIL 23
FIGURE 22 FLASHING POSITIONING 24
FIGURE 23 MEASURE AND PRE-DRILL 25
FIGURE 24 INSTALL LAG BOLTS 25
FIGURE 25 GEOCEL PROFLEX 26
FIGURE 26 GEOCEL 4500 26
FIGURE 27 CAULKING PATH 26
FIGURE 28 INSTALLED FLASHING 26
FIGURE 29 HANGER BOLT RIDGE INSTALLATION 28
FIGURE 30 HANGER BOLT TROUGH INSTALLATION 28
FIGURE 31 INSTALLED RAILS 30
FIGURE 32 END AND MID CLAMP POSITIONS IN CONVENTIONAL AND SHARED RAIL LAYOUTS 32
FIGURE 33 INTEGRATED CABLE MANAGEMENT 33
FIGURE 34 INTEGRATED CABLE MANAGEMENT 35

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27 May 2019
4. Certification Details
This racking system may be used to ground and/or mount a 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. Please see Kinetic Solar’s List of
Compatible Modules April 29th Revision 5 for more details.
5. Common System Features
5.1. Torque Specifications
Figure 1 - Torque Specifications
Product
Fastener Size
Torque
ft-lbs (N-m)
Lay-In Ground Lug (Nut and Bolt)
#8
N/A
L-Bracket
5/16”
12 (16.27)
Flashing Kit (Excluding Lag Screws)
Mid-Clamp / End Clamp
Joiner
Micro-Inverter Mount
Standing-L
Hanger Bolts (Excluding Lag Screw Portion)
Flashing Kit Base Plate
4” Base Plate (Excluding Lag Screws)
Hat Rail Micro Inverter Mount
Conduit Clamp
Conduit Attachment Bracket for Flashing Kit
Grounding Lug (to rail)
Kinetic Rail Jumper Kit (to rail)
Grounding Lug (to wire)
3 (4.07)
Kinetic Rail Jumper Kit (to wire)
Rodent Guard Clamp
N/A
End Cap
N/A
Custom L
3/8”
20 (27.12)
Fall Restraint

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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
A-Type
(For use with anodized rail or mill finish rail)
KJS2W-MA
KJS2W-BA
KJS2W-CA
KHGLUG-A
KMWCxxxx-BA
KMWCxxxx-CA
KECxxxx-BA
KECxxxx-CA
G-Type
(For use with galvanized steel only)
KHGLUG-G
KMWCxxxx-G
KECxxxx-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
KJS2W-MA
Example
Kinetic Joiner - Mill Finish for Anodized Rail or Mill Finish
Rail

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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
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.
Figure 3 - Inserting K-Nut into Top Channel (End-Clamp shown)

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5.3.2. Steel Nut
When installing Mid or End Clamps onto the Hat Rail, follow the steps shown below:
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
Figure 4 - Hat Rail Nut Insertion Procedure

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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.
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 6 Lock-on Cable Tie
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 and Hat 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, the KJS2W must
be used. For mill finish rail, either the KJS2W or KJS2 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
Figure 11 Grounding Path of Conventional and Shared Rail Systems
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

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6.2.Groundhog Rail Grounding Path
Figure 12 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 13 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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Installation guide
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6.4.Joiners
If there are any rail joiners, adequate bonding must be used between rail sections. If an
anodized rail is being used then a KJS2W joiner must be used.
Figure 14 Joiner Compatibility
6.5.Thermal Break
If there is a thermal break, two ground lugs (KHGLUG-M, KHGLUG-A or KHGLUG-G)
either side of the break, joined with a piece wire that meets the specifications in the
table below is required.
6.6.Grounding
Grounding is to be achieved through the Kinetic Grounding Lug (KHGLUG-M,
KHGLUG-A or KHGLUG-G) and a copper or aluminum wire that meets the
specifications in the table below. Systems mounted in a conventional rail design require
a minimum of one ground lug per row. Systems mounted in a shared rail design require
a minimum of one ground lug per array.

