Mounting systems Sigma tracker User manual

Sigma Tracker

Installation Manual

Photovoltaic system

Horizontal single-axis tracker as per EN 62817

Tracker name:Sigma Tracker

ENGLISH

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1Table of contents

1 Table of contents .................................................................................................................................................2

2 Product type / model ..........................................................................................................................................4

2.1 Manufacturer ................................................................................................................................................................4

2.2 Document number.......................................................................................................................................................4

2.3 Important notes about these instructions............................................................................................................4

2.3.1 Purpose of the document.....................................................................................................................................4

2.3.2 Target group............................................................................................................................................................4

2.3.3 Symbols used...........................................................................................................................................................5

2.3.4 Other applicable documents..............................................................................................................................5

2.3.5 Storage of the document.....................................................................................................................................5

2.4 Legal disclaimer ...........................................................................................................................................................5

2.4.1 Disclaimer .................................................................................................................................................................6

2.4.2 Guarantee ................................................................................................................................................................6

2.4.3 Warranty ...................................................................................................................................................................6

2.4.4 Copyright and trademarks ..................................................................................................................................6

3 Safety requirements.............................................................................................................................................7

4 List of tracker components.................................................................................................................................9

4.1 Main components........................................................................................................................................................9

5 Goods receipt, transport and storage ............................................................................................................11

5.1 Goods receipt.............................................................................................................................................................. 11

5.2 Transport and storage.............................................................................................................................................. 11

5.2.1 Storage..................................................................................................................................................................... 11

6 Installation........................................................................................................................................................... 12

6.1 Cabling ......................................................................................................................................................................... 12

6.1.1 Network ................................................................................................................................................................... 12

6.1.2 Motor cable ............................................................................................................................................................ 12

6.1.3 Sensor cables ........................................................................................................................................................ 12

6.1.4 Modbus cables...................................................................................................................................................... 12

6.1.5 Potential equalisation......................................................................................................................................... 13

6.1.6 Cable trench .......................................................................................................................................................... 13

6.2 Pile-driven support post.......................................................................................................................................... 14

6.2.1 General driving tolerances ................................................................................................................................ 14

6.2.2 Adjustment dimensions for motor stanchions .............................................................................................. 14

6.3 Post extensions and motor mount........................................................................................................................ 16

6.3.1 Tools and equipment........................................................................................................................................... 16

6.3.2 Work steps.............................................................................................................................................................. 16

6.3.3 Installing the post extensions ............................................................................................................................17

6.3.3.1 Installing the motor mount....................................................................................................................... 18

6.4 Rafter installation ...................................................................................................................................................... 19

6.4.1 Tools and equipment........................................................................................................................................... 19

6.4.2 Work steps.............................................................................................................................................................. 19

6.4.3 Install rafter ........................................................................................................................................................... 20

6.5 Adjustment device and spindle holder................................................................................................................ 21

6.5.1 Tools and equipment........................................................................................................................................... 21

6.5.2 Work steps.............................................................................................................................................................. 21

6.5.2.1 Installing the adjusting device ...............................................................................................................22

6.5.2.2 Set horizontal alignment to 0°................................................................................................................23

6.5.2.3 Mounting the spindle holder tube on post extension ..................................................................... 24

6.5.2.4 Mounting the spindle holder tube on spindle.....................................................................................25

6.5.2.5 Mounting the spindle stopper at the spindle .....................................................................................26

6.6 Installing the geared motor and chain drive .....................................................................................................27

6.6.1 Tools and equipment...........................................................................................................................................27

6.6.2 Work steps..............................................................................................................................................................27

6.6.2.1 Installing the motor....................................................................................................................................27

6.6.2.2 Installing the chain drive ..........................................................................................................................29

6.6.3 Installing the trap torsion ring........................................................................................................................... 31

6.6.3.1 Connecting the motor.............................................................................................................................. 34

6.7 Installing the torque tubes......................................................................................................................................35

6.7.1 Tools and equipment...........................................................................................................................................35

6.7.2 Work steps..............................................................................................................................................................35

6.8 Module carrier rails....................................................................................................................................................37

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6.8.1 Tools and equipment...........................................................................................................................................37

6.8.2 Work steps for installation of mono-facial module rail system...............................................................37

6.8.3 Work steps for installation of bifacial module rail system ........................................................................39

