Wattsun AZ-125 User manual

1
INSTALLATION GUIDE
Guide for your AZ-125, Azimuth Drive Solar Tracker
Congratulations, you have purchased the finest solar tracker available. With proper installation, your tracker will
provide years of trouble-free service while maximizing your solar power production.
Your tracker may include one of the following options: (Check your packing slip.):
♦Stainless Steel Hardware Option - Recommended for high humidity and salt laden environments.
♦Wattsun Voltage Converter Option - Required for PV Systems other than 24 VDC.
♦Manual Control Option - Exterior switches so you may manually operate the tracker.
The tracker comes complete with all the hardware necessary for assembly and mounting the PV modules. The
Wattsun™ Tracker requires a length of Six-Inch ID Schedule 40 Steel Pipe for use as the pipe mast.
Specifications for the pipe mast can be found on the data sheet for this particular tracker. The steel mounting
pipe and PV modules are not included. Your electrician should provide all additional array wiring, fusing,
power disconnects, grounding equipment and electrical junction boxes.
WARNING:
If the Wattsun™ Azimuth Solar Tracker is not installed to manufacturer’s specifications, such
failure to properly install unit may cause tracker malfunction and or serious bodily injury or
death. This tracker moves, therefore the tracker should be situated away from anybody or
anything that may come in contact with it as it moves.
KEEP CHILDREN AWAY FROM TRACKER AT ALL TIMES.
Array Technologies, Inc.
3312 Stanford NE
Albuquerque, NM 87107
Tel: [phone]
Fax: [phone]
URL: www.wattsun.com

2
Copyright © Array Technologies, Inc.
All rights reserved.
Wattsun™ is a trademark of Array Technologies, Inc.
AZ-125 Azimuth Gear Drive
Side View
AZ-125 Azimuth Gear Drive
Front View
Elevation Actuator for the
Dual-Axis Option
Wattsun Solar Tracker Controller
(Shown with Manual Control Option)
Remote Sun Sensor that connects
to the Wattsun Solar Tracker Controller
AZ-125 Installation Guide: Revision 6
AUG 2009

3
WARNING TO ELECTRICIAN OR INSTALLER
♦Please read this instruction manual completely.
♦If you are unfamiliar with NEC compliant solar electric installation, then
consult with the dealer that supplied your tracker. They should have the
skill and expertise to supply you with the necessary wiring diagrams and the
appropriate connection wire, grounding equipment, junction boxes and fusing.
♦Failure to ground the array structure, including each module frame, the
aluminum tracker frame, the drive head assembly and the pipe mast may
make the tracker susceptible to damage by lightning.
♦Do not rely on the pipe mast to act as a ground rod. It is not a reliable
substitute for a properly installed ground rod.
♦Please send in the Wattsun Tracker Warranty Card. Array Technologies
does not share any of the information provided on the warranty card.
♦Please leave this manual for the tracker owner(s). It is their property and
will help resolve any potential problems.
♦Please provide the following information for the owner:
Serial Numbers: __________________________________ ______________________________________
Serial Number located on the controller Serial Number located on the drive assembly
Tracker Type: AZ-125 Dual-Axis Option? _ Yes _ No
Controller is powered from: Battery Bank Array-Direct
System Type:
Off-Grid/Remote Home Grid-Intertie - no battery backup Grid-Intertie - battery backup
Water Pumping Other _____________________
PV Array: PV System Voltage is ______ VDC Number of Modules: __________
Module Manufacturer: ____________ Module Model: ____________
Mounting Pole Height above the Ground is: ________ FT

4
TABLE OF CONTENTS
SECTION TITLE PAGE
1
Installation of the Tracker Pipe Mast and Foundation. 5
2
Install the Azimuth Gear Drive Assembly on Top of the Pipe Mast 6
3
Install Single-Axis Bar Elevation or Actuator 8
4
Installing the Torque Tube & Module Support Frame Assembly 11
5
Installing the Tracker Controller 17
6
Power Connection to the Elevation Actuator 24
7
Power Connection to the Tracker Controller 25
8
Operating the Tracker Controller 28
9
Setting the Azimuth Drive Motor Limits 29
10
W48-24 LVC: Pre-Regulator for 48 VDC PV Systems 31
11
Manual Control Option 33
12
Periodic Maintenance 34
13
Suggested Grounding Methods for Wattsun Solar Trackers 35
14
Warranty 39

5
Section
1
I nstallation of Tracker pipe mast and foundation
WARNING! WINDY CONDITIONS CAN EXERT EXTREME FORCES ON THE ARRAY, FOUNDATION,
AND PIPE MAST OF YOUR TRACKER.
1.1)Choose an optimum solar location to install the PV array for in the ground mounting. The location should be
free from obstructions. Keep in mind that over a period of time, that trees, shrubs, etc. may grow enough to
obscure the PV array from the sun. Consult with your dealer for proper tracker spacing and alignment
regarding multiple tracker installations.
1.2)Dig an appropriate sized hole for your tracker’s foundation using a shovel, auger, or backhoe. The variables
that affect the design of the foundation include: tracker size, pipe mast height, soil conditions, geographical
location, weather and local building codes. Employ a qualified professional to design the foundation for your
tracker.
1.3)A general rule of thumb is to have an equal amount of pipe underground as above the ground and a three-foot
diameter reinforced concrete foundation. Please have a professional design the size and type of foundation
required!
1.4)Use the appropriate length of 6" ID, Schedule 40 Steel Pipe in order to leave the recommended maximum
pipe mast height protruding from ground. Consult your specific Wattsun Technical Data Sheet for the
appropriate mast height and pipe diameter size. Note: If the recommended pipe mast height is exceeded, it
may be necessary to telescope a larger diameter pipe in the lower portion and increase the foundation size in
order to withstand the increased forces exerted during windy conditions.
1.5)Cut at least two pieces of re-bar or steel angle at lengths equal to the full diameter of the foundation. Weld re-
bar onto (or drill holes and insert re-bar into) the underground portion of the pipe so that the pieces of re-bar
form an ‘x’ pattern that remains parallel to the ground. When the tracker pipe mast is completely installed, the
re-bar will be perpendicular to the pipe and parallel to the ground and protrudes radially outward into the
concrete foundation. The re-bar acts as an "anti-rotation" device and will keep the pipe from spinning in the
hole if the concrete shrinks back from the pipe.
1.6)Set the pipe into the hole and pour concrete around the pipe until it completely fills the hole. Also pour
concrete into the pipe to secure the re-bar inserted in the bottom portion of pipe. Make certain the pipe is
vertically plumb and allow concrete to set for at least 24 hours. If you fill the entire pipe mast with concrete,
leave at least one foot of hollow pipe at top for azimuth drive assembly clearance.
SIMPLIFIED TRACKER FOUNDATION DIAGRAM
(Using recommended mast height from your Technical Data Sheet)
Array Technologies, Inc. assumes no liability for your foundation installation. Please consult with a local
professional or your Wattsun Solar Tracker Dealer to design your foundation!