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.

Kinetic Solar K-Rack™
Installation guide
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27 May 2019
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

Kinetic Solar K-Rack™
Installation guide
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27 May 2019
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

Kinetic Solar K-Rack™
Installation guide
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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

Kinetic Solar K-Rack™
Installation guide
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27 May 2019
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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Installation guide
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27 May 2019
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

Kinetic Solar K-Rack™
Installation guide
Page 7of 37
27 May 2019
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)

Kinetic Solar K-Rack™
Installation guide
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27 May 2019
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

Kinetic Solar K-Rack™
Installation guide
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27 May 2019
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