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Table of Contents
Summary of Contents for AllEarth Renewables AllSun Tracker 20 Series
- Page 1 Instructions for INSTALLATION MANUAL AllSun Tracker Series 20 & Series 24 AllEarth Renewables, Inc. 94 Harvest Lane • Williston, VT 05495 Phone 802-872-9600 info@allearthrenewables.com • www.allearthrenewables.com AllSun Tracker Above Ground Installation Instructions...
- Page 2 AllSun Tracker installation. This installation manual assumes that a base (helical pile, precast or pour-in-place) has already been installed and is ready to receive the mast for the AllSun Tracker. AllEarth Renewables, Inc. 94 Harvest Lane • Williston, VT 05495 Phone 802-872-9600 info@allearthrenewables.com •...
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Page 3: Table Of Contents
TABLE OF CONTENTS Revision Table ..............Recommended Tools List ..........Heavy Equipment Requirements ........Taking Apart the Pallet ............Installing the Mast ............Precast Base and Custom Pour Base ......Preparing Can Assembly ........... Installing Provided Inverter ..........Preparing Provided Inverter .......... -
Page 4: Revision Table
REVISION TABLE Changed in Version of Description of Change Date of Change Page Number(s) * Manual Complete Update 7/15/13 Inverter Switch 10/15/13 11-13 Anemometer point of use instructions added to 10/15/13 packaging Module clamp profile modification to help 10/15/13 promote proper installation Rail layout updates 11/20/13 Ground wire updates... - Page 5 FRAME ASSEMBLY LIFTING & HANDLING...
- Page 6 ADDITIONAL TOOLS AllSun Tracker Above Ground Installation Instructions...
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Page 7: Heavy Equipment Requirements
INSTALLATION HEAVY EQUIPMENT REQUIREMENTS GROUND WORK Concrete Base • Capability to excavate soil for concrete precast or pour-in-place concrete base (6'+ depth) • Capability to install rock anchors into ledge for custom pour bases in poor soil conditions • Capability to handle 4,200 lb precast Helical Pile •... -
Page 8: Taking Apart The Pallet
TAKING APART THE PALLET Pallet parts Complete pallet 240/208 V Load Center 277 V Load Center Small box hardware > 1408 Large box hardware > 1407 DIRECTIONS • Remove straps • Remove plywood from ends of pallet • Remove rails from inside of beams. Each beam contains three rails for the Series 20 Tracker or four rails for the Series 24 Tracker. -
Page 9: Installing The Mast
INSTALLING THE MAST NOTE : Crew could be split, part working on installing the mast and preparing the assembly, preparing the inverter and installing the can assembly. The other part of the crew could simultaneously work on putting together the entire rail and frame assembly. The process for installing the mast differs according to the type of base: screw-in, precast or poured concrete. -
Page 10: Precast Base And Custom Pour Base
PRECAST BASE & CUSTOM POUR BASE Required Tools: Required Parts: 1 - 5/8" wrenches 1” - 8 Galvanized nuts Compass 1" Hardened washers Magnetic Level 1" Direct Tension Indicating (DTI) washers Precast base with flat washers Mast installed on precast base DIRECTIONS Thread nuts down as far as possible on studs and place 1 washer over each nut ▪... -
Page 11: Preparing Can Assembly
PREPARING THE CAN ASSEMBLY Attaching straps through can holes Preloaded top of mast Can assembly on pallet strap Required Tools: Required Parts: 3/4" Drive torque wrench Can assembly 3/4" Drive, 1 1/16” socket ½ 5/8” - 11 x 1 - "... -
Page 12: Installing Provided Inverter
INSTALLING PROVIDED INVERTER REQUIRED TOOLS REQUIRED PARTS 3/8" Battery impact driver 4.2 or 6 kW Power One inverter 3/8” Drive, 9/16” impact socket Inverter mount bracket #2 Phillips head screw driver 3/8” Self-tapping screws 3/8" Drive, 3/8” socket ½ ” Cord grip 3/16"... - Page 13 INSTALLING PROVIDED INVERTER For 6 kW inverter (and equivalent physical size Power-One inverters) Install inverter bracket onto can by first attaching by UPPER screw holes ▪ only, using (2) 3/8” self-tapping screws Attached Power-One factory inverter bracket to AllSun Tracker inverter ▪...
