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kinetic K-RACK Installation Manual

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

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Summary of Contents for kinetic K-RACK

  • Page 1 KINETIC SOLAR K-RACK™ INSTALLATION GUIDE Kinetic Solar Racking and Mounting UL 2703, LTR-AE-001-2012 and TIL A-40 Listed 274725...

  • Page 2: Disclaimer

    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.

  • Page 3: Table Of Contents

    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.

  • Page 4: List Of Figures

    FIGURE 25 BONDING AND GROUNDING DEVICES FIGURE 26 MODULE REMOVAL PROCEDURE FIGURE 27 UL 2703 DESIGN LOADS FIGURE 28 LTR-AE-001-2012 DESIGN LOADS FIGURE 29 CONVENTIONAL VS SHARED RAIL FIGURE 30 FLASHING POSITIONING Kinetic Solar K-Rack™ Page 3 of 55 15 June 2023 Installation guide...
  • Page 5 FIGURE 48 AWNING MOUNTS FIGURE 49 END AND MID CLAMP POSITIONS IN CONVENTIONAL AND SHARED RAIL LAYOUTS 52 FIGURE 50 INTEGRATED CABLE MANAGEMENT FIGURE 51 INTEGRATED CABLE MANAGEMENT Kinetic Solar K-Rack™ Page 4 of 55 15 June 2023 Installation guide...

  • Page 6: Certification Details

    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.

  • Page 7: Kinetic Product Configurations

    5.2. Kinetic Product Configurations Product Category Components KJS2-MM KHGLUG-M KMWCxxxx-MM M-Type KECxxxx-MM (For use with mill finish aluminum rail only) KHMNS-MM KHMNL-MM KHMNT-MM KHMTB-MM KJS2W-MA KJS2W-BA KJS2W-CA KBRJ-MA KBRU-MA KHGLUG-A A-Type KMWCxxxx-BA (For use with anodized rail or mill finish rail)

  • Page 8: Components

    KJS2-MA 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.
  • Page 9 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. Kinetic Solar K-Rack™ Page 8 of 55 15 June 2023...
  • Page 10 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. Kinetic Solar K-Rack™ Page 9 of 55 15 June 2023 Installation guide...
  • Page 11 A maximum of two cables can be secured this way using the channel. Figure 7 Integrated Cable Management Kinetic Solar K-Rack™ Page 10 of 55 15 June 2023 Installation guide...
  • Page 12 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 Kinetic Solar K-Rack™ Page 11 of 55 15 June 2023 Installation guide...

  • Page 13: Bonding Path

    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.
  • Page 14 One ground lug is required per array. modules. KHGLUG-A must be used on KHGLUG-A must be used on anodized rail anodized rail Figure 11 Grounding Path of Conventional and Shared Rail Systems Kinetic Solar K-Rack™ Page 13 of 55 15 June 2023 Installation guide...
  • Page 15 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) Kinetic Solar K-Rack™ Page 14 of 55 15 June 2023...

  • Page 16: Groundhog Rail Grounding Path

    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. Kinetic Solar K-Rack™ Page 15 of 55 15 June 2023...

  • Page 17: 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. Kinetic Solar K-Rack™ Page 16 of 55 15 June 2023...

  • Page 18: Grounding Path In Bifacial Rail

    (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 Kinetic Solar K-Rack™ Page 17 of 55 15 June 2023...
  • Page 19 Figure 17 Static Ground Mount Grounding Path through Tube-Clamp Figure 16 Static Ground Mount Grounding Path through Rail Joiner Kinetic Solar K-Rack™ Page 18 of 55 15 June 2023 Installation guide...

  • Page 20: 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 Kinetic Solar K-Rack™ Page 19 of 55 15 June 2023...

  • Page 21: Joiners

    For mill finished bifacial rails, a bifacial rail joiner is not required when the rail joint is over a supporting member. A tube U-Clamp (KRBU-MA) is required on all supporting members. Kinetic Solar K-Rack™ Page 20 of 55 15 June 2023...
  • Page 22 1. Insert the K-nut into the deep groove of the bifacial rail and tighten the 5/16" Bolt with a ½” socket with extension. 2. Install End-Clamps and Mid-Clamps on the ridge rail. Figure 21 Landscape Ridge Rail Kinetic Solar K-Rack™ Page 21 of 55 15 June 2023 Installation guide...

  • Page 23: Thermal Break

    6.8. 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.
  • Page 24 Figure 23 Ground Lug Mounting Options Kinetic Solar K-Rack™ Page 23 of 55 15 June 2023 Installation guide...

