REFLECT Non-Penetrating Ground Mount Manual

REFLECT Non-Penetrating Ground Mount Manual
REFLECT Delta Rail Non-Penetrating Ground Mount
Installation Manual
TKS UIG 10017.01
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
tenKsolar REFLECT Delta Rail Non-Penetrating Ground Mount 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 Delta Rail Non-Penetrating System Overview...................................................................................................... 4
Hardware and Tools............................................................................................................................................................ 5
tenKsolar REFLECT 26 Fastening Hardware .................................................................................................................... 5
Recommended Tools ...................................................................................................................................................... 5
Mechanical Installation 1.................................................................................................................................................... 5
Terrain Requirements – Localized Curvature or Undulations ........................................................................................ 5
Rails................................................................................................................................................................................. 6
Site Preparation .............................................................................................................................................................. 7
Lay Out Support Blocks, Rail Pads................................................................................................................................... 7
Place First Rail ................................................................................................................................................................. 7
Install First Fin and Second Rail ...................................................................................................................................... 7
Install and Locate Front Fin ............................................................................................................................................ 9
Place a Second Set of Rails ........................................................................................................................................... 10
Install Reflector Struts .................................................................................................................................................. 10
Attach Stabilizer Cables ................................................................................................................................................ 11
Install First Module ....................................................................................................................................................... 12
Connect Module to Reflector Struts ............................................................................................................................. 13
Complete the Front Row .............................................................................................................................................. 13
Install Keeper Plugs, Torque Tap Bolts and Nuts .......................................................................................................... 14
Build Out the Array ....................................................................................................................................................... 15
Electrical Installation ........................................................................................................................................................ 16
Install Inverter Bus ........................................................................................................................................................ 16
Install DC Conductor ..................................................................................................................................................... 16
Connect Modules to Inverter Bus ................................................................................................................................. 18
Install AC Disconnect .................................................................................................................................................... 19
Array Grounding ........................................................................................................................................................... 20
Mechanical Installation 2.................................................................................................................................................. 21
Connect Stabilizer Cables and Install Reflectors........................................................................................................... 21
Install Ballast ................................................................................................................................................................. 24
Appendix I – Stabilizer Cable Placement .......................................................................................................................... 26
Appendix II – Module Status LED Sequences ................................................................................................................... 27
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 method to install the tenKsolar REFLECT System with delta rails for a non-penetrating
ground mount solution. For installation of the REFLECT system using the tenKsolar tubular rail in penetrating or nonpenetrating ground mount applications, see REFLECT Tubular Rail Ground Mount Installation Manual TKS UIG 10009.04.
The tenKsolar 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 lay out 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 Delta Rail Non-Penetrating System Overview
The tenKsolar REFLECT Delta Rail Non-Penetrating Ground Mount System array is comprised of tenKsolar Modules,
tenKsolar Reflectors, and tenKsolar Inverter Buses mounted on tenKsolar delta rails (see Figure 1) set on top of
concrete blocks or pre-cast concrete pads on reasonably flat terrain. Complete details of system assembly are
provided in this document.
The tenKsolar Module is protected by its integrated electronics to produce energy only 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 tenKsolar Module and Reflector 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.
Delta Rail Profile
(Not to array scale)
Figure 1
Page 4 ©tenKsolar, Inc., 2015
Hardware and Tools
tenKsolar REFLECT 26 Fastening Hardware
Use only specified fasteners with the tenKsolar REFLECT 26 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
Locations Used
¼" Star Washer, Stainless Steel
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
5
Fin-Module connection, Fin-Reflector Strut connection
/16" Star Washer, Stainless Steel
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
5/
16"-18
Stainless Steel Combination Hex Nut
with Star Washer
Fin-Module connection, Fin-Reflector Strut connection
Chamfered aluminum pin
Module-Reflector Strut connection
Hair Pin Cotter
Module-Reflector Strut connection, Reflector-Strut connection
Module Keeper Plug
Fin-Module connection
Recommended Tools
You will need the following tools for the proper installation of the tenKsolar REFLECT 26 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
A torque wrench with an effective working range that includes 9 ft-lbs (108 in-lbs) and a 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
tenKsolar Fin Spacing Tool - Ensures each fin is placed exactly the correct distance apart.
Mechanical Installation 1
Terrain Requirements – Localized Curvature or Undulations
The REFLECT system is designed to comply with an east-west out-of-flat condition between two wavelets of +3”/-2”
of displacement between the outside edges of any two adjacent wavelets (i.e., +3”/-2” over 13’ of width). This
tolerance is cumulative, so that an array 20 modules wide can have a total tolerance of +25’/-16’-8”. See Figure 2.
