K2 CrossRail Shared Rail System Assembly Instructions Manual Download Page 2

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Content

About Us

General Safety Information

Roof requirements

Structural requirements

Important mounting instructions

Bonding and Grounding

Fire Rating

Tools Overview

Quality tested – several certifications

K2 Systems stands for secure connections, highest quality and precision. Our
customers and business partners have known that for a long time. Independent
institutes have tested, confirmed and certified our capabilities and components.

Please find our quality and product certificates under:

https://k2-systems.com/en-US/company/quality-management-and-certificates

Summary of Contents for CrossRail Shared Rail System

Page 1: ...k2 systems com We support PV systems Formerly Everest Solar Systems CrossRail Shared Rail System ASSEMBLY INSTRUCTIONS ...

Page 2: ...nents 13 T Assembly 16 T Notes 24 Quality tested several certifications K2 Systems stands for secure connections highest quality and precision Our customers and business partners have known that for a long time Independent institutes have tested confirmed and certified our capabilities and components Please find our quality and product certificates under https k2 systems com en US company quality ...

Page 3: ...esign and installation Our designs result in cost competitive racking systems with dedicated support that will position you to win more projects We partner with our customers and suppliers for the long term High quality materials and cutting edge designs provide a durable yet functional system Our product line is comprised of a few coordinated components that lower the cost of materials and simpli...

Page 4: ...allation consult our website at https k2 systems com en US downloads documentation for up to date instructions We can send you the latest version on request T The assembly instructions of the module manufacturer must be adhered to T Equipotential bonding grounding earthing between individual parts is to be performed according to country specific standards as well as national laws and regulations T...

Page 5: ...ty of the roof must be reviewed on site and approved by a licensed structural engineer T Roof mean height 0 60 ft T For allowable roof pitch refert to the CrossRail engineering letters on our website https k2 systems com en US downloads documentation Structural requirements T Wind speed 95 200 mph T Ground snow load 0 100 psf T Clearance 2 to 10 clear from the top of the roof to the top of the PV ...

Page 6: ...At least one ground lug per sub array must be used to ground all strings although additional may be used for redundancy When installed per these installation instructions all connections meet the requirements of NEC 690 43 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 compl...

Page 7: ...odule with a fire performance rating of Type 1 Type 2 or Type 3 Consult the module manufacturer for specific fire performance rating information T CrossRail may be mounted using any stand off height to maintain the Class A fire rating Always consult the module manufacturer s installation instructions to ensure your installation is in compliance with their UL 1703 Listing T The results of the racki...

Page 8: ...G9 XXX Q PEAK DUO XL G9 2 XXX Q PEAK DUO XL BLK G9 XXX Q PEAK DUO XL BLK G9 2 XXX Q PEAK DUO XL BLK G9 3 XXX Q PEAK DUO XL G9 3 XXX Q PEAK DUO ML G9 3 XXX Q PEAK DUO ML BLK G9 3 XXX Q PEAK DUO ML G9 XXX Q PEAK DUO ML G9 XXX Q PEAK DUO BLK ML G9 XXX Q PEAK DUO BLK ML G9 XXX Q PEAK DUO BLK G10 Q PEAK DUO BLK ML G10 Q PEAK DUO BLK G10 AC Q PEAK DUO BLK ML G10 a Q PEAK DUO XL G10 d T UL NRTL Listed Ha...

Page 9: ...Q1C A5 LGxxxQ1K A5 LGxxxN2W V5 LGxxxN1C V5 LGxxxN1W V5 LGxxxN1K V5 LGXXXN2W V5 LGXXXN1C V5 LGXXXN1W V5 LGXXXN1K V5 LGXXXN2T V5 LGXXXN1C N5 LGXXXQ1C N5 LGXXXQ1K N5 LGXXXN1K L5 LGXXXN2W L5 LGXXXN2T L5 LGXXXN1W L5 LGXXXN1T L5 LGXXXA1C V5 LGXXXA1K V5 LGXXXM1C N5 LGXXXM1K L5 LGXXXQ1C A6 LGXXXQ1K A6 LGXXXQAC A6 LGXXXQAK A6 LGXXXN1C A6 LGXXXN1K A6 LGXXXN2W E6 LGXXXN2W E6 AW5 LGXXXN2T E6 LGXXXN1K B6 LGXXX...

Page 10: ...xxSX6W MSExxxSX6Z MSExxxSX5R T UL NRTL Listed Sanyo Electric Co Ltd of Pana sonic Group Modules VBHNxxxSA16 VBHNxxxSA17 VBHNxxxSA18 VBHNxxxSA16 VBHNxxxSA17 VBHNxxxSA18 VBHNxxxKA01 VBHNxxxKA03 VBHNxxxKA04 T UL NRTL Listed Sharp Modules NU SCxxx NU SAxxx T UL NRTL Listed Mission Solar Modules MSExxxSB1J MSExxxSO5T MSExxxSO4J MSExxxSQ6S MSExxxSO6J MSExxxSQ4S MSExxxSQ5T MSExxxSQ5K MSExxxSQ8T MSExxxSQ8...