  • Page 25: Bonding And Grounding Devices

    Use With Associated Hardware - 5/16” x 2 ¼” Stainless Hex Head Bolt - 5/16” Stainless Flat Washer KMWC3037 Kinetic Mid Clamp with Bonding - 5/16” Stainless Lock Washer - Mill Finish Rail Washer 30-37mm (Mill Finish) - K-Nut - SBWK-312 or WEEB-M-KR - 5/16”...
  • Page 26 - 5/16” x 2 1/2” Stainless Hex Head Bolt - 5/16” Stainless Flat Washer KMWC3843 Kinetic Mid Clamp with Bonding - Mill Finish Rail - 5/16” Stainless Lock Washer Washer 38-43mm (Mill Finish) - K-Nut - SBWK-312 or WEEB-M-KR - 5/16” x 2 1/2” Stainless Hex Head...
  • Page 27 K-Nut (Mill Finish or Black Anodized) SBWK-312 or WEEB-M-KR or KHBW 5/16” x 2 1/2” Stainless Hex Head Bolt Kinetic Long Mid Clamp with 5/16” Stainless Flat Washer KMWC3046L- Bonding Washer 30-46 mm (Mill 5/16” Stainless Lock Washer MM/BM Finish or Black Anodized)
  • Page 28 5/16” x 3” Stainless Hex Head Bolt 5/16” Stainless Flat Washer Kinetic Long Mid Clamp with - Mill Finish Rail 5/16” Stainless Lock Washer KMWC4750L- Bonding Washer 47-50 mm (Mill K-Nut MM/BM Finish or Black Anodized) KHBW 5/16” x 3” Stainless Hex Head Bolt 5/16”...
  • Page 29 - 5/16” Stainless Lock Washer 47-50 mm - Hat Rail Nut - KHBW - 5/16” x 2 ¼” Stainless Hex Head Bolt Kinetic End Clamp with Bonding - 5/16” Stainless Flat Washer KEWC3037- Washer 30-37mm (Mill Finish) - Mill Finish Rail - 5/16”...
  • Page 30 - 5/16” x 2 1/2” Stainless Hex Head Bolt - 5/16” Stainless Flat Washer Kinetic End Clamp with Bonding - Mill Finish KEWC3843- - 5/16” Stainless Lock Washer Washer 38-43mm (Black - Black Anodized BA/CA - Clear Anodized - Serrated K-Nut...
  • Page 31 - 5/16” x 3” Stainless Hex Head Bolt KECW4750L- - 5/16” Stainless Flat Washer Kinetic Long End Clamp with - Mill Finish Rail - 5/16” Stainless Lock Washer Bonding Washer 47-50 mm - K-Nut (Mill Finish) - KHBW - 5/16” x 3” Stainless Hex Head Bolt - 5/16”...

  • Page 32: Removing Modules From An Array

    If there are two or more modules remaining at the end of a row, there is no need to remove the modules at the end. Figure 26 Module Removal Procedure Kinetic Solar K-Rack™ Page 31 of 55 15 June 2023 Installation guide...

  • Page 33: List Of Compatible Modules

    7. List of Compatible Modules Please see Kinetic Solar’s List of Compatible Modules Revision 7 for a full list of modules certified for use with our system. 8. Required Maintenance All installed systems should be checked at least annually to ensure that no components have come loose, become damaged or corroded.
  • Page 34 48” depending on local wind and snow loads. When installing a shared rail system, the top and bottom rails can be installed in a conventional Kinetic Solar K-Rack™ Page 33 of 55 15 June 2023...
  • Page 35 The rail positions of shared and conventional. It is recommended that the upper and lowermost rails in a shared rail configuration be installed conventionally in order to make installation easier. Please note that not all panel manufacturers support this clamping configuration. Kinetic Solar K-Rack™ Page 34 of 55 15 June 2023 Installation guide...