Note that for this this cumulative tolerance the terrain elevation change must be roughly uniform such that any two
adjacent wavelets comply with the +3”/-2” tolerance.
In the north-south direction (along the direction of the rails), tolerances are the same as for east-west when using the
delta rail, which supports one wavelet per rail.
Page 5 ©tenKsolar, Inc., 2015
Figure 2
Rails
You will receive two different lengths of rails with your shipment. One will be the standard rail for your system. The
other will be the front/rear rail and will be 3-3/4" longer. The two lengths will arrive on separate pallets and the
longer front/rear rails will be marked for identification in your shipment.
The front/rear rail is used as a front rail at any location in an array where another rail will not be placed immediately
to the south. It is used as a rear rail at any location in an array where another rail will not be placed immediately to
the north. Thus front rails will be used along the entire front of an array, but may also be used in the interior of an
array as it flows around obstructions. Rear rails will be used along the entire rear of an array, but also may be used in
the interior. See the plan view of an array shown in Figure 3 for examples.
Rear Rails
Front Rails
Figure 3
Page 6 ©tenKsolar, Inc., 2015
Site Preparation
Prepare your site as necessary to ensure proper drainage/erosion control and vegetation suppression.
Lay Out Support Blocks, Rail Pads
Lay out your support blocks in a grid with the blocks 5’- 10 ⅞” on center north-south and 6’- 5 ⅞” on center east-west.
Note: Concrete paving block supports will be shown in this manual. Other appropriate supports may also be used.
Place an 8” x 4” x ½” rubber rail pad on each block. See Figure 4.
South
Figure 4
Place First Rail
Place a front/rear (longer) rail across two support blocks at the front of the array. Center the north end of the rail on
the rearward block. Snap the rail pad into the rail so that half of the pad protrudes. Snap the rail pad on the front
block into the rail with none of it protruding. See Figure 5.
Front Pad Snaps
Completely into Rail –
None of it Protrudes
Half of Pad Snaps into Rail –
Remainder Protrudes for
Subsequent Rail
Front (South) Rail
Use Longer
Front/Rear Rail
Figure 5
Install First Fin and Second Rail
The fins connect the modules and reflector struts to the rails. They come pre-assembled with necessary hardware as
shown in Figure 6. Fins are asymmetrical and must be oriented correctly. The upper bolt connects to the reflector
strut and the lower bolt connects to the module.
Page 7 ©tenKsolar, Inc., 2015
Threaded stud for module
(toward back – north – of array)
Reflector strut bolt (toward
front – south – of array)
Figure 6
Slide the base of a fin into the rear (north) end of the rail. See Figure 7. The threaded stud should be to the back
(north) end of the array.
Allow the star washer to slide into the rail with the fin foot. The star washer is an integral part of the electrical
grounding system. See Figure 8.
Figure 7
Page 8 ©tenKsolar, Inc., 2015
Figure 8
Place a standard (shorter) rail to the north of the first, leaving a ⅜” gap. Snap the rail onto the first rail’s rail pad. Snap
the pad at the other end into the rail leaving about 4” protruding. Slide the fin rearward so that its base is centered
across the two rails. See Figure 9. Tighten the fin’s two ¼"-20 × ⅝" cap screws to 6 ft-lbs to secure it to the rails.
Center Fin Across
the Two Rails
Shorter Standard Rail
Figure 9
Install and Locate Front Fin
Slide a fin into the end of the front rail. Do not tighten the cap screws yet. Use the fin spacing tool to set the correct
distance between fins. The fin spacing tool will arrive, with instructions, bolted in its collapsed state for easy
transport; assemble it to its expanded state before use.
Page 9 ©tenKsolar, Inc., 2015
Place the slot in one end of the assembled fin spacing tool over the threaded stud in the fin connecting the two rails.
Shift the rear fin until the slot in the other end of the fin spacing tool drops over its tap bolt. Once the fin has been
properly located by the fin spacing tool, tighten the fin’s two ¼"-20 x ⅝" cap screws to 6 ft-lbs. See Figure 10.
It is not advised to tighten, loosen, and re-tighten the ¼"-20 × ⅝" cap screw – for instance if disassembling, moving,
and then re-assembling an array – more than five times without replacing the rail.
Fin-Spacing Tool
Figure 10
Place a Second Set of Rails
Repeat the above steps to assemble another two-rail section on the blocks to the east or west of the original section.
See Figure 11.
Figure 11
Install Reflector Struts
Install two reflector struts onto the northernmost fin on each rail. See Figure 12. Use the fin's 5/16"-18 x ¾" cap screw
and 5/16"-18 combo nut and star washer to attach the lower ends of the struts (see inset) to the west side of each fin.
