REFLECT Tubular Rail Ground Mount System Installation Manual

REFLECT Tubular Rail Ground Mount System Installation Manual

REFLECT Tubular Rail Ground Mount System

Installation Manual

TKS UIG 10009.04 tenKsolar

9231 Penn Avenue South

Minneapolis, MN 55431

Toll free: 877-432-1010 www.tenKsolar.com

[email protected]

@tenKsolar.com

Simply More Energy

About tenKsolar

tenKsolar designs, manufactures and markets a unique photovoltaic module that provides unmatched production, reliability and safety.

Copyright Notice

REFLECT Tubular Rail Ground Mount System Installation Manual © 2015 tenKsolar, Inc. All rights reserved.

Trademarks and Patents

tenKsolar and tenK are registered trademarks of tenKsolar, Inc. All other product names trademarks within are the property of their owners, and appear in this document solely for identification purposes.

Disclaimer

tenKsolar makes no express or implied warranty as to the accuracy, suitability, or completeness of the information provided in its documentation. tenKsolar assumes no liability for loss or damage which results from the use of such information. Use of this information will be assumed to be at the user’s risk. The native language of all documentation is U.S. English. While every effort has been made to ensure the accuracy of this documentation, any translations into other languages cannot be guaranteed for accuracy.

Contact Information

tenKsolar, Inc.

9231 Penn Avenue South

Suite 100

Minneapolis, MN 55431

USA

Telephone:

877-432-1010

Fax Number:

952-303-7601

Email:

[email protected]

Website:

www.tenksolar.com

About tenKsolar

tenKsolar, Inc., provides a photovoltaic solar solution that delivers on the promise of the lowest cost of solar electricity, while at the same time improving power density, safety, longevity and bankability of photovoltaic systems.

Since its founding in 2008, tenKsolar has been a leading innovator in the delivery and implementation of photovoltaic solar systems for commercial customers. More information about tenKsolar is available online at www.tenKsolar.com

Page 2 ©tenKsolar, Inc., 2015

Contents

Introduction ........................................................................................................................................................................ 4

REFLECT Tubular Rail Ground Mount System Overview .................................................................................................... 4

Hardware and Tools ............................................................................................................................................................ 5

REFLECT Fastening Hardware ......................................................................................................................................... 5

Recommended Tools ...................................................................................................................................................... 5

Ground Penetrating Mounting ........................................................................................................................................... 6

Driven Piles ..................................................................................................................................................................... 7

Helical Piles ..................................................................................................................................................................... 8

Non-Ground Penetrating Mounting ................................................................................................................................... 9

Mechanical Installation ....................................................................................................................................................... 9

Install Rails ...................................................................................................................................................................... 9

On Driven Piles ............................................................................................................................................................ 9

On Helical Piles ........................................................................................................................................................... 9

On Non-Penetrating Pre-Cast Piers .......................................................................................................................... 10

Install Fins ..................................................................................................................................................................... 11

Square the Rails ............................................................................................................................................................ 12

Install Reflector Struts .................................................................................................................................................. 13

Install Modules ............................................................................................................................................................. 13

Connect Module to Reflector Struts ............................................................................................................................. 14

Install Keeper Plugs, Torque Nuts ................................................................................................................................. 15

Install Reflectors ........................................................................................................................................................... 16

Build Out Array ............................................................................................................................................................. 18

Attach Stabilizer Cables ................................................................................................................................................ 19

Electrical Installation ........................................................................................................................................................ 20

Install Inverter Bus ........................................................................................................................................................ 20

Install DC Conductor ..................................................................................................................................................... 20

Connect Modules to Inverter Bus ................................................................................................................................. 22

Install AC Disconnect .................................................................................................................................................... 23

Array Grounding ........................................................................................................................................................... 24

Appendix – Module Status LED Sequences ...................................................................................................................... 25

Page 3 ©tenKsolar, Inc., 2015

Introduction

Welcome to Simply More Energy! The tenKsolar REFLECT PV System is a unique approach to solar energy generation that delivers the best value in solar today!

This guide describes the proper installation method of the REFLECT System onto a supported ground structure.

