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Sigma Tracker

Installation Manual

Photovoltaic system

Horizontal single-axis tracker as per EN 62817

Tracker name: Sigma Tracker

ENGLISH

Summary of Contents for Sigma Tracker

Page 1: ...Sigma Tracker Installation Manual Photovoltaic system Horizontal single axis tracker as per EN 62817 Tracker name Sigma Tracker ENGLISH Copyright 2020 Mounting Systems GmbH All Rights Reserved...

Page 2: ...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 Installin...

Page 3: ...ent 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 in...

Page 4: ...ermit 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 o...

Page 5: ...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 i...

Page 6: ...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 gen...

Page 7: ...fe 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 t...

Page 8: ...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...

Page 9: ...t 7 Motor post 7 1 Motor bracket 11 Geared motor 12 Chain drive B Support post 6 Pile driven support post 5 Post extension 3 Rafter 9 Scissors jack 9 Spindle holder C Torque tube 10 Torque tubes 10 Co...

Page 10: ...yright 2020 Mounting Systems GmbH F Components not shown F1 Mounting tools F2 Parameter loader with pre programmed memory card F3 Control software pre installed on memory card F4 Cabling optional F5 M...

Page 11: ...aged 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 yo...

Page 12: ...nd 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 inve...

Page 13: ...e 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 loca...

Page 14: ...ons 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...

Page 15: ...specific documents F Height 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 t...

Page 16: ...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...

Page 17: ...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...

Page 18: ...y 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...

Page 19: ...tems GmbH 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...

Page 20: ...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 Se...

Page 21: ...Circlip pliers Soft head hammer Spanner ring spanner and torque wrench M6 M8 Tape measure spirit level 6 5 2 Work steps Check all parts for completeness and damage Do not use damaged parts Adjusting d...

Page 22: ...ings 2 Connecting duct 5 Rafter 3 Nut with groove Insert the adjusting device 1 so that the integrated nut 3 which is marked with a groove always points north An incorrect installation direction will...

Page 23: ...o compensate for this align the rafter 5 to 0 horizontally using the spirit level While doing so rotate the threaded spindle to the right or left by hand 4 full 360 rotations of the spindle will resul...

Page 24: ...dle holder tube 6 Retaining nut Align the Spindle holder tube 3 and secure it with the hexagonal bolt 4 as illustrated Ensure that the thrust washer 5 is installed between the Spindle holder tube 3 an...

Page 25: ...e spindle holder 4 into the retaining clamp 5 and press both parts by gently bending them around the non threaded part of the threaded spindle 1 Spindle holder tube 3 should be centrally aligned with...

Page 26: ...g clamp must be secured using spindle stoppers on both sides as described below This construction prevents the plastic spindle holder from travelling on the spindle threads and damage of the scissor j...

Page 27: ...gs end sleeves 6 6 2 Work steps 6 6 2 1 Installing the motor 1 Geared motor weight approx 30 kg 2 Motor mount 3 Fixings Place the geared motor 1 on the pre installed motor mount 2 The motor mount 2 an...

Page 28: ...ld rest against the outer surfaces of both the post extensions 3 north and south of the motor stanchion Align the geared motor parallel with the guideline 1 and the lateral surface of the gear box foo...

Page 29: ...GmbH 6 6 2 2 Installing the chain drive Check all parts for completeness and damage Do not use damaged parts Chain drive with ball bearings pre installed Weight approx 23 kg Counterweight Weight appr...

Page 30: ...f present pull off the protective skin Apply sliding paste to the shaft against corrosion 2 Turn the chain until the keyway of the gear shaft 2 and the groove of the pinion on the chain drive 1 are al...

Page 31: ...2 Pan counter drill scwM8x12 4 Square nut M8 To install the trap torsion ring Pos 1 dissemble the M12x20 with big washer Install on both sides the ring with screw split washer and nut Fasten the screw...

Page 32: ...ain drive 1 using the fixings 3 as shown hand tight approx 30 Nm Hexagonal bolt M10x70 ISO 4014 2x washer M10 ISO 7089 Hexagonal nut M10 ISO 4032 Figure 17 Installing the counterweights Chain lubricat...

Page 33: ...Tighten the screws by hand An accurate level of torque can be specified by securing the plastic cover with a lock washer The protective cover 1 contains 3 holes at the bottom These allow dirt and moi...

Page 34: ...e post section using pipe clips 2 Figure 19 Installing the motor cable The protective covers must be installed before connecting the motor The motor may only be operated with the protective covers ins...

Page 35: ...1 tilted downwards slide the left torque tube 4 over the connector and repeat these steps for the right side C D Now push both torque tubes 4 to the outside so that the chain drive 1 can be tilted up...