For now, do not tighten, and allow the struts to rest on the rails.
Page 10 ©tenKsolar, Inc., 2015
The lower end of the strut
has slots in its flanges.
The small slot goes up.
Figure 12
Attach Stabilizer Cables
For wavelets that require stabilizer cables (see Appendix 1 for cable placement guidelines), they should be attached
to the front fins prior to installing the module. Slip the loop of one end of a stabilizer cable over the rear cap screw of
the front fin. See Figure 13. For the time being, leave the other ends of the cables unattached.
Page 11 ©tenKsolar, Inc., 2015
Figure 13
Install First Module
Orient a module with its electrical connector lugs to the east or west, per your wiring plan. Slip the slots in the
module’s frame over the fin tap bolts, in the space between the fins. Adjust the spacing between rails as necessary to
accommodate the module. See Figure 14. Be sure that the dog-leg slot in the module frame seats properly on the
fin tap bolt. See Figure 15.
Figure 14
Page 12 ©tenKsolar, Inc., 2015
Figure 15
Connect Module to Reflector Struts
Lift the reflector struts and line up the upper holes in the struts with the holes in the module frame. Starting on the
array perimeter side of module, use a chamfered aluminum pin, with a hairpin cotter inserted in the flat end hole, to
attach the upper ends of the struts to the modules. Insert a second hairpin cotter into the aluminum pin to lock the
module and reflector strut together. See Figure 16.
Figure 16
On the other side of the module, toward the center of the array, insert an aluminum pin with one hairpin cotter into
the module slot and reflector strut hole far enough to hold them together. Once the adjacent module is installed,
insert another hairpin cotter to lock the two modules and the reflector strut together.
Complete the Front Row
Add more two-rail columns to the east or west of the wavelet already constructed to complete the first row of the
array section. See Figure 17.
It is essential to keep the array square. Use a line or laser to ensure that the front fins are closely
aligned along the East-West direction. See Figure 17. Be sure that the rails are in a straight line northsouth and are perpendicular to the line established by the front row of fins.
Ensure that the front fins are
closely aligned along the east-west
direction, square to the first rail
Page 13 ©tenKsolar, Inc., 2015
Figure 17
Install reflector struts, modules, aluminum pins and hairpin cotters to complete the front row of the array per the
steps above. See Figure 18.
Figure 18
Install Keeper Plugs, Torque Tap Bolts and Nuts
Insert a Module Keeper Plug in each of the lower Module frame ends in the completed row. Push the Module Keeper
Plug in until it clicks into place. This will mechanically lock the Module to the Fin bolt. See Figure 19. The Module
Keeper Plug can be removed simply by pulling on its stem. Do not tighten the Fin Tap Bolts or Nuts until the Keeper
Plugs are installed.
Figure 19
Once the keeper plugs are installed, torque the nuts that attach the modules to the fins, and those that attach the
reflector struts to the fins to 9 ft-lbs.
Page 14 ©tenKsolar, Inc., 2015
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 modules
and reflector struts to the fins to 9 ft-lbs will void the system’s warranty.
Build Out the Array
Install reflector struts and modules as described above on the rest of the array section. See Figure 20. Do not install
reflectors yet.
NOTE: It is recommended to omit installation of any module that will cover an inverter bus until the inverter bus is
installed! See page 16.
Note: You may want to connect DC conductors to the modules in each row as it is completed. See page 17.
Figure 20
Page 15 ©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 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, 25" forward (south) of the rail end. See
Figure 21. 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 21
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 aluminum or copper 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.
In North America, only the following DC conductor types are approved for use with the tenKsolar Module:
Page 16 ©tenKsolar, Inc., 2015




Alcan 2 AWG Compact STABILOY ® AA-8030 AL Series XLPE 600 V USE-2 or RHH or RHW-2 SUN-RES, Black
Southwire AlumaFlex TM 2 AWG aluminum alloy AA8176, XLP insulated, USE-2 Black
Southwire AlumaFlex TM 2 AWG 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 22.
Figure 22
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 23.
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 23
Page 17 ©tenKsolar, Inc., 2015
After the screw has been properly tightened, install the connector cap as shown in Figure 24. 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 24
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 thermal contraction and 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 25.