The REFLECT PV system is designed for flexibility, safety, ease of installation and simple maintenance. Please be sure to follow this instruction guide carefully to meet its design goals. We are happy to partner with you in making the world a cleaner, better place.

Caution: It is important that the installer read through all instructions carefully and layout a project plan prior to beginning physical installation. Any concerns or questions the installer may have should be directed to tenKsolar. Additional information can be found at www.tenKsolar.com.

Caution: The instructions contained in this installation manual are guidelines. Actual project details and considerations vary greatly. Please consult with your structural engineer and authorities having jurisdiction in order to validate that these guidelines are acceptable for your project installation.

REFLECT Tubular Rail Ground Mount System Overview

The REFLECT Tubular Rail Ground Mount System array is comprised of tenKsolar Modules, tenKsolar Reflectors, and tenKsolar Inverter Buses mounted on rails supported by pilings, piers, or other support systems. Complete details of system assembly are provided in this document.

The tenKsolar Module is protected by its integrated electronics to only produce energy when the system is safely connected to the grid. The tenKsolar Reflector boosts energy output by increasing the amount of light collected by each tenKsolar Module. The tenKsolar Inverter Bus provides the system's DC-AC inversion.

The modules and reflectors are aligned in a wave pattern that repeats throughout the installation.

See Figure 1

.

This wave pattern creates a wind shield that adds to the system's structural integrity.

Figure 1

The REFLECT PV System is available in two variations: the REFLECT 26 - best suited for sites below 35° latitude - and the REFLECT 28 - preferred for sites above 35° latitude. The REFLECT 28 has a wider gap between the module and reflector to facilitate snow shedding, but requires approximately 20% more space for installation. REFLECT 26 and

REFLECT 28 use the same components, with minor variations to the struts and rails. The installation process for the two is identical.

Page 4 ©tenKsolar, Inc., 2015

Hardware and Tools

Before installing your REFLECT System, make sure you have the recommended tools and hardware.

REFLECT Fastening Hardware

Use only specified fasteners with the REFLECT system.

Replacing the specified fasteners with unapproved fasteners could disrupt the electrical grounding circuit and could result in damage to the panels or reflectors, or to nearby personnel or property.

Replacing the specified fasteners with unapproved fasteners will void the warranty.

Description

¼" Star Washer, Stainless Steel

Locations Used

Fin-Rail connection, Inverter Bus Bracket-Rail connection

¼"-20 X ⅝" Stainless Steel Hex Head Cap Screw Fin-Rail connection

¼"-20 Stainless Steel Combination Hex Nut with

Star Washer

Inverter Bus Bracket- -Rail connection

¼"-20 x 1" Stainless Steel T-bolt Inverter Bus Bracket-Rail connection

¼"-20 x 2 ½" Stainless Steel T-Bolt

5

/

16

" Star Washer, Stainless Steel

5

/

16

"-18 Stainless Steel Combination Hex Nut with Star Washer

Pile Cap Clamp

Fin-Module connection, Fin-Reflector Strut connection

5

/

16

"-18 x 2" Stainless Steel Threaded Stud Fin-Module connection

5

/

16

"-18 x ¾" Stainless Steel Hex Head Cap Screw Fin-Reflector Strut connection

Fin-Module connection, Fin-Reflector Strut connection

3-Hole Chamfered aluminum pin

Hair Pin Cotter

Module Keeper Plug

⅝"-11 hex nut, stainless steel

Module-Reflector Strut connection

Module-Reflector Strut connection, Reflector-Strut connection

Fin-Module connection

Pile Cap Assembly

⅝"-11 x 1 ¼" hex head cap screw, stainless steel Pile Cap Assembly

⅝" external tooth star washer, stainless steel Pile Cap Assembly

Recommended Tools

You will need the following tools for the proper installation of the REFLECT PV System. Additional tools may be required based on your specific site requirements.

Standard Tools

7

/

16

" hex socket; ½" hex socket and ½" deep hex socket;

15

/

16

" hex socket

A torque wrench with an effective working range that includes 10.5 ft-lbs (128 in-lbs) and a minimum resolution of

1 ft-lb

3

/

16

" hex key

Tape measures and levels may be required, depending on the site

Special Tools, available for sale by tenKsolar

Fin Spacing Tool - Ensures each fin is placed exactly the correct distance apart.

