TennaMINI Plug-In Solar Tracker Installation

The below are installation instructions for installing the TennaMINI Plug-In Solar tracker (#BEL-PLS2-PA).

General Notes

The TennaMINI Plug-In Solar is powered by the equipment in which it is installed. When the ignition is off, the tracker sleeps to conserve power. The tracker has a built-in backup battery that preserves settings when disconnected.

For best results, mount the tracker in an unenclosed location so that its top surface has an unobstructed view of the sky.

Safety Information

Notices

• To ensure proper adhesion, only apply VHB tape in temperatures above 50 °F. Butane torch recommended for lower temperatures to heat mounting surface.
• If screws are used to mount this Tenna product to the asset, ensure that the back side of the mounting location provides adequate clearance. Be careful not to drive screws into coolant lines, radiators, electrical wiring, fluid tanks, or moving components.
• Do not install the tracker in assets where the battery is old or depleted. Replace the asset battery or batteries if, after charging, the rest state voltage drops below 12.6 volts for a single battery or below 25.2 volts for a 24-volt dual-series battery system.
• In the case of a battery connection which is in series, the power supply for the tracker should be drawn across the full stack rather than just one battery.
• The TennaMINI Plug-In Solar power cable and ignition cable each include a weather-protected, inline fuse housing. Make sure that FUSES ARE NOT INSTALLED in the fuse housings prior to connecting the cables to power and ignition sources. Only install fuses after all wiring connections have been completed.
• Do not poke into existing wires for testing; doing so will damage the insulation, causing it to fray and corrode over time and ultimately destroy the connection.
• This product is powered by an internal rechargeable lithium battery. Recycle or dispose of lithium batteries in accordance with applicable local, state, and federal regulations.
• This device may only be shipped via ground transportation.

Tools and Materials Required

• Mobile device with Tenna App installed
• Impact Driver with 5/16” bit
• 1-inch diameter step drill bit
• Test probe or Digital Voltmeter
• Crimpers, strippers, and cutters
• Heat gun for shrinking heat-shrinkable splices and terminals to protect against weather
• 18-gauge silicone coated wire (UL3135 type) in red/black/white to match kit cabling
• Ring terminals for 18-gauge wire (crimp-on; heat-shrinkable to protect against weather)
• Butt-joint splices for 18-gauge wire (heat-shrinkable)
• Cable ties and automotive wire harness tape
• 3-amp fast-blow automotive ATC/ATO blade-type fuses
• Extension cables (available from Tenna)
• Acetone-based cleaner
• Clean, absorbent rags or towels
• Materials for your chosen mounting method (screw, magnet, or tape) as listed below

For screw mounting:

• Stainless steel self-tapping screws (included)
• Impact Driver with 1/4” bit

For magnet mounting:

• Magnet mounting kit (available from Tenna: part number CAT-MKIT-2M)
• Phillips screwdriver
• 8-mm wrench or socket

For tape mounting:

• Cutting tool (scissors, side cutters, or knife)
• Double-sided Very High Bond (VHB) tape
• Butane torch to heat surfaces

Hardware Included

• TennaMINI Plug-In Solar
• #8 x 3/4” 410 stainless self drilling screws (quantity 2)
• TennaMINI Installation Cable Kit:
  • Tracker power cable (red and black leads)
  • Ignition cable (white)
  • Breakout cable
  • 3-amp fast-blow automotive ATC blade-type fuses (quantity 2)

• Tracker power cable (left) and ignition cable (right)
  • (A) Fuse
  • (B) Fuse housing
  • (C) Connector to breakout cable

• Breakout cable
  • (A) Connector to tracker
  • (B) Connector to tracker power cable
  • (C) Connector to ignition cable

• BEW Cable Section

Test Probe

This procedure requires a test probe. You can use a digital voltage probe or a digital multimeter (DMM).

If you are using a digital voltage probe:

• Ground of multimeter should be connected to the ground used for the install. Probe the contact with the red probe.