6.9 Compensation pile-driving tolerances on the torque tube ......................................................................... 42

6.10 Potential equalisation ............................................................................................................................................. 42

6.11 Module installation................................................................................................................................................... 45

6.11.1 Tools and equipment.......................................................................................................................................... 45

6.11.2 Work steps for click-stone................................................................................................................................ 45

6.11.3 Work steps for screw connection.................................................................................................................... 46

6.12 Control unit..................................................................................................................................................................47

6.12.1 General installation instructions.......................................................................................................................47

6.12.2 Electrical connection .......................................................................................................................................... 48

6.13 Frequency inverter.................................................................................................................................................... 48

6.14 Installing the tilt sensors ......................................................................................................................................... 49

6.14.1 Tilt sensor cabling connection at the sensor............................................................................................... 50

6.14.1.1 Work steps ................................................................................................................................................... 51

6.14.2 Tilt sensors calibration ........................................................................................................................................ 51

6.14.3 Wind sensor Installation .....................................................................................................................................53

6.14.3.1 Connecting the main supply .................................................................................................................. 54

6.15 Emergency power supply ....................................................................................................................................... 54

6.16 Met masts ....................................................................................................................................................................55

7 Legal information ...............................................................................................................................................57

7.1 Published by................................................................................................................................................................57

7.2 Picture credits.............................................................................................................................................................57

8 Index of illustrations...........................................................................................................................................58

9 Revision history ...................................................................................................................................................59

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2Product type / model

Product: Sigma Tracker

Abbreviation: ST

Product type: HSAT (Horizontal Single Axis Tracker)

Module installation: 2 PV modules installed vertically

The module installation, size and number of modules may vary depending on the project-

specific requirements.

2.1 Manufacturer

Mounting Systems GmbH

Tempelhofer Weg 39–47

D 10829 Berlin

GERMANY

Telephone: +49 30 328972 -100

Fax: +49 30 328972 -199

info-de@mounting-systems.com

If you have any questions, please first contact your supplier.

2.2 Document number

ST_PM_Installation Manual_EN_V1.0

2.3 Important notes about these instructions

2.3.1 Purpose of the document

This document is intended to permit the correct and safe installation and commissioning

of the product, as well as serving as a training document and reference work for power

plant operators.

Read these instructions along with all other applicable documents before starting work

and train your staff accordingly.

2.3.2 Target group

These instructions are intended for all persons representing both contracting partners,

especially professionals and trained personnel.

A professional is anyone who, by virtue of their vocational training, is able to carry out

installation and commissioning work in a correct and professional manner.

Trained personnel refer to anyone who has been appropriately trained for the assigned

tasks and instructed about the potential dangers resulting from incorrect behaviour.

A trained person must have been instructed in the necessary devices, safety measures,

relevant regulations, accident prevention guidelines and operating conditions and have

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demonstrated their ability to comprehend these. The work carried out must be signed off

by professionals.

Third parties are persons who do not have any relationship with either of the two

contracting parties.

2.3.3 Symbols used

The following symbols indicate warning and safety instructions, as well as important

information regarding various operating sequences.

Warning of a hazard

This symbol indicates that particular care and attention are required.

Warning of hazardous electric voltage

When working on or near live parts, particular care and attention are required.

This work should only be carried out by appropriately trained and authorised

professionals.

General notes

This symbol indicates important information and useful notes.

2.3.4 Other applicable documents

The following documents apply in addition to these instructions:

•Operating and maintenance instructions

•Project-specific layout drawings

•Control cabinet wiring diagrams

•Project-specific parts lists and spare parts lists

•Project-specific statics

•Reports

2.3.5 Storage of the document

These instructions should be read carefully and stored so that they are accessible to

operators of the system at all times.

2.4 Legal disclaimer

All users must be familiar with the employed warning and safety notes. It is essential to

take account of and adhere to all the specifications made in these instructions in order to

ensure safe and correct operation.

All issues relating to feed-in and technical issues must be clarified during the planning

phase with the responsible network operator (energy supply company) and

corresponding agreements made.

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2.4.1 Disclaimer

No liability or responsibility will be accepted in respect of any loss or damage resulting

from any failure to comply with the safety-related provisions set out in these instructions.

No responsibility will be accepted for the infringement of other third-party rights that

result from the use of this product.