Page 5 ©tenKsolar, Inc., 2015

Ground Penetrating Mounting

It is recommended that the support structure be fully installed prior to delivery of the tenKsolar System.

The REFLECT System can be installed on a variety of ground penetrating support structures. The two most common, helical piles and driven piles, will be covered in this manual. Installation on either type of piles is very similar. The only differences are the piles themselves, and the way that the array rails are attached to each type of pile.

Two to six wavelets of the REFLECT system can be supported on one N-S length of tubular rail that will rest on two piles. The rails ends of the rails will be cantilevered out from the piles. Successive rails to the north or south will rest on another two piles. The rails will be separated by 1”.

The support piles of your tenKsolar REFLECT PV System must be installed 77-⅞" on-center in the east–west direction.

The north–south spacing and pile depth will be determined by your structural engineer, and must be installed accordingly.

See Figure 2

. (Note: Figure 2 shows W6x9 piles, but the dimensions apply to helical piles as well.)

Failure to install piles in accordance with structural engineering report will void system warranty.

Failure to install piles within accepted tolerance guidelines will void system warranty.

Figure 2

The following table shows acceptable variances in pile positions:

Axis

East–West

North–South

Height

Pile

Depth

Installation

77-⅞" OC

Determined by PE Report

Determined by PE Report

Plumb

Determined by PE Report

Tolerance

+/- 2"

Determined by PE

+/- ½"

5° off plumb

Determined by PE Report

Page 6 ©tenKsolar, Inc., 2015

Driven Piles

If you are using driven H-piles, the flanges of the shape must run north-south and the web must run east-west.

See

Figure 3.

North

Figure 3

Driven piles require a ¾" diameter hole in the web of the pile for mounting the pile cap. The location of the hole is shown in

Figure 4.

The piles should be driven in such a manner that no mushrooming of the top of the piles occurs.

Note:

the pile shown in

Figure 4

is a W6X9 structural steel member. Your PE may specify a different structural steel member, but the hole location will stay the same.

Figure 4

Once the piles are driven, attach a pile cap to each pile using a ⅝"-11 x 1 ¼" bolt, a ⅝"-11 nut and two ⅝" star washers.

See Figure 5.

Page 7 ©tenKsolar, Inc., 2015

Figure 5

Helical Piles

Helical piles should have integral 8" x 8" x ½" steel mounting plates on the top of each pile. These mounting plates will provide a level surface for the REFLECT System's rails to install on.

See Figure 6

for typical helical pile.

Mounting Plate - Rails will rest on this surface

Pile Shaft - actual length will depend on site characteristics

Helical Anchor Feature

Figure 6

Page 8 ©tenKsolar, Inc., 2015

Non-Ground Penetrating Mounting

Pre-cast concrete piers can be used in place of pilings for non-ground penetrating requirements. The pre-cast piers must be positioned in the same locations that pilings would be in ground penetrating arrays. The pre-cast pier must be installed 77 ⅞" on-center in the east–west direction. The north–south spacing will be determined by your structural engineer.

See Figure 2.

Note that this manual will show mounting on driven piles. With the exception of the way rails are connected to the supporting system, the installation is the same for all support systems.

Mechanical Installation

Install Rails

To install the first oval rail, set the rail on the first two piles or piers on either the eastern or western edge of your array.

On driven piles, the rail will sit on top of the pile caps that you installed on the piles.

On helical piles, the rail will sit on the pile manufacturer’s 8" x 8" x ½" top plate.

On non-penetrating pre-cast piers, the rail will rest on the pre-cast pier with rubber pads between the rail and the piers.

Position the front of the rail so that its cantilever length is in accordance with your structural engineer's specifications.

Insert a ¼"-20 x 2-½" T-bolt into the rail’s bottom channel. Slide a universal clamp over the T-bolt and thread a ¼" -20 combination star washer-hex nut onto the T-bolt and finger-tighten.

On Driven Piles

For driven piles, use one clamp. It can be on either side of the pile cap.

See Figure 7.

Figure 7

On Helical Piles

For helical piles use

two

clamps, one on each side of the pile’s top plate.