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Conductor
Material
Minimum
Cable Size
Cable Type
Temperature
Rating
Aluminum
10 AWG
Solid or
Braided
75 °C
Copper
8 AWG
Solid or
Braided
60 °C
Figure 15 Bonding Conductor Requirements
Figure 16 Ground Lug Mounting Options

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6.7.Bonding and Grounding Devices
SKU
Component Description
Use With
Associated Hardware
KMWC3037
-MM
Kinetic Mid Clamp with
Grounding Washer 30-
37mm (Mill Finish)
- Mill Finish Rail
-5/16” x 2 ¼” Stainless Hex Head Bolt
-5/16” Stainless Flat Washer
-5/16” Stainless Lock Washer
-K-Nut
-SBWK-312 or WEEB-M-KR
KMWC3037
-BA/CA
Kinetic Mid Clamp with
Grounding Washer 30-
37mm (Black Anodized or
Clear Anodized)
- Mill Finish
- Black Anodized
- Clear Anodized
-5/16” x 2 ¼” Stainless Hex Head Bolt
-5/16” Stainless Flat Washer
-5/16” Stainless Lock Washer
-Stainless K-Nut
-SBWK-312 or WEEB-M-KR
KMWC3037
-G
Kinetic Mid Clamp with
Grounding Washer 30-
37mm
-Galvanized Rail
-5/16” x 2 ¼” Stainless Hex Head Bolt
-5/16” Stainless Flat Washer
-5/16” Stainless Lock Washer
-Hat Rail Nut
-SBWK-312 or WEEB-M-KR
KMWC3843
-MM
Kinetic Mid Clamp with
Grounding Washer 38-
43mm (Mill Finish)
- Mill Finish Rail
-5/16” x 2 1/2” Stainless Hex Head Bolt
-5/16” Stainless Flat Washer
-5/16” Stainless Lock Washer
-K-Nut
-SBWK-312 or WEEB-M-KR
KMWC3843
-BA/CA
Kinetic Mid Clamp with
Grounding Washer 38-
43mm (Black Anodized or
Clear Anodized)
- Mill Finish
- Black Anodized
- Clear Anodized
-5/16” x 2 1/2” Stainless Hex Head Bolt
-5/16” Stainless Flat Washer
-5/16” Stainless Lock Washer
-Stainless K-Nut
-SBWK-312 or WEEB-M-KR
KMWC3843
-G
Kinetic Mid Clamp with
Grounding Washer 38-
43mm
-Galvanized Rail
-5/16” x 2 1/2” Stainless Hex Head Bolt
-5/16” Stainless Flat Washer
-5/16” Stainless Lock Washer
-Hat Rail Nut
-SBWK-312 or WEEB-M-KR
KMWC4450
-MM
Kinetic Mid Clamp with
Grounding Washer 44-
50mm (Mill Finish)
- Mill Finish Rail
-5/16” x 3” Stainless Hex Head Bolt
-5/16” Stainless Flat Washer
-5/16” Stainless Lock Washer
-K-Nut
-SBWK-312 or WEEB-M-KR
KMWC4450
-BA/CA
Kinetic Mid Clamp with
Grounding Washer 44-
50mm (Black Anodized or
Clear Anodized)
- Mill Finish
- Black Anodized
- Clear Anodized
-5/16” x 3” Stainless Hex Head Bolt
-5/16” Stainless Flat Washer
-5/16” Stainless Lock Washer
-Stainless K-Nut
-SBWK-312 or WEEB-M-KR
KMWC4450
-G
Kinetic Mid Clamp with
Grounding Washer 44-
50mm
-Galvanized
Steel
-5/16” x 3” Stainless Hex Head Bolt
-5/16” Stainless Flat Washer
-5/16” Stainless Lock Washer
-Hat Rail Nut
-SBWK-312 or WEEB-M-KR
KHGLUG-M
Kinetic Ground Lug for Mill
Finish Systems
- Mill Finish Rail
-5/16” x 3/4” Green, Stainless, Hex Head
Bolt