The operator has the sole responsibility for protecting the power plant system against

access by third parties or taking additional measures to this end if required. The

manufacturer reserves the right to make changes to the technical data of this product or

these instructions without prior announcement or notification provided that such changes

do not relate to safety regulations or CE conformity.

It is prohibited to make changes to the photovoltaic system. Any misuse will result in the

cancellation of the warranty, guarantee and any liability on the part of the manufacturer.

This also includes modifications to factory-set parameters of system parts.

2.4.2 Guarantee

The product guarantee applies in accordance with the current warranty agreements, the

general terms and conditions of business and the additional contractual provisions

concluded with the supplier.

2.4.3 Warranty

The legal framework conditions of the country of manufacture apply. Any further-

reaching agreements must be set out contractually with the manufacturer prior to the

awarding of the order.

2.4.4 Copyright and trademarks

All specifications made in this documentation are confidential and are subject to

manufacturer's approval.

“Mounting Systems” is a registered trademark of Mounting Systems GmbH. Safety

requirements. The operator must ensure that each person instructed to carry out

installation work can show evidence that they have received appropriate professional

training.

This document is confidential and only for the information for the intended recipient and

may be not used, published or redistributed without the prior written consent of Mounting

Systems GmbH.

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3Safety requirements

All technicians must have read and understood these instructions and must comply with

them at all times, in order to:

•Prevent hazards to life and limb.

•Safeguard the operational safety of the tracking system.

•Rule out any system downtime or environmental impacts resulting from incorrect

handling.

Failure to comply with the safety regulations listed below may result in serious

injury or even loss of life.

All electrical work must only be carried out by trained electricians.

No work may be carried out on electronic or electrical components while they

are live.

The tracking system may only be supplied through a TN-S network system.

Only PV modules of protection class II or IEC application class A may be

installed.

Only dual-insulation DC cables approved for photovoltaics (protection class II)

may be used.

The DC cabling may only be secured to the tracker parts designated for this.

The DC cabling must be installed so that it is resistant to grounding faults and

short-circuits.

The operator must provide string monitoring through the inverters.

All work must comply with the country-specific safety regulations.

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For the entire duration of the installation and commissioning work, only

authorised, skilled specialists and authorised, trained personnel may enter the

installation area. The operator must ensure appropriate protection.

Personal safety equipment must be worn by anyone commissioned to work on

the tracking system.

The operator must ensure that nobody enters the installation area and that no

work is performed during extreme weather conditions such as storms, heavy

rain, lightning, etc.

Only original components may be used. The original components may not be

modified without the manufacturer's permission.

The photovoltaic modules may only be mounted in the safety position.

Carry out all work carefully and with the safety aspect first.

During all work, note the relevant regulations relating to safety in the

workplace and environmental protection.

Note the instructions on the type panels and warning signs throughout the

system. All signs must be recognisable, legible and free of dirt. Replace any

missing signs.

Keep fastening materials for safety devices safe if they are removed. Reattach

removed safety devices before commissioning.

Do not carry out any welding work in the area of the power plant.

Do not clean the geared motor or control cabinet with high-pressure cleaning

equipment or sharp-edged tools.

Note the permissible tightening torques of the fastening bolts.

Replace any bolts that have become unusable with new bolts of the same

strength class and design.

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4List of tracker components

4.1 Main components

Figure 1 Tracker components

Drive unit

Motor post

7-1

Motor bracket

Geared motor

Chain drive

Support post

Pile-driven support post

Post extension

Rafter

Scissors jack

Spindle holder

Torque tube

Torque tubes

Connector

Retaining rings

Module carrier

Module carrier rail

Rail connector

Module fixation rip screw

Control cabinet

Cabinet pile (optional)

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Components not shown

Mounting tools

Parameter loader with pre-programmed memory card

Control software pre-installed on memory card

Cabling (optional)

Met mast 10m (optional)

Wind sensor

Tilt sensors

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5Goods receipt, transport and storage

5.1 Goods receipt

The delivered goods may only be accepted by authorised or trained personnel.

All deliveries must be inspected immediately upon receipt for completeness and

any transport damage! The sender must be notified of any damage without

delay. The nature of the damage must be documented as accurately as possible

on the freight documents and must be confirmed by the carrier. It is advisable to

take photographs of the delivery. In the case of major damage to freight, an

expert must be consulted and the supplier must be informed. The content of the

goods delivery is listed in the shipping documents.