See Figure 8.

Note:

The universal clamp may be oriented one of three ways to accommodate helical piles that are out of plumb or with top plates not aligned with the direction of the oval rail.

Page 9 ©tenKsolar, Inc., 2015

Two clamps on helical piles

Figure 8

On Non-Penetrating Pre-Cast Piers

For non-penetrating pre-cast piers, clamping options will depend on your design for the pier. The rail rests on two 4” x

8” x ½” rubber pads, each inserted in a pad shoe, on each pre-cast pier.

See Figure 9.

Place a pad shoe with a pad at the front and rear of each pier so that the tab on the inboard end of the shoe fits into the rail’s bottom slot. Twist a

¼”-20 x 1” hammer head bolt into the rail slot and slide it into the slot on each pad shoe’s tongue. Install a ¼” flat washer and a ¼”x20 combination star washer and hex nut on to each hammer head bolt. Tighten the nut to 6 ft-lbs.

Clamp the rail in position using the clamping system you have designed for you pier.

One pad and shoe assembly at each end of each pier

Hammer head bolt with flat washer and combo star washer and hex nut in rail slot. Install one set on each of the two pads on each pier.

Figure 9

Page 10 ©tenKsolar, Inc., 2015

With whichever support system you are using (driven piles will be illustrated in this manual), repeat these steps for the rail’s other pile. Once the rail is properly positioned and you have verified that it is aligned such that the other rails, when spaced at multiples of 77 ⅞" on center from the first, will sit properly on their piles or piers, torque the nuts on the clamp T-bolts to 6 ft-lbs.

Install the remaining rails in the section, spacing them at 77 ⅞" on center. Keep the front edges of the remaining rails square to the first rail.

Only finger tighten the nuts on the clamp T-bolts of the other rails for now.

Install Fins

The fins connect the modules and reflector struts to the rails. They come pre-assembled with necessary hardware as shown in

Figure 10

.

Fins are not symmetrical and must be oriented correctly.

The upper bolt connects to the reflector strut and the lower bolt connects to the module.

Threaded stud for module

(toward back – north – of array) Reflector strut bolt

(toward front – south – of array)

Figure 10

Slide the necessary number of fins – one more than the number of modules that will be carried by the rail – into each rail. Be sure fins are properly oriented. Allow the star washers to slide into the rail with the fin base plates.

The star washer is an integral part of the electrical grounding system and must be installed inside the fin-slot.

See Figure 11.

Star washer

Fin inserted in rail; cap screw not yet tightened

End view of rail with fin inserted, before and after tightening cap screw

Cap screw tightened, pulling fin base and star washer up against top of rail slot

Figure 11

Page 11 ©tenKsolar, Inc., 2015

Align the front foot of the first fin in each rail so that it is flush with the rail's front edge. Torque the cap screws of the

front-most

fin to 6 ft-lbs. Move the other fins into their approximate position.

Use the Fin-Spacing Tool to position the next fin back.

See Figure 12.

Once the fin has been positioned with the fin spacing tool, torque its cap screws to the rail to 6 ft-lbs. Then use that fin and the fin spacing tool to locate the next fin back. Continue the process until all fins on each rail are properly located and torqued.

Fin Foot Flush with

End of Rail

Figure 12

Square the Rails

The oval rails must form a rectangle

to ensure proper installation and maximum energy generation of your system.

Using a string or a laser, establish a line perpendicular to the first rail that passes along the front edge of the front fin of the first rail.

See Figure 13.

One rail at a time, loosen the finger tightened pile clamp bolt nuts of the other rails and adjust the rail forward or backward as necessary to bring the front of the fin to the line you established perpendicular to the first rail. Once in position finger tighten the clamp bolt nuts again. Throughout the remainder of the installation process check to verify that the rails maintain their north-south position in line with the perpendicular line so that the array is squared up.

Align Front Fins

Perpendicular to First

(Clamped) Rail

Figure 13

Page 12 ©tenKsolar, Inc., 2015

Install Reflector Struts

Attach reflector struts to all fins except the front fin on each rail. Use the

5

/

16

"-18 cap screw and combo nut and star washer. Attach the end of the strut that has slots in the strut’s flange. Attach the reflector struts to the

west

side of the fins.