Page 36: ...0 Mounting Systems GmbH A B C D E F Figure 21 Torque tubes drive unit Now connect all threaded spindles using the torque tubes 4 The lengths may vary depending on the spacing between the support posts...

Page 37: ...e module number configuration and the structural requirements The precise distances and lengths are specified in the project specific part lists and layout drawings Example L1 Length of module carrier...

Page 38: ...ng the first module carrier rail 2 on the rafter 1 and securing it with two module rail mounting clamps 3 per rafter and a tightening torque of 18 Nm Figure 23 Installing the module carrier rail 1 The...

Page 39: ...the purlins on the north side of the tracker array by placing the first purlin 2 on the rafter 1 and securing it with cross rail connectors 3 per rafter and a tightening torque of 10 Nm Then lay the...

Page 40: ...he module frames and the modules are to be screwed directly onto the module rails Place the module on the module carrie rails and slide it over the pre drilled holes in the profile Slide in the module...

Page 41: ...9 Connectors for C Purlins N S fixed left variable right Various module rail distance can be realized using the slotted holes as shown above on the right Place the connector against the rear of the mo...

Page 42: ...tion is an important part of electrical protection Therefore this must be implemented precisely as described here To prevent high contact voltages all components that come into contact with live equip...

Page 43: ...talled so that it is resistant to grounding faults and short circuits Anticipated external influences such as wind ice formation temperatures and sunlight must be taken into account Cables and wiring...

Page 44: ...e connected to the equipotential bonding strip 2 in the control cabinet 1 1 Tracker array 2 Support post 3 Equipotential bonding strip 4 Control cabinet Support post 5 Grounding conductor Figure 32 Co...

Page 45: ...ion refer to your project specific documents Use only the designated clamps with the clamping system The middle clamps must be fitted with a grounding plate The module clamps are specially adapted to...

Page 46: ...ideline 6 Middle clamp Start with the installation of the modules on an expansion joint 4 by laying the first module 1 on the module carrier rails 2 and installing it using precise measurements At the...

Page 47: ...st only be carried out by qualified electricians and while the system is not live Please refer to the respective assembly instructions provided by the base supplier The control cabinet must be install...

Page 48: ...t be routed to the frequency inverter Analog Input connection AI 1 and AI 2 6 13 Frequency inverter Setting the basic parameters using the parameter loader For information about operating the V20 freq...

Page 49: ...inverter to a consecutive MODBUS address from 1 to the number of tracker arrays in the system This MODBUS address should match the tracker numbering on the control panel The numbering of the control p...

Page 50: ...The shielding for the tilt sensors must cover a large area The sensor cable must be routed via the provided empty cable duct 6 14 1 Tilt sensor cabling connection at the sensor Prefabrication of Senso...

Page 51: ...gether Fix the Sensor together with junction box and sensor cable at the module rail and the control unit One sensor at the south rafter one sensor at the north rafter As shown in the following figure...

Page 52: ...ue must not exceed 50 3 in the horizontal orientation Make a note of the deviation as E 0 50 r0754 0 3 Correcting the sensor value To change the value of the first sensor you must adjust the parameter...

Page 53: ...followed The Sensor cable needs to be grounded The installation of the wind sensor must be carried out by an authorized technician The functionality of sensor cable should be teste before the cable i...

Page 54: ...ctrical data is included in your project specific documents As the inverter has an increased ground leakage current the minimum cross section of the PE conductor must be observed 6 15 Emergency power...

Page 55: ...that the entire plant is covered with a radius of 400 m per met mast Figure 45 Met masts and wind zones position The mast foundation must be designed according to the wind loads Each met mast must be...

Page 56: ...20 Copyright 2020 Mounting Systems GmbH Figure 46 Position of the name plate Once all systems have been commissioned the power plant is operational Nevertheless all functions should be observed and mo...

Page 57: ...of the texts or illustrations used in these instructions is not permitted These instructions may not be copied or transferred disclosed or translated in any form or using any medium without the publis...

Page 58: ...tor 34 Figure 21 Torque tubes drive unit 36 Figure 22 Installation dimensions for module carrier rails 37 Figure 23 Installing the module carrier rail 1 38 Figure 24 Installing the module carrier rail...

Page 59: ...016 LEMB First version 01 26 01 2017 LEMB Technical adjustment 02 27 01 2017 LEMB Technical adjustment 05 27 09 2017 FRHE Adjustment to Sigma Tracker 1 6 06 07 12 2017 FRHE Adjustment to current versi...

Page 60: ...Tel 49 30 328972 100 Fax 49 30 328972 199 info mounting systems com www mounting systems com Mounting Systems GmbH Mittenwalder Strase 9a D 15834 Rangsdorf Germany Tel 49 33708 529 100 Fax 49 33708 5...

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