- Page 14 PREPARING THE SUPPLIED INVERTER ▪ Install (2) 1” cord grips in the bottom of the DC disconnect Install 1/2” cord grip in the rightmost knockout (as shown) ▪ Route communications cable through wire duct and install in terminal blocks as shown ▪...
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Page 15: Installing Dealer-Supplied Inverter
Mount inverter to the generic mount bracket, drill holes in bracket as necessary ▪ CONTROL BOX: When using an inverter that is not compatible with the AllEarth Renewables ▪ monitoring system (see AER Tech Note 0033 Inverter Support for details), remove communication cable and plug hole with provided plug ▪... -
Page 16: Installing Can Assembly
INSTALLING THE CAN ASSEMBLY preloaded bolts Installing can assembly; applying Loctite 263 to bolts Dropping SO cable down mast "Face Hole North" indicator DIRECTIONS ▪ Lift can assembly above mast ▪ With can assembly over mast, drop black SO cable down inside mast and out the hole on North side of mast as shown Orient can assembly so the "FACE HOLE NORTH"... -
Page 17: Frame & Rail Assembly
FRAME & RAIL ASSEMBLY Cylinder Mount Bracket Cylinder Cross Beam Bracket Beam Right Coupling Bracket 6' Beam Axle Left Coupling Bracket Black UHMW Block 8' Beam Large Black HDPE Washer 6' Beam Required Tools: 3/8" Battery impact driver 3/8” Drive, 9/16” impact socket ¼... -
Page 18: Assembling Frame Components
ASSEMBLING FRAME COMPONENTS DIRECTIONS 2-8' beams required ▪ Slide (2) UHMW bearing blocks into the end of the 8' beams ▪ When the center holes in the blocks line up with the 6th large hole from the end of ▪ the beam, insert (8) lag screws into the pilot holes. -
Page 19: Assembling Frame
ASSEMBLING FRAME DIRECTIONS Slide one large plastic washer onto each end of the axle ▪ Slide end of axle through bearing blocks in cross beams with the long side on the same side as the ground wire on axle ▪ ▪... -
Page 20: Assembling Rails
ASSEMBLING RAILS Required Parts: SERIES 20 (24) Rail pieces (96) 3/8” - 16 x 1” Geomet bolt (96) 3/8” - 16 Geomet Spiralock nut The Series 20 middle rail has a wider profile ▪ and nests on top of the top and bottom sections ▪... - Page 21 SERIES 20 Overlap: Table 1.1 Overhang on Joint Overlap Module Width Overlap of Joint I Overlap of Joint II Overall Length Bottom of Frame Frame Beam? 31.5 157.5 24.5 31.5 - 31.75 158.75 24.5 31.75 - 32 25.75 32.01 - 32.25 161.25 25.75 32.26 - 32.5...
- Page 22 SERIES 24 Overlap: Table 1.2 Overlap of Overlap of Overlap of Joint Overall Overhang on Bottom Joint Overlap Module Width Joint 1 Joint II Length of Frame Frame Beam? 32.51 - 32.71 196.25 43.25 32.72 - 32.92 197.5 44.5 32.93 - 33.13 198.75 44.5 33.14 - 33.33...
- Page 23 SERIES 24 Overlap: Table 1.2 (Cont.) Overlap of Overlap of Overlap of Joint Overall Overhang on Bottom Joint Overlap Module Width Joint 1 Joint II Length of Frame Frame Beam? 39.80 - 40.00 65.75 40.01 - 40.21 241.25 65.75 40.22 - 40.42 242.5 40.43 - 40.63 243.75...