The smaller slot in the strut’s flange goes up

.

See figure 14.

Do not tighten the nuts for now. Allow the struts to rest on the rails.

The smaller slot goes up

Attach the end of the strut that has slots in the flange

Figure 14

Install Modules

Orient the module with the electrical connector lugs to the east or west, per your wiring plan. Slip the slots in the module’s frame over the fin stud bolts.

See Figure 15.

Adjust the spacing between rails as necessary to accommodate the module. Be sure that the dog-leg slot in the module frame sits properly on the fin stud bolt.

See Figure 16.

Only finger tighten nuts on fin studs for now.

Figure 15

Page 13 ©tenKsolar, Inc., 2015

Figure 16

Connect Module to Reflector Struts

Lift the reflector struts and line up the upper hole in the strut with the hole in the module frame. Use a 3-hole chamfered aluminum pin to attach the struts to the modules.

See Figure 17.

Insert one hairpin cotter into an end hole of each 3-hole aluminum pin. For struts at the east or west edge of the array, insert an additional hairpin cotter into the middle hole, securing both sides. For struts in the interior of the array, slide the aluminum pin in only far enough to support the module and strut. After the adjacent module has been installed, push the pin through the next module frame and insert a final hairpin cotter.

3-hole aluminum pin with hairpin cotters

Figure 17

Page 14 ©tenKsolar, Inc., 2015

Note:

This manual assumes that the installer will be able to work from underneath the array. If that is not true, the order of assembly will be different than detailed in this manual. In that case the order of assembly will be the same as for roof-mounted systems (see REFLECT Rooftop Installation Manual TKS UIG 10008.05).

Note:

Assuming that the installer can work under the array, installation can proceed from this point either by row or by column, per installer’s preference. This manual will detail installation by row, but the principles will be the same for installation by column.

Install reflector struts, modules, 3-hole aluminum pins and hairpin cotters along this front row of the array per the steps above.

See Figure 18.

Verify that the front row is square to the first rail, and that rail spacing is correct for exact fit of modules to fins. Adjust locations of all rails except the first one as necessary.

Figure 18

Install Keeper Plugs, Torque Nuts

Insert a module keeper plug in each of the lower module frame ends. Push the module keeper plug in until it clicks into place.

See Figure 19.

This mechanically locks the module to the fin bolt. The module keeper plug can be removed by pulling on its stem.

Do not tighten the Fin Tap Bolts or Nuts until the Keeper Plugs are installed.

Figure 19

With the keeper plugs installed, torque the nuts on the fin studs that attach the modules to the fins to 9 ft-lbs.

Proper tightening of these bolts and nuts is essential for structural integrity and for proper electrical grounding. Failure to install the keeper plugs, or to torque the bolts and nuts connecting the module and reflector struts to the fins to 9 ft-lbs will void the system’s warranty.

Page 15 ©tenKsolar, Inc., 2015

Note:

You may want to install DC conductors and inverter buses as each row is completed. See page 19. This manual will describe the rest of the mechanical installation first, and then address electrical installation.

Install Reflectors

The tenKsolar REFLECT reflector is not reversible; it has defined upper and lower sides. The upper reflector frame has a hooking channel at its outer edge and the lower reflector frame does not.

See Figure 20.

Upper frame has hooking channel

Lower frame has no channel

Figure 20

Insert the lower flange of a reflector into the lower slots on the reflector struts.

See Figure 21.

Caution:

See Figure 23

for correct seating of reflector.

Figure 21

Page 16 ©tenKsolar, Inc., 2015

Slide the lower reflector frame along the tab on the reflector strut until its groove hooks onto the tab. Then lower the top of the reflector down until it rests on the strut.

See Figures 22 and 23.

Finally, push the reflector slightly up along the strut until the hooking channel on the upper frame slips over the flange of the strut. When properly seated, the reflector cannot be rotated up and out of place.

Figure 22

Caution!