Page 11: ... MBE MCE xxxV SC25 72MAE MCE xxxV SD25 60BDE xxxV SD25 72BDE xxxV T UL NRTL Listed Trina Solar Modules TSM xxxDE14A TSM xxxDD05A 08 DUOMAX SPECS 1 PEG14 DUOMAX SPECS 2 PEG5 DUOMAX SPECS 3 PEG5 07 DUOMAX SPECS 4 PDG5 T UL NRTL Listed Talesun Modules Hipro TP660M xxx Hipro TP672M xxx T UL NRTL Listed Yingli Solar Modules YL xxxP 29b YL xxx 35b T UL NRTL Listed V Energy Modules Series 200 PV TSM DE15...

Page 12: ...L2703 M8 Allen Bolts 10 3 ft lb 14 Nm T All other components M8 Hex Bolts 10 3 ft lb 14 Nm Tools and materials for the installation of third party items such as roof attachment products roof covering and sealing products or items used for bonding and grounding are not listed here Please refer to the instructions of those third party products Optional ...

Page 13: ... Hex 30 50mm module frame height L Foot Slotted Set End Clamp or Yeti Clamp 30 50mm module frame height 4000019 4000020 4000021 4000022 4000662 4000675 4000695 4000705 4000630 4000631 4000429 4000430 4000050 H 3 2 5 1 4 6 7 8 9 4000601 H 4000602 H 4000688 H 4000689 H ...

Page 14: ...hments Accessories EverFlash eComp SR Kit Available in Mill or Dark 4000015 4000027 4000029 Standing Seam PowerClamp Available in Mini and Standard sizes CR Microinverter Optimizer Mounting Kit 13mm Hex 4000629 H CrossRail 3 Black Sleeve Compatible with CR 48 X 48 XL 4000583 TC Wire Management Clip 4000069 Omega Cable Clip 4005394 HEYCO Sunrunner Cable Clip 4000382 9 Add On Available in 5mm or 10m...

Page 15: ...be installed in an array It cannot be installed on a single module that is not connected to the array by a mid clamp Important note for Yeti Clamp installs Frame Compatibility Flange Thickness 1 2 2 5 mm Flange Width 15 40 mm ...

Page 16: ...he standing seam making sure it hugs the rib Tighten set screw s so the clamp is secure but leave it slightly lose to allow for later adjustment Insert the hex screw through the slot of the L Foot and into the PowerClamp Tighten to 12 ft lbs 16 3 Nm 2 1 ...

Page 17: ...urn T Bolt 90º clockwise so that the mark at the end of the T Bolt is pendicular indicating proper alignment Torque to 25 8 ft lbs 35 Nm Due to thermal expansion we recommend placing a gap of 1 25 2 3 5cm every 65 ft 20m between rails Maximum allowable spacing between thermal expansion gaps shall not exceed 80 ft 24 4m In areas that experience snow loads install the rail on the roof ridge side of ...

Page 18: ...ttachment Attach rail connector using two T Bolts and serrated hex nuts per side 4 total Ensure that the slot on the bottom of the T Bolt is perpendicular to the rail indicating proper alignment Torque to 25 8 Ft lnbs 35 Nm Using the CrossRail Microinverter and Optimizer Mounting Kit hardware from K2 Systems attach your chosen device to the top channel of Cross Rail Torque to 10 3 ft0lbs 14 Nm 5 6...

Page 19: ...he plastic tabs rotate 90º clockwise to engage into rail channel Place Add On over clamps and into rail channel after clamps are installed Using the standard End Clamps attaach the Array Skirt to the top channel of CrossRail Torque clamps to 10 3 ft lbs 14 Nm Place Array Skirt into channel ensuring tabs lock into channel Place clamp into rail channel Place Add On over clamp and into rail channel O...

Page 20: ...module frame Torque to 12 ft lbs Use your hand to ensure the Yeti Clamp is fully engagaed with the frame of the module as shown in the image Note The Yeti Clamp must be installed in an array It can not be installed on a single module that is not connected to the array by a mid clamp Lay modules down in a row one at a time Safely connect and properly manage wires before module installation We recom...

Page 21: ...V module manufacturer s guidelines Torque to 12 ft lbs Ensure modules are flush against the clamp Tighten end clamps to module at spcified locations per PV module manufacturer s guidelines Torque to 10 3 ft lbs Ensure clamp sits flush against module frame 10 11 ...

Page 22: ...ckwise to engage into rail channel Ensure bonding teeth are perpendicular to the rail channel Torque to 10 ft lbs Insert a 6 or 8 AWG solid copper wire and tighten terminal screw to 35 60 in lbs Please note if the Everest Ground Lug is used on a rail that is shared it must be outside of the modules on the end of the rail It can be used on one of the non shared rails underneath the module or on the...

Page 23: ...nfiguration All intermediary rail between front and last rows must be aligned carefully using the steps outlined above 13b 14 To attach WEEB Lug 10 3 insert T Bolt into side channel of CrossRail and rotate clockwise 90º Tighten serrated hex nut to 15 ft lbs 20 3 Nm Insert a 6 or 8 AWG solid copper wire and tighten terminal screw to 5 ft lbs 6 7 Nm ...

Page 24: ...24 Notes ...

Page 25: ...25 Notes ...

Page 26: ...SA 1 760 301 5300 info us k2 systems com www k2 systems com Thank you for choosing a K2 mounting system Systems from K2 Systems are quick and easy to install We hope these instructions have helped Please contact us with any questions or suggestions for improvement Our contact info T k2 systems com en US contact T Telephone 1 760 301 5300 We support PV systems Formerly Everest Solar Systems ...

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