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Kinetic Solar K-Rack™
Installation guide

Page 2 of 37

27 May 2019

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Table of Contents

Disclaimer ................................................................................................................. 1

Table of Contents ..................................................................................................... 2

List of Figures ........................................................................................................... 3

Certification Details ................................................................................................... 4

Common System Features ....................................................................................... 4

Torque Specifications ................................................................................................................................... 4

Kinetic Product Configurations ..................................................................................................................... 5

Components ................................................................................................................................................. 6

Bonding Path .......................................................................................................... 11

Traditional Grounding Path ......................................................................................................................... 11

Groundhog Rail Grounding Path ................................................................................................................ 13

Hat Rail Grounding Path ............................................................................................................................. 14

Joiners ........................................................................................................................................................ 15

Thermal Break ............................................................................................................................................ 15

Grounding ................................................................................................................................................... 15

Bonding and Grounding Devices ................................................................................................................ 17

Removing Modules from an Array .............................................................................................................. 20

List of Compatible Modules .................................................................................... 21

Required Maintenance ............................................................................................ 21

Pitched Roof Installation Instructions ...................................................................... 22

Layout Considerations ................................................................................................................................ 22

Install Roof Mounts ..................................................................................................................................... 24

L-Brackets / Rails ....................................................................................................................................... 30

Rail Joiners ................................................................................................................................................. 30

Micro Inverters ............................................................................................................................................ 30

Mount Solar Modules .................................................................................................................................. 31

Wire Management ...................................................................................................................................... 32

Venture Rail System ............................................................................................ 34

O-Ring Cord Sealing Channel .................................................................................................................... 34

Install Rails ................................................................................................................................................. 34

Mounting Modules ...................................................................................................................................... 34

Wire Management ...................................................................................................................................... 34

Micro-Inverter Mounts ................................................................................................................................. 35

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Summary of Contents for K-RACK

Page 1: ...KINETIC SOLAR K RACK INSTALLATION GUIDE Kinetic Solar Racking and Mounting UL 2703 and LTR AE 001 2012 Listed 274725 ...

Page 2: ...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 specificat...

Page 3: ...rounding 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...

Page 4: ...TOM 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...

Page 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...

Page 6: ...Cxxxx 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 w...

Page 7: ...de 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 ...

Page 8: ...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 Nu...

Page 9: ...ay 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 ...

Page 10: ...nects 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...

Page 11: ...an 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 ...

Page 12: ... 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 corr...

Page 13: ...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 ...

Page 14: ...igure 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 ...

Page 15: ...Page 14 of 37 27 May 2019 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 ...

Page 16: ...ound 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 ...

Page 17: ...ge 16 of 37 27 May 2019 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 ...

Page 18: ...3 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...

Page 19: ...langed 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 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 Stainle...

Page 20: ... 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 ...

Page 21: ...m second from the end of a row the modules on the end need to be removed first This may be avoided if module 1 is grounded independently of module 2 Never remove the module second from the end of a row before removing the end module unless the end modules are grounded independently If there are two or more modules remaining at the end of a row there is no need to remove the modules on the end Figu...

Page 22: ...List of Compatible Modules April 29th Revision 5 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 If any inadequacies are found they are to be immediately remedied ...

Page 23: ...derations 9 1 1 Design Loads 9 1 1 1 UL 2703 Design Load Maximum Span Downward Design Load 3600 Pa 75 3 lb ft2 48 Upward Design Load 1600 Pa 33 4 lb ft2 48 Down Slope Load 239 Pa 5 0 lb ft2 48 Figure 19 UL 2703 Design Loads 9 1 1 2 LTR AE 001 2012 Design Load Please note that for loads greater than 2400 Pa 50 lb ft2 the attachment to the L Bracket must be positioned at the bottom of the slot Groun...

Page 24: ...ending on local wind and snow loads See design loads above Figure 21 Conventional vs Shared Rail 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 Pro Tip When installing a s...

Page 25: ...ed The ability to do this will ultimately rely on the structural assessment of the roof and whether or not it can be supported Other than the orientation of the rails the installation will be identical to a conventional rail system 9 2 Install Roof Mounts 9 2 1 Shingled Roof 9 2 1 1 Flashing Mounting Kit i Measure and mark the appropriate bracket locations Use a measuring tape to ensure chalk line...