Do not seat this angle on strut flange tab or reflector will be damaged when rotating into place

Groove on reflector frame hooks onto upper strut flange tab

Figure 23

Bottom edge of reflector frame hooks over lower strut flange tab

Page 17 ©tenKsolar, Inc., 2015

Install a hairpin cotter through lower hole on each reflector strut to lock the reflector in place. (You can also use the upper hole, but it will be much harder to get at when working from below the array.)

See Figure 24.

Where adjacent reflectors will be installed, do not install the cotter until both reflectors are installed.

Hairpin cotter through reflector strut locks reflector in place

Figure 24

Complete the installation of reflectors and hairpin cotters along the row.

See Figure 25.

Figure 25

Build Out Array

Build out the rest of the array section as above.

See Figure 26.

Again verify that the front row is square to the first rail, and that rail spacing is correct for exact fit of modules to fins. Adjust locations of all rails except the first one as necessary.

Page 18 ©tenKsolar, Inc., 2015

NOTE: It is recommended to omit installation of any modules and reflectors that will cover an inverter bus until the inverter bus is installed! See page 20.

Figure 26

Attach Stabilizer Cables

Attach stabilizer cables to the cap screws on the

rear two fins only

on each rail to create an "X" across the rails.

See

Figure 27.

Slip the loops on the stabilizer cables over the cap screw heads. This can be done prior to the installation of the back row of reflectors if preferred.

Figure 27

Page 19 ©tenKsolar, Inc., 2015

Electrical Installation

Install Inverter Bus

The tenKsolar Inverter Bus mounts across two adjacent rails under the tent formed by a module and a reflector. The inverter bus should be installed only on the array’s perimeter or immediately adjacent to an aisle in order to provide access to the DC distribution box.

NOTE: Omit installation of the module and reflector that will cover the inverter bus until the inverter bus is installed.

Set the inverter bus bracket feet on the two rails that will carry the inverter bus. Set it 25" forward (south) of the next fin to the north for REFLECT 26 systems, or 40 ½” for REFLECT 28 systems.

See Figure 28

. Insert two t-bolts into each rail and slide them into the slots on the inverter bus bracket feet (t-bolts and their combo nuts will be found inside the

DC distribution box on the inverter bus assembly). Orient the DC distribution box facing toward the back (north) of the array.

Install a ¼"-20 combination star washer and hex nut on each t-bolt and torque to 6 ft-lbs.

Figure 28

Install DC Conductor

The design of a tenKsolar system does not require string computations (e.g. open-circuit voltage and short-circuit current) as does a traditional serially-connected system, as the tenKsolar module’s output is voltage-regulated and current-limited. All modules are connected in parallel; 2 AWG copper or aluminum conductors are required.

The maximum current output of the module, shown on the module’s label, is not dependent on environmental and illumination conditions. It is a hard limit and will never be exceeded. Thus, by using 1) the appropriate ampacity of the 2 AWG wire selected (dependent on the environmental exposure) and 2) the maximum current output rating of the module, the maximum number of interconnected modules may be determined using the methods outlined in the

National Electric Code or other applicable codes.

CAUTION! Do not connect tenKsolar modules in series! They may only be connected in parallel.

Page 20 ©tenKsolar, Inc., 2015

In North America, only the following DC conductor types are approved for use with the tenKsolar Module:

Alcan #AWG Compact STABILOY ® AA-8030 AL Series XLPE 600 V USE-2 or RHH or RHW-2 SUN-RES, Black

Southwire AlumaFlex TM 2AWG aluminum alloy AA8176, XLP insulated, USE-2 Black

Southwire AlumaFlex TM 2AWG aluminum alloy AA8176, XLP insulated, USE-2 White

Encore Wire 2AWG Copper conductor, Cross-linked polyethylene (XLPE) XHHW-2/RW90, Black

No other conductors may be used.

tenKsolar can supply approved conductor if needed.

-The tenKsolar module features insulation displacement connectors that allow the 2 AWG conductor to be connected to the module without stripping the insulation. For the first module on a circuit (the one on that circuit furthest away from the inverter bus), place an end cap over the end of the approved conductor as shown in

Figure 29.

Figure 29

To connect the conductor to the first module, lay the conductor into the lug opening, leaving the end cap one to two inches outside of the lug opening. Be sure that the wire is lying flat within the boundaries of the wire channel in the plastic housing.