Do not open or damage any parts of the packaging which are designed to

preserve the goods.

Transport damage may impair the proper functioning of the components.

Do not use damaged components.

5.2 Transport and storage

The suppliers' packaging guidelines and regulations must be observed during the

entire transport chain. For individual weights and dimensions please refer to your

project-specific documents.

The weights of the individual packing units are stated on the delivery note.

Avoid excessive physical shocks and vibration.

All parts must be protected against mechanical shock and vibration during

transportation and storage. It is important to protect components against water

(rainfall), corrosion aggressive environment and excessively high/low

temperatures.

5.2.1 Storage

•The permissible ambient temperature range for transport and storage is -25°C to

+60°C.

•Geared motors, chain drives, control cabinets and other electronic components must

be stored in dry, dust-free and temperature-controlled rooms.

•All parts that are packed in boxes, such as: fixing materials, cables, sensors, etc.

should be stored in dry conditions.

•Steel parts may be stored outdoors. When storing steel parts with corrosion

protection, ensure that the items are stacked using timber liners and are well

ventilated.

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6Installation

6.1 Cabling

The cabling can be routed differently depending on the project planning

requirements.

Please find the exact details in your project-specific documents.

6.1.1 Network

Each master control unit must be connected to the other master control units via the TCP

network. The connection is made to the on-site network by means of a ground-layable

Cat 7 connecting cable. The maximum length of the connecting cable is 100 m.

The master control units must be connected to the internet to enable support and

upgrades and to synchronise the time.

With an internet connection, the network should be protected from unauthorised

access.

6.1.2 Motor cable

Each power connection in the control cabinet is connected separately to the

corresponding motor on the tracker array. This connection cable must be ground-layable

and shielded. The maximum cable length, between the motor and the frequency inverter

is 50 m, due to the voltage drop in accordance with the data sheet of the frequency

inverter.

Frequency inverter: Siemens SINAMICS V20, 400V, frame size FSA

Connecting cable: 2YSLCYK-JB 3X1.5+3G0.25 BK

Motor connection: MSWTL 25 ISO cable gland

6.1.3 Sensor cables

Each tracker array is equipped with a tilt sensor, fitted directly over the related control

unit at the rafter. The sensor cable is preinstalled at the tilt sensor.

The wind sensor is connected to the analogue input module in the master control cabinet.

The corresponding control cabinet for the wind sensor connection must be indicated in

the project-specific documents.

Sensor cable: Li2YCYv 2X2X0.34 SW

The motor cable and sensor cables must be laid in accordance with current

standards (respecting the prescribed distances).

6.1.4 Modbus cables

The slave control units must be connected to the assigned master control unit via

Modbus cable as a daisy chain. This connection cable must be ground-layable and

shielded. See the project specific documents.

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6.1.5 Potential equalisation

Via the support posts, the individual tracker arrays must be connected with each other

and to the equipotential bonding strip in the control cabinet using grounding conductors.

The control cabinets must be connected to the on-site grounding system.

Grounding conductor: round wire galvanised RD 8 (minimum cross-section as per

the relevant standard)

6.1.6 Cable trench

The exact location and dimensions of the cable trench are defined by the

project planners and are specified in your project-specific documents.

1Inverter/transformer station 4 Cable trench 7 Control cabinet

2Sigma View (optional) 5 Tilt sensor

3Wind mast 6 Motor

Figure 2 Schematic diagram of cable trench

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6.2 Pile-driven support post

The profile type, driving depth and spacing of the support posts are specially calculated

for each project and structurally verified according to the environmental and soil

conditions at the project site.

All units in mm (millimetres).

The exact dimensions are specified in your project-specific documents.

All support posts (C-sections) must be aligned so that the opening faces south.

Figure 3 Orientation of support posts

6.2.1 General driving tolerances

The support posts must be aligned as shown in the specified project tolerances

document. Deviations can lead to problems during the rest of the installation process and

may impair tracker function.

6.2.2 Adjustment dimensions for motor stanchions

1Motor stanchion 3Geared motor

2Support posts 4Geared motor

Figure 4 Support post height, geared motor post height

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Figure

5 Support post spacing

Support post

A, B The driving depth (B) and the overall length (A) of the support post depend on the

structural analysis and are specified in the project-specific documents.

CHeight above ground

The height (C) is specified in the project-specific documents

Motor post

D, E The driving depth (E) and the overall length (D) of the motor post depend on the

structural analysis and are specified in the project-specific documents.