Page 26: ...g two 7 32 pilot holes through the roof and into the rafter for each Base Plate that will be affixed iii Screw each Base Plate into position using two lag bolts The Base Plate should be facing downward holes up with respect to the peak of the roof stud facing outwards Figure 23 Measure and Pre Drill Figure 24 Install Lag Bolts ...

Page 27: ... Sealant BES 925 or equivalent to the underside of your K Flash sheet v Slide the K Flash sheet under shingles and position over the base plate stud the K Flash sheet should sit flush against the roof Figure 27 Caulking Path Figure 28 Installed Flashing Figure 26 Geocel 4500 Figure 25 Geocel PROFLEX ...

Page 28: ...y drilling two 7 32 pilot holes through the roof and into the rafter for each mount that will be affixed 3 Peel wax paper off backing of mount prior to its final placement 4 Screw each mount into position using two lag bolts 9 2 2 Metal Roof 9 2 2 1 Trapezoidal Corrugated 9 2 2 1 1 Hippo Mount i Drill two 7 32 pilot holes through the seam and into the rafter for each Hippo Mount ii At each locatio...

Page 29: ...t a bead of Geocel 4500 or BES 925 into the pilot hole iv Optional Apply a bead of Geocel 4500 or BES 925 around the outside perimeter of the hole v If installing into the ridge of the roof insert the optional spacer around the pointed end of the bolt a If mounting into the lower portion of the roof trough skip this step vi Insert Hanger Bolt assembly into the drilled hole vii Using a long series ...

Page 30: ... the appropriate mount locations Use a measuring tape to ensure chalk lines are straight and square iii Prepare roof for the installation of lag bolts by drilling two 7 32 pilot holes through the roof and into the rafter for each mount that will be affixed iv Peel wax paper off backing of mount prior to its final placement v Screw each mount into position using two lag bolts 9 2 2 2 Standing Seam ...

Page 31: ...ange nut The long end should be upright 9 4 Rail Joiners If not using Rail Joiners continue to section 9 5 a Insert the Joiner assembly into the side channel of the rail at the ends being joined Ensure Joiner is centered between the two rail ends b Tighten the bolts of the Joiner Torque to 12 ft lbs 16 3 N m 9 5 Micro Inverters Install Micro Inverters according to manufacturer specifications The f...

Page 32: ...tate flat c Tighten and torque to spec 9 5 2 Side Mount a Insert K Nut portion of micro inverter mount assembly into side channel of Rail at 30 degrees b Install micro inverter onto mount c Tighten and torque to spec 9 6 Mount Solar Modules a Position module on the rails make sure to hold modules securely until properly fastened Ensure the first module is square before continuing as this will affe...

Page 33: ...thods can be combined 9 7 1 Cable Raceway i Hang the Cable Raceway segment on the bottom edge of the side channel of the rail ii Lay cables into Cable Raceway segment Rotate Raceway segment until it snaps into top edge of side channel of rail 9 7 2 Lock On Cable Tie i Place on rail where needed approximately 1 x Cable Tie for every 1 foot of rail ii Wrap Cable Tie around cables and fasten tightly ...

Page 34: ...elf 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 33 Integrated Cable Management ...

Page 35: ...and insert the bolts from the underside and attach the K Nuts b Starting from either end slide the rail onto the K Nuts c Position the rail and tighten the bolts 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 b Ensure the first module is square before continui...

Page 36: ...or every 1 foot of rail b Wrap Cable Tie around cables and fasten tightly 10 4 3 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 10 ...

Page 37: ...rque to spec 10 5 1 2 Closed Slot a Install micro inverter mount assembly into mounting slot of micro inverter b Insert K Nut portion of micro inverter mount assembly into top channel of Rail at 30 degrees and rotate flat c Tighten and torque to spec 10 5 2 Side Mount a Insert K Nut portion of micro inverter mount assembly into side channel of Rail at 30 degrees b Install micro inverter onto mount...

Page 38: ...Kinetic Solar K Rack Installation guide Page 37 of 37 27 May 2019 www kineticsolar com ...

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