If you are using a DMM:

• Set the meter to read DC volts.
• Ensure that the probes are plugged into the ground and voltage-measuring sockets, not into the current-measuring socket (marked A for amps).
• Double-check the meter setup before you make any test connections.
• Ensure that the meter’s ground lead is securely connected to the chassis of the asset.

For both probe and DMM:

• Measure voltages only at the connection terminals.
• Never poke into existing wires for testing as this damages the insulation

Installation Steps

Step 1: Link the Tracker to the asset in the Tenna App

1. Go to where the asset is located (so that you can see and touch the asset).

2. Open the Tenna App on your mobile device and log in.

3. Using the Search function, find and select the asset that you want to track with this tracker.

4. From the Asset page, tap Add Tracker.

5. Follow the prompts along with these installation instructions.

6. Add Hours: Observe your machine’s hours and input the hours when prompted.

Step 2: Determine the location on the asset to install the tracker

• Select the best location for the tracker:
  • Horizontal mounting is ideal (for example, on the roof of the equipment cab or cabinet).
  • Vertical mounting is acceptable provided that the top of the tracker has a clear view of the sky.
• Choose a location where the tracker is unlikely to be damaged or knocked off during normal operation of the asset.
• You can place the tracker inside the operator cab of the equipment, but do not install it under the dash or in any place where there is poor sky visibility.
• If you must enclose the tracker, use a nonmetallic housing and ensure that the tracker has good RF signal sky visibility through the enclosure. The tracker will not function well when placed inside a metal cabinet or case, or on the underside of the equipment.
• If you use screws to mount the tracker, choose a location that is not backed by any component that the screws could damage, such as coolant lines, radiators, electrical wiring, fluid tanks, or moving components.
• You must be able to route the cables from the tracker to the battery and ignition contact safely. Ensure there is:
  • No possibility of wire pinching
  • No interference with moving parts
  • No unsecured cable run
  • No swinging or dangling cable

Step 3: Clean the selected location

1. Scrape any loose debris from the surface.
2. Use the acetone-based cleaner to remove grease, oil, and dirt from the mounting location.
3. Wipe the area dry with a clean, absorbent rag or towel.

Step 4: Activate the tracker

The TennaMINI Plug-In Solar trackers ship with a light blocking sticker secured to the top of the tracker. This sticker must be removed from the tracker to activate it.

1. Remove the sticker located at the top of the device covering the light sensor.

1. Shake the tracker vigorously two to three times to activate it.
2. Hold the device’s light sensor up to direct sunlight for three seconds before mounting.

Step 5: Find an ignition-sensing voltage source

1. Ensure that the equipment ignition is in the OFF position.
2. Connect the negative lead of a DMM or digital voltage probe to the asset’s ground connection which you plan to attach the ground wire of the tracker to.
   1. See Test Probe
3. Find a location that is a candidate for the ignition source; then:
   1. Use a multimeter or probe to check the voltage. Verify that the voltage is zero.
   2. Turn on the ignition and start the equipment.
   3. With the probe, verify that the ignition source voltage is at least 12 volts.
   4. Turn the ignition to the OFF position and verify that the voltage returned to zero.
      1. If the voltage at this point cycles on and off with the ignition switch, you have found a suitable ignition-signal source.
      2. If the voltage did not drop to zero after you switched off the ignition, that connection is not an ignition-signal source. Find a suitable ignition source.

Step 6: Find a source for continuous power

Sourcing power and ignition from the alternator

This procedure can also be used with non-rolling stock.

1. Using a DC voltage multimeter probe, measure voltage on all three terminals of the alternator (Main power is usually the largest post on the alternator):
   1. For the power source: Locate a 12-volt or 24-volt (DC) source of continuous power.
      1. A suitable continuous power source usually has a red wire running to it.
   2. For the ignition source: Locate a source for non-continuous power that turns on and off in response to the ignition switch position (that is, a terminal with a wire that energizes only when the asset’s engine is running).
      1. A suitable ignition-sense terminal usually has a brown wire running to it.