FHeight above ground

The top of the motor post must be 122,5 mm above the support post.

The centre-to-centre distance of the two support posts before and after the motor post,

and the spacing on the north side between the support post and the motor post are

project-specific.

All other spacing intervals for the support posts and the number of posts per tracker array

may change depending on the project planning and environmental conditions and is

specified in your project-specific documents.

↓Centre-to-centre distance of the tracker array (project-specific)

 Location of the tracker

array with offset motor

post.

 Variable post spacing

(project-specific)

 Variable post spacing

(project-specific)

16/60

Once the support posts have been placed, the pile heads should be treated with

zinc dust primer. This prevents premature corrosion and thus increases the

longevity of the system.

6.3 Post extensions and motor mount

The post extensions are pre-assembled with all connections and bearing parts.

6.3.1 Tools and equipment

•Cordless screwdriver with adjustable torque or torque wrench (M12)

•Tape measure, guideline or laser level

•Spirit level, angle meter with spirit level

•Assembly jig for motor mount

6.3.2 Work steps

Check all parts for completeness and damage. Do not use damaged parts.

 Pre-assembled post extension

Weight approx. 15 kg

(The 2 "ZFM-3034-06-VS" plastic plain bearings on the upper

connector are either secured against falling out or are

delivered separately in boxes.)

 Motor mount

Weight approx. 2.8 kg

 Assembly jig

Weight approx. 1.3 kg

17/60

6.3.3 Installing the post extensions

After inserting the support posts, you can begin installing the post extensions.

1Guideline 3Fixing bolts

2Post extension 4Motor post

Always start in the centre of the array, with the two post extensions (2) north and south of

the motor stanchion (4). Attach the post extensions (2) to the centre slotted holes on the

support posts and tighten the bolts (3) by hand.

Hexagonal bolts M12x35 – ISO 4017, washer M12 – ISO 7089, hexagon nut M12 – ISO 4032.

Measure the vertical alignment with a spirit level and tighten the bolts with a torque of 90

Nm. All other post extensions should be aligned using the guideline (1) over a length of 3 to

5 posts depending on the terrain.

Figure 6 Installation of post extensions

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6.3.3.1 Installing the motor mount

After aligning and attaching the post extensions, the motor mount can be adjusted and

fixed to the motor stanchion.

1Guideline 4Motor mount

2Post extension 5Motor stanchion

3Assembly jig 6Fixing bolts

Tension the guideline (1) through the Ø9mm holes on the aligned post extensions (2).

Place the motor mount (4) on the motor stanchion (5) with the assembly jig (3) and align it

to roughly the correct height using the guideline (1). The guideline (1) should be aligned

parallel with the notch in the top of the assembly jig (3).

Slide the motor mount (4) and assembly jig (3) until there is a distance of L3 mm between

the post extension (2) and the edge of the assembly jig (3).

Now insert the bolts (6) with washers into the appropriate mounting holes and tighten by

hand. After readjusting, the bolts should be tightened with a torque of 90 Nm. The

assembly jig can now be removed.

Hexagonal bolts M12x30 – ISO 4017 (outside), washer M12 – ISO 9021 (outside), washer M12

– ISO 7089 (inside), hexagonal nut M12 – ISO 4032 (inside).

Figure

7 installing the motor mount

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6.4 Rafter installation

6.4.1 Tools and equipment

•Circlip pliers

•Soft-head hammer

6.4.2 Work steps

Check all parts for completeness and damage.

Do not use damaged parts.

 Rafter (length 3350 mm)

Weight approx. 26.5 kg

 Bolt Ø30 x 75 mm with 2 retaining rings Ø30x1.5 – DIN 471

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6.4.3 Install rafter

Please note the orientation of the rafter. The holes (6) in the rafter must be on the same

side as the connecting parts (7) on the post Extension (5).

Insert the two "ZFM-3034-06-VS" plastic plain bearings (1) into the rafter bracket (2).

Lift the rafter (3) over the rafter bracket (2) and attach it using the bolt (4).

Figure 8 Rafter installation

Secure the bolt with the retaining rings and carefully lower the rafter on the west side.

Check the placement of the "ZFM-3034-06-VS" plastic plain bearings.

The bearing should not be pushed out of the rafter bracket when the bolt is

inserted.

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