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SKU
Component Description
Use With
Associated Hardware
-5/16” x 1” Stainless Hex Head Bolt
-5/16” Stainless Flat Washer
-5/16” Stainless Lock Washer
-K-Nut
KHGLUG-A
Kinetic Ground Lug for
Anodized Finish Systems
- Mill Finish
- Black Anodized
- Clear Anodized
-5/16” x 3/4” Green, Stainless, Hex Head
Bolt
-5/16” x 1” Stainless Hex Head Bolt
-5/16” Stainless Flat Washer
-5/16” Stainless Lock Washer
-Stainless K-Nut
KHGLUG-G
Kinetic Ground Lug for
Galvanized Finish Systems
-Galvanized
Steel
-5/16” x 3/4” Green, Stainless, Hex Head
Bolt
-5/16” x 1 1/4” Stainless Hex Head Bolt
-5/16” Stainless Flat Washer
-5/16” Stainless Lock Washer
-5/16” Stainless Hex Nut
KJS2-
MA/BA/CA
Kinetic Joiner for Anodized
Systems (Mill Finish, Black
Anodized or Clear
Anodized)
- Mill Finish
- Black Anodized
- Clear Anodized
-5/16” x 3/4” Stainless Serrated Flanged
Hex Head Bolt (2)
-SBWK-312 or WEEB-M-KR (2)
KJS2-MM
Kinetic Joiner (Mill Finish)
- Mill Finish Rail
-5/16” x 3/4” (2) Stainless Serrated Flanged
Hex Head Bolt
-Kinetic Joiner Clamp
KEWC3037-
MA
Kinetic End Clamp with
Grounding Washer 30-
37mm (Mill Finish)
- Mill Finish Rail
-5/16” x 2 ¼” Stainless Hex Head Bolt
-5/16” Stainless Flat Washer
-5/16” Stainless Lock Washer
-K-Nut
-SBWK-312 or WEEB-M-KR
KEWC3037-
BA/CA
Kinetic End Clamp with
Grounding Washer 30-
37mm (Black Anodized or
Clear Anodized)
- Mill Finish
- Black Anodized
- Clear Anodized
-5/16” x 2 ¼” Stainless Hex Head Bolt
-5/16” Stainless Flat Washer
-5/16” Stainless Lock Washer
-Stainless K-Nut
-SBWK-312 or WEEB-M-KR
KEWC3843-
MA
Kinetic End Clamp with
Grounding Washer 38-
43mm (Mill Finish)
- Mill Finish Rail
-5/16” x 2 1/2” Stainless Hex Head Bolt
-5/16” Stainless Flat Washer
-5/16” Stainless Lock Washer
-K-Nut
-SBWK-312 or WEEB-M-KR
KEWC3843-
BA/CA
Kinetic End Clamp with
Grounding Washer 38-
43mm (Black Anodized or
Clear Anodized)
- Mill Finish
- Black Anodized
- Clear Anodized
-5/16” x 2 1/2” Stainless Hex Head Bolt
-5/16” Stainless Flat Washer
-5/16” Stainless Lock Washer
-Stainless K-Nut
-SBWK-312 or WEEB-M-KR
KEWC4450-
MA
Kinetic End Clamp with
Grounding Washer 44-
50mm (Mill Finish)
- Mill Finish Rail
-5/16” x 3” Stainless Hex Head Bolt
-5/16” Stainless Flat Washer
-5/16” Stainless Lock Washer
-K-Nut
-SBWK-312 or WEEB-M-KR

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SKU
Component Description
Use With
Associated Hardware
KEWC4450-
BA/CA
Kinetic End Clamp with
Grounding Washer 44-
50mm (Black Anodized or
Clear Anodized)
- Mill Finish
- Black Anodized
- Clear Anodized
-5/16” x 3” Stainless Hex Head Bolt
-5/16” Stainless Flat Washer
-5/16” Stainless Lock Washer
-Stainless K-Nut
-SBWK-312 or WEEB-M-KR
KSGMM-G
Mounting Kit for Hat Rail
-Galvanized
Steel
-5/16” x 3/4” Serrated Flanged Hex Head
Bolt (4)
-5/16” Serrated Nut (4)
KRJK-M
Kinetic Rail Jumper Kit
-Mill Finish
-KHGLUG-M (2)
-8 AWG Braided Copper Wire
KRJK-A
Kinetic Rail Jumper Kit
- Mill Finish
- Black Anodized
- Clear Anodized
-KHGLUG-A (2)
-8 AWG Braided Copper Wire
Figure 17 Bonding and Grounding Devices