The table below lists the acceptable voltage range for the continuous power source in 12-volt and 24-volt systems.

• A running vehicle will read toward the upper end of these ranges as its alternator is charging the battery.
• A vehicle in Key-Off or one with a depleted battery will read toward the lower end of the ranges.

2. Test the terminal that you identify as a candidate for the power source. Verify that voltage is present while the asset’s ignition is in the OFF position.
3. Test the terminal that you identify as a candidate for the ignition source. Verify that the voltage on this line rises to at least 12 volts when the asset is running, and drops below 3 volts when the asset is shut down.
4. Plan the cable routing path as described in the main installation procedure. (See Step 7)
5. Prepare the tracker’s power cable and the ignition cable from the TennaMINI Installation Cable Kit:
   1. Open each inline fuse housing and confirm that it is empty.
   2. Crimp on ring terminals as appropriate.
   3. Heat-shrink the insulators on the ring terminals and butt-splices (if used).
6. Connect the tracker’s power cable to the continuous power source you verified in step 2 of this procedure.
7. Connect the tracker’s ignition cable to the ignition source you verified in step 3 of this procedure.
8. After you have connected the tracker’s power cable and the ignition cable to suitable sources, resume the main installation procedure at step 8 (“Connect the breakout cable”) on page 7.
9. Ensure that the equipment ignition is in the OFF position.
10. Connect the negative lead of a DMM or voltage probe to the asset’s ground connection.
11. If you are using the alternator as the power source:
    1. Locate a DC power line (for example, a large diameter wire attached to the asset’s alternator terminal).
    2. Touch the positive probe to the terminal at the alternator connection.
12. If you are using a fuse point as the power source:
    1. Select a suitable fuse or circuit breaker.
       1. NOTE: If using an Add-a-Fuse-Kit to asset’s fuse panel, crimp wire into splice end or the Add-a-Fuse-Kit.
    2. Touch the positive probe to a terminal of the desired fuse or to a circuit breaker in the block.
13. Read the voltage at the location you selected:
    1. If voltage is present while the asset’s ignition is in the OFF position, that test point is a continuous power source.
14. Switch the asset ignition ON and verify that the power remains stable.
    1. NOTE: The voltage should gradually increase as the engine runs. If the voltage increases rapidly, the battery might require servicing or replacement.

Step 7: Plan a cable routing path

After you have decided where to mount the tracker and have found suitable sources for ignition and power, plan how you will route the cables.

Ensure that the cable routing path meets these requirements:

• All cables must be clear of any moving parts when the asset is operating.
• Cables must not extend across segments of the equipment that are routinely separated. The entire tracker installation must be on one contiguous section of the equipment.
• Cables must be able to reach the desired mounting location for the tracker without stretching and without interfering with asset operation. Extensions are available from Tenna if needed.
• Ensure that the cables will not be pulled taut or be subject to any physical stresses while the equipment is operating or in storage.

Step 8: Connect the tracker power cable to power and ground

1. Get the power cable from the TennaMINI Installation Cable Kit.
2. Open the inline fuse housing and confirm that it is empty.

3. Prepare the tracker’s constant power cable:
   1. Strip and tightly twist the loose ends of the red and black wires.
   2. Crimp ring terminals onto the stripped wire ends.
      1. NOTE: Use a size that matches the size of the screws or studs to which you are connecting. The terminals must be compatible with 18 AWG wire.
   3. Heat-shrink the insulation on the ring terminals until watertight.

• After you have attached a terminal to both the red and black wires, continue to step 4.

3. Connect the black wire of the tracker’s power cable (with terminal attached) to the asset’s alternator ground connection.

5. Connect the red wire of the tracker’s power cable (with terminal attached) to asset’s positive alternator terminal.

Step 9: Connect the ignition cable to the ignition source

1. Get the ignition cable from the TennaMINI Installation Cable Kit.
2. Open the inline fuse housing and confirm that it is empty.