  • Page 36: Install Roof Mounts

    – do not install over cut out or butt edge of the shingle. If the flashing bubble interferes with the shingle edge, minor trimming may be required of the lower edge of the top shingle. Kinetic Solar K-Rack™ Page 35 of 55 15 June 2023...
  • Page 37 Figure ii. K-Flash attaching to Truss: (a) When using Kinetic 4” self-drilling screws, install baseplate using one or two 4” self-drilling screws. When installing with only one self-drilling screw, install it the center hole closest to the stud. The Base Plate should be facing downward (holes up with respect to the peak of the roof, stud facing the eves).
  • Page 38 (b) If two 5/16” lag bolts are used, prepare the roof by pilot drilling two 7/32” holes into the rafter for each baseplate that will be affixed. Figure 32 Measure and Pre-Drill Kinetic Solar K-Rack™ Page 37 of 55 15 June 2023...
  • Page 39 Figure 33 Installing ¼” self-drilling screws Note: Watertight assumes that an appropriate roof surface is being used. Not intended for use on roofs less than 4:12 in areas where ice damming may occur. Kinetic Solar K-Rack™ Page 38 of 55 15 June 2023...
  • Page 40 Slide the K-Flash sheet under shingles and position over the baseplate stud; the K-Flash sheet should sit flush against the roof. Figure 37 Installed Flashing (Truss Mounting Shown) Kinetic Solar K-Rack™ Page 39 of 55 15 June 2023 Installation guide...
  • Page 41 Load tables in Appendix 3. A. For Attaching to the truss: 1. When using one or two Kinetic 4” self-drilling screws, install the self-drilling screw(s) into the rafter similar to Figure 38. No predrilling is required. The wood roof truss or joist should have at least a 1.5” chord width.
  • Page 42 Insert Hanger Bolt assembly into the drilled hole. v. Using a long series ½” socket drive, tighten until the EPDM Neoprene Washer is seated firmly enough to ensure a watertight seal. Kinetic Solar K-Rack™ Page 41 of 55 15 June 2023...
  • Page 43 Insert Hanger Bolt assembly (with spacer) into the drilled hole. Using a long series ½” socket drive, tighten until the EPDM Neoprene Washer is seated vii. firmly enough to ensure a watertight seal. Kinetic Solar K-Rack™ Page 42 of 55 15 June 2023 Installation guide...
  • Page 44 At each location, install two Lag Bolts through the holes of the steel plate into the predrilled holes. iv. Lay a bead of Geocel 4500, BES 925 or equivalent on the roof around the outside edge of the plate. Kinetic Solar K-Rack™ Page 43 of 55 15 June 2023 Installation guide...
  • Page 45 Please note that the Giraffe Mount is designed to attach rail that is running towards the peak of the roof i.e., perpendicular to the eaves. Kinetic Solar K-Rack™ Page 44 of 55 15 June 2023...
  • Page 46 Attach the mount to the roof strapping or sheathing using lag bolts or self- drilling screws. Figure 42 Top- Giraffe Mount (self-drilling screws shown), Bottom- Rhino Mount (2” lag bolts shown) Kinetic Solar K-Rack™ Page 45 of 55 15 June 2023...
  • Page 47 Standing L rests on top of the seam. iii. Torque to 12 ft-lbs (16.3 N-m). Figure 43 Standing L 9.2.3.2.2. S-5! / A2 Please refer to the manufacturer’s installation instructions. Kinetic Solar K-Rack™ Page 46 of 55 15 June 2023 Installation guide...
  • Page 48 Figure 45 Modules mounted on a Quonset Hut The Quonset Hut Mount is attached to Rapid1 Rails using a K-Nut. The modules and clamps are mounted on the rails following steps that were previously described. Kinetic Solar K-Rack™ Page 47 of 55 15 June 2023 Installation guide...

  • Page 49: L-Brackets / Rails

    Insert the nose of the bear clamp ensuring that the clamp’s groove is aligned on the length wise protrusion of the rail. b) Position the rail by installing the bolt and nut. c) Torque to spec. Kinetic Solar K-Rack™ Page 48 of 55 15 June 2023 Installation guide...

  • Page 50: Rail Joiners

    The maximum spacing between the awning brackets is 48 in and the maximum cantilever is 19 in. b) Using fasteners of choice, attach the awning brackets to the wall in marked locations. Kinetic Solar K-Rack™ Page 49 of 55 15 June 2023 Installation guide...

  • Page 51: Micro Inverters

    19” Maximum Cantilever 48” Maximum Figure 48 Awning Mounts 9.7. Micro Inverters *Install Micro Inverters according to manufacturer specifications. The following attachment methods can be used. Kinetic Solar K-Rack™ Page 50 of 55 15 June 2023 Installation guide...

  • Page 52: Mount Solar Modules

    Insert the K-Nut of the End-Clamp assembly into the top channel of the rail. Insert the K-Nut of the Mid-Clamp assembly into the top channel of the rail. Slide Mid and End-Clamps into place against the edge of the panel. Kinetic Solar K-Rack™ Page 51 of 55 15 June 2023...

  • Page 53: Wire Management

    9.9.2. Lock-On Cable Tie i. Place on the rail where needed; approximately 1 x Cable Tie for every 1 foot of rail. ii. Wrap Cable Tie around cables and fasten tightly. Kinetic Solar K-Rack™ Page 52 of 55 15 June 2023...

  • Page 54: Venture Rail System

    *Ensure bolt does not come into contact with top edge of bottom channel 10.3. Mounting Modules a) Position the module on the rails (make sure to hold modules securely until properly fastened) Kinetic Solar K-Rack™ Page 53 of 55 15 June 2023 Installation guide...

  • Page 55: Wire Management

    A maximum of two cables can be secured this way using the channel. Figure 51 Integrated Cable Management Kinetic Solar K-Rack™ Page 54 of 55 15 June 2023 Installation guide...

  • Page 56: Micro-Inverter Mounts

    Insert K-Nut portion of micro inverter mount assembly into top channel of Rail at 30-degrees. e) Install micro inverter onto mount f) Tighten and torque to spec www.kineticsolar.com Kinetic Solar K-Rack™ Page 55 of 55 15 June 2023 Installation guide...

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