See Figure 30.

Each module has a black positive terminal and a white negative terminal. There are also corresponding plus and minus symbols on the labels. For each branch circuit, all of the positives get wired together with one conductor, and all of the negatives get wired together with a second conductor. Note that this is contrary to traditional module strings. (Refer to your DC wiring plan for branch design.) Be sure to keep track of which conductor is positive and which is negative—they should not be interchanged at the combiner box. Also, if you run more than one circuit together, do not interchange pairs of conductors. The positive and negative of each circuit must be connected to the same bus in the DC combiner box. Failure to follow these instructions will result in no generation from that branch.

Using a

3

/

16

" hex key, tighten the screw so that it just makes contact with the conductor’s insulation ("finger tight").

Then tighten the set screw 3 ¼ turns. Wait at least 10 seconds, then tighten the set screw ¼ turn more. This is equivalent to torqueing the screw to 9.5 ft-lbs. Tip:

use a marker to put an index mark on the set screw so that you can easily count the turns.

Figure 30

Page 21 ©tenKsolar, Inc., 2015

After the screw has been properly tightened, install the connector cap as shown in

Figure 31.

Note that the cap is prefilled with silicone gel. Align the cap over the lug assembly and snap into place, aligning the tabs with the slots.

Repeat the above steps for the other connector. Both positive and negative connectors must have a sealed connector cap.

Figure 31

Connect the remaining modules on the circuit using the same method. Leave at least an inch of slack between adjacent east-west connections to allow for a drip loop which will direct rainwater away from the connectors. Install connector caps on all connectors. Make sure that the drip loops of the DC conductors sag downward. Use zip ties or other means to secure the dc conductors where necessary to meet code requirements or to keep the conductors from contacting the roof or other surfaces.

Connect Modules to Inverter Bus

The inverters on the inverter bus will come prewired to each other and to the DC distribution box in the appropriate configuration for your order. To connect the modules to the inverter bus first pry off the DC distribution box door and remove the dead front cover. Make sure all circuit breakers are off. Strip ½" of insulation off the ends of the positive and negative conductors of one branch of modules.

Depending on the inverter bus model and the DC wiring plan, there will be from one to four circuits of modules that need to be connected to the DC distribution box. All of the DC conductors should enter through the centermost cord grips on the bottom of the distribution box. Connect the negative conductors to the negative terminal bars on either side of the distribution box. Connect the positive conductors to the lugs on the circuit breaker bus bars, landing each positive conductor on the same side of the DC distribution box as its matching negative conductor.

It is very important to land the positive and negative conductors of a circuit to the same side of the DC distribution box.

Torque both connections to 50 in-lbs.

See figure 32.

Page 22 ©tenKsolar, Inc., 2015

Positive conductor from Branch 1 of modules

Negative conductor from Branch 1 of modules

Positive conductor from Branch 2 of modules

Negative conductor from Branch 2 of modules

Figure 32

Tighten the cord grips finger tight plus one-half turn. Replace the dead front. You may turn the circuit breakers on at this time, but be aware that the DC voltage will rise to 59 volts and stay there. Replace the cover and secure it.

Install AC Disconnect

An AC disconnect may be required for each inverter bus, or for a group of inverter buses; check your wiring plan for specific locations. The AC disconnect will come with a back plate to be mounted onto one of the inverter bus brackets.

See Figure 33

. The AC disconnect will also come with wire whips to connect it to the inverter bus(es) (note: wire whips are not shown in the illustration).

Select the inverter bus on which you will mount the AC disconnect. Attach the AC disconnect's mounting plate to the inverter bus side bracket with four ¼"-20 x ¾" hex head bolts, four ¼" star washers, and four ¼"-20 combination star washers-hex nuts as shown in

Figure 33

.

Be sure there is a star washer on each side of the connection.

Torque the nuts to 6 ft-lbs.

Note: If the AC disconnect will be connected to two inverter buses, install it on the bracket of the northernmost of the two. If it will be connected to three inverter buses, install it on the bracket of the center inverter bus. If it will be connected to four inverter buses, install it on the bracket of one of the two center inverter buses.