3. Prepare the ignition cable:
   1. Strip and tightly twist the loose end of the ignition cable (white wire).
   2. Crimp an appropriately sized ring terminal onto the stripped wire end, or if using an Add-a-Fuse-Kit to asset’s fuse panel, crimp wire into splice end or the Add-a-Fuse-Kit.
      1. NOTE: Use a size that matches the size of the screw or stud to which you are connecting. The terminal must be compatible with 18 AWG wire.
   3. Heat-shrink the insulation on the ring terminal to provide protection against weather.
4. Connect the white wire (with terminal attached) to the ignition source you identified in step 3.

Step 10: Connect the breakout cable

1. Connect the connector on the end of the tracker’s power cable to the corresponding connector on the breakout cable.
2. Connect the connector on the end of the tracker’s ignition cable to the corresponding connector on the breakout cable.
3. Route the remaining end of the breakout cable toward the tracker’s intended location.

Step 11: Mount the tracker on the asset

Follow the instructions below for screws, magnets, or VHB tape, depending on your preferred mounting method.

Using self-tapping screws

You can use the provided self-tapping screws to mount the tracker on steel that is up to 1/8-inch thick. For thicker steel, use machine screws, magnets, or VHB tape.

1. Place the tracker in the desired location on the asset.
2. Using an impact driver with a 1/4-inch bit, drive the provided stainless steel self-tapping screws through the mounting holes of the tracker into the asset.
3. Ensure that each screw is seated securely.

Using magnets

Industrial strength magnets are a useful mounting option if the equipment is a rental, if it might be sold, or if you might want to re-purpose the tracker in the future.

1. Get magnet kit CAT-MKIT-2M and remove the parts from the bag.
2. Attach a magnet to the tracker:
   1. Insert a provided screw into the magnet from the underside (so that the blunt tip of the screw protrudes from the top side of the magnet).

   2. 

      
      
   3. Insert the screw/magnet combination up through one of the mounting holes of the TennaMINI Plug-In Solar (from the bottom of the tracker toward the top).

   4. 

      
      
   5. Place one of the provided self-locking nuts onto the machine screw where it protrudes on the top side of the tracker; then tighten the nut securely.

   6. 

      
      
3. Repeat step 2 to attach each remaining magnet to a mounting hole.
4. After you have attached both magnets to the tracker, place the tracker onto the asset at the desired location.

Using VHB tape

1. Turn the tracker upside down to expose the underside.
2. Measure the VHB mounting tape to cover the entire bottom of the mounting surface. Cut the tape to fit so that it does not extend beyond the ends of the tracker.

3. Remove the backing from the VHB tape.

4. Following the tape manufacturer’s recommendations, adhere the tracker to the clean, dry surface of the asset.

Step 12: Route the tracker cable into the asset enclosure

1. If a suitable hole does not exist, drill a 1-inch diameter hole for the tracker cable in the asset enclosure.
2. Route the tracker cable through the hole.
3. Use the grommet (already present on the cable) to plug the hole.
4. Connect the end of the tracker cable to the corresponding connector on the breakout cable.

Step 13: Secure the cables

1. Inspect the wire connections to ensure safe conditions:
   1. All wires are connected correctly.
   2. All connections are watertight.
2. Inspect the routing for the tracker’s power, ignition, breakout, and tracker cables to ensure safe conditions:
   1. Cables are not pinched.
   2. Cables are not exposed to sharp edges.
   3. Cables are not near a heat source.
   4. Cables are not near moving parts.
   5. Cables are not swinging or dangling.
   6. There are no long, unsecured runs.

Step 14: Install the fuses

The tracker uses two 3-amp (purple) fast-blow automotive ATC blade-type fuses (provided).

1. Locate the fuses provided in the TennaMINI Installation Cable Kit.
2. Insert one fuse into the fuse housing on the tracker’s ignition cable; then close the fuse housing.
3. Insert one fuse into the fuse housing on the tracker’s power cable; then close the fuse housing.

Step 15: Verify the tracker

Complete the remaining steps presented in the Tenna App to finalize and verify the installation.

Final verification from the Tenna online portal must be completed before a tracker is considered fully online.