Page 18 ©tenKsolar, Inc., 2015
Positive conductor
from Branch 1 of
modules
Positive conductor
from Branch 2 of
modules
Negative conductor
from Branch 2 of
modules
Negative conductor
from Branch 1 of
modules
Figure 25
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 26. 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 26. 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 19 ©tenKsolar, Inc., 2015
Figure 26
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 20 ©tenKsolar, Inc., 2015
Mechanical Installation 2
Connect Stabilizer Cables and Install Reflectors
Once an array section is completed with all other parts, it is time to install the reflectors. While assembly of the rest of
the array begins at the front (south) of the array and proceeds toward the back (north), installation of the reflectors
begins at the back of the array and proceeds toward the front.
Before installing a reflector on any wavelets that have stabilizer cables attached to their front fins, complete the
stabilizer cable installation. Make an “X” across the wavelet with the cables and slip their back loops over the forward
cap screw of the fins at the rear of that wavelet. See Figure 27. The installed cables will be slightly slack.
Figure 27
The RAIS XT 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 28.
Upper frame has
hooking channel
Lower frame
has no channel
Figure 28
Page 21 ©tenKsolar, Inc., 2015
Start along the back (north) row of reflector struts. Insert the lower flange of a reflector in the lower slots on the
reflector struts. See Figure 29.
Figure 29
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 30 and 31. 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 30
Page 22 ©tenKsolar, Inc., 2015
Figure 31
Install a hairpin cotter through either of the small holes on each reflector strut (one by upper flange, one by lower
flange) to lock the reflector in place. See Figure 32. Where adjacent reflectors will be installed, do not install the
cotter until both reflectors are installed.
Figure 32
Page 23 ©tenKsolar, Inc., 2015
Complete the installation of reflectors and hairpin cotters along the back row. This can be done while standing on the
north side of the array.
Move to the next row to the south. Install reflectors by standing in the space between the back row modules and the
modules in the next row to the south, facing toward the back of the array. Seat the bottom of the reflector as
previously. Then while holding the top edge of the reflector, step out of the reflector space and lower the reflector
onto the struts. From the side of the reflector, push the reflector slightly up along the strut until the hooking channel
on the upper frame slips over the flange of the strut. Do not install hairpin cotters yet.
Complete installing all reflectors in that row. Then move to the space between modules in the next row to the south.
Reach over the modules to install reflector-locking hairpin cotters in the row of reflectors you just installed. Then
install reflectors in that row, and install hairpin cotters by reaching over the modules from the next space forward.
Once the final, southernmost, row of reflectors is installed, move to the very front of the array and reach over to
install hairpin cotters.
Install Ballast
Determine the required quantity and location of ballast based on the wind loading for your site in consultation with
your structural engineer. Ballast hardware is designed for standard 16" x 8" x 4" concrete blocks.
For up to four standard blocks (generally 140 lbs) per rail on a wavelet, use ballast hooks to install ballast. Install a
ballast hook in the rail at one end of the where the block will be placed. Add another at the other end of where the
block will be placed. Lay the block onto the ballast hooks. Then insert a ballast hook plate into the notch of each
ballast hook. Additional ballast blocks can be installed on either side of the first one, using the other half of the ballast
hook as a starting point. See Figure 33.
Figure 33
Page 24 ©tenKsolar, Inc., 2015
Whenever installing ballast under the northernmost wavelet in an array section, and for any wavelets that require
larger quantities of ballast blocks than can be accommodated with ballast clips, use ballast rails to mount the
ballast. Construct a ballast tray by placing two aluminum ballast rails across the top of the rails. See Figure 34. The
tabs on the ballast rails will locate them on the array rails to receive the ballast blocks across their width dimension.
The ballast rails have double-stick tape on the bottom. Peel the release paper off the tape and locate them on the
roof rails.
Ensure that the ballast rails are adhered to the roof rails to ensure the structural integrity of the array.
Place ballast blocks as close as possible to the most outboard rail of the rail pair they span. Should you need more
than 220 lbs of ballast under a wavelet, construct a second ballast tray. Be sure extra rail pads have been installed
under ballast locations as indicated in ‘Additional Pads” on page 8.
Figure 34
Page 25 ©tenKsolar, Inc., 2015
Appendix I – Stabilizer Cable Placement
Stabilizer cables must be installed on all array sections according to the following rules:

Every other north row wavelet, including all NE and NW corners. North row, in this context, includes “indented”
sections on the north of the array that are wider than two wavelets.

Along the easternmost and westernmost two columns, again including indented sections, fill in the diagonals, like
black squares on a checkerboard.
See the example arrays below. Stabilizer cables are marked with an “X.”
South
Page 26 ©tenKsolar, Inc., 2015
Appendix II – 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
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
3 blinks
4 blinks
5 blinks
6 blinks
1 wink
2 winks
3 winks
7 winks
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 27 ©tenKsolar, Inc., 2015
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