Page 23 ©tenKsolar, Inc., 2015

Figure 33

The inverter AC cables are prewired to make chains of inverters. There are two types of AC chains on an inverter bus: complete chains and incomplete chains. The incomplete chains are identified by red tape on the end connectors. Each incomplete chain must be connected to an incomplete chain on an adjacent inverter bus. You can choose either of the red-taped connectors on both inverter buses, and use the supplied bus-interconnect patch cable to make the connections. There will then be two red-taped connectors left (one on each inverter bus); one should be capped and the other should connect to any of the AC disconnect whips.

The complete chains will have connectors without red tape on them. Connect each complete chain to one of the remaining AC disconnect whips. When you are finished, each AC chain should have one end capped and the other end connected to an AC disconnect whip.

If your design does not include the AC disconnects in the kit, you will need to supply your own or use a junction box.

Array Grounding

If the modules, fins, reflector struts, rails and connectors have been installed according th the instructions provided in this manual – using appropriate hardware and tightening torque – the entire assembly can be effectively grounded by use of a suitable ground lug attached to one point along one of the rails.

Page 24 ©tenKsolar, Inc., 2015

Appendix – Module Status LED Sequences

The PV module is equipped with an LED that indicates the module’s status. The LED will generally “blink” or “wink” in a five second cycle, and the number of blinks/winks within that five second cycle indicates the module’s status as shown in the following table. A blink is the LED turning on from an otherwise mostly off state, and a wink is the LED turning off from an otherwise mostly on state.

Be careful not to cast a shadow on the module under inspection while checking the LED.

LED Sequence Module Status

1 blink

2 blinks

3 blinks

4 blinks

5 blinks

6 blinks

1 wink

2 winks

3 winks

7 winks

Normal Operation

– Producing power

Output Power Reduced/Off

– Operating at max voltage

The module is limiting its output current (possibly to 0 A) because the DC voltage measured at this module is approximately 59 V. This state is normal if the inverter or battery has reached its maximum capacity or if the inverter is not connected to AC.

DC Line Potential Out of Range

(<35V or >60V) – Not producing power

This condition is normal if the module is not connected or the DC distribution box is off.

Ground Fault Detected

– Not producing power

If a single module flashes this code, turn off the DC switches in the DC distribution box, wait for one minute, and then turn the switches back on. This should clear the error. If it does not clear the error, contact a tenKsolar Applications Engineer. Multiple modules indicating this condition suggests a more serious system issue has occurred. Check all wiring for breaks or damage where possible, and consult your local electrician or installer if required. Do not contact an Applications Engineer for this condition until the integrity of all wiring has been validated.

CAUTION:

A ground fault occurring on the system represents a potentially serious condition –

DO NOT RESET THE SYSTEM WITHOUT A FULL INSPECTION OF ALL

INTERCONNECTIONS AND WIRING.

Output Power Off/Reduced

– Insufficient irradiance or partially shaded

The module will not produce power while the internal panel voltage is too low, most likely because of insufficient irradiance or the module being partially shaded. Be sure to not shade the module while monitoring the LED.

Overtemperature Protection

– Not producing power

The module output current will remain off until the internal temperature drops. Verify the module is clean on the front and the back. If the condition persists, report this to tenKsolar, but do not remove the module from the system.

Internal Fault

The module will reboot within a minute; contact a tenKsolar Applications Engineer if the problem persists.

Overcurrent Protection

– Not producing power

The output power is off, and the module will reboot within a minute.

Short Circuit Across Module Terminals

Reversed Polarity Connection

In addition to LED sequences that repeat every 10 seconds, the LED may display in the following manners:

Flashing (one second on, one second off, repeating)

Continuously On or

Continuously Off

Other

Power-Up Initialization

– If the module remains in this state for more than 3 minutes, contact a tenKsolar Applications Engineer.

Internal Fault Or Insufficient Irradiance

– Contact a tenKsolar Applications Engineer if the state persists with sufficient irradiance.

Contact a tenKsolar Applications Engineer

, and report the exact LED sequence.

CAUTION: There are no serviceable parts in the tenKsolar module; any attempt to open the module system will void the initial and power warranties.

Page 25 ©tenKsolar, Inc., 2015

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