- Page 24 SEE TABLES ON PAGES 19 - 21 FOR CORRECT OVERLAP - Use Table 1.1 for the Series 20 and Table 1.2 for the Series 24 to determine the correct overlap of rails. The Series 20 uses three pieces of rail to make one full section; the Seriest 24 uses four pieces for each full section, except for modules that are less than 32.5"...
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Page 25: Mounting Rails
MOUNTING RAILS Required Parts: Rail assemblies: 3 sections for Series 20 & 4 sections for Series 24 (32) 3/8” - 16 x 1” Geomet bolt (32) 3/8” - 16 Geomet Spiralock nut Inserting bolts AllSun Tracker Above Ground Installation Instructions | 25... - Page 26 INSTALL RAIL OVER SECOND HOLE FROM THE END OF BEAM DIM FROM TABLE 1.1, 1.2, or 1.3 DETAIL B 16 1/8" INSTALL RAIL ON BRACKET USE PUNCH OR POINTED BAR TO REMOVE KNOCKOUTS 22 9/16" DETAIL A DIRECTIONS ▪ Layout rails as shown (above) * When supplying modules, verify that the layout meets manufacturer requirements ▪...
- Page 27 RAIL ASSEMBLY LAYOUT Inside Outside Attach rail assembly to beam using two bolts in cross pattern Inside Outside If overlapping joint lands on a beam, bolt through beam in three places. BEFORE PROCEEDING: • Vertify that all rails are correctly positioned •...
- Page 28 DIM FROM TABLE 1.1, 1.2, or 1.3 16 1/16" 22 9/16" CENTERLINE AllSun Tracker Above Ground Installation Instructions | 28...
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Page 29: Mounting Trim
MOUNTING TRIM Required Parts: Trim channels Trim coupler plates (40) 3/8” - 16 X 1” Geomet bolt (40) 3/8” - 16 Geomet Spiralock nut Frame with mounted trim DIRECTIONS: Place three trim channels over end of rails on frame ▪ top and bottom, leg with holes goes on bottom as shown Bolt trim on using (2) 3/8”... -
Page 30: Installing Frame
INSTALLING FRAME & RAIL ASSEMBLY ON TO MAST ASSEMBLY Required Parts: Frame Weight Fully assembled frame with rails & trim Series 20: ~ 975 lbs. (12) 3/8” - 16 x 1” Geomet bolt Series 24: ~ 1,100 lbs. (12) 3/8” - 16 Geomet Spiralock nut Required Tools: 3/8"... - Page 31 Bolting axle to can Bolt axle to can assembly with (12) 3/8” bolts facing in. ▪ Be sure to catch the two internal stiffening brackets on the ▪ indicated holes Torque all bolts to 25-40 ft-lbs ▪ ▪ Unhook slings from frame internal stiffening bracket 2 bolts pick up stiffening brackets (both sides) ▪...
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Page 32: Installing Pv Modules
INSTALLING PV MODULES Required Parts: Required Tools: 3/8" Battery impact driver Series 24: 3/8” Drive, 9/16” impact socket Series 20: Ratchet Strap (24) PV Modules (20) PV Modules 6” Wood block (96) PV Clamps (80) PV Clamps Side cutting pliers (96) 3/8”... - Page 33 Wiring Diagram II: Series 24 Two Strings Connect to inverter leads AllSun Tracker Above Ground Installation Instructions | 33...
- Page 34 INSTALLING PV MODULES First open hole Installing second row of PV modules PV modules flush with trim Correct placement of bolt DIRECTIONS Modules will be oriented per previous diagrams. The lowest row will be flush with the outside of the trim ▪...
- Page 35 INSTALLING PV MODULES Installing fourth row of PV Using chainfall to tilt frame Using the same sling, tilt the frame back over center in the opposite direction ▪ Strap frame in place with 6" wood block between the frame and mast ▪...
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Page 36: Wiring Array
WIRING ARRAY Required Tools: Required Parts: Side cutting pliers (33) Black zip ties SS wire clips DIRECTIONS: All of the wiring with the exception of the connections to the ▪ PV leads should be completed while populating the array Using (4) zip ties per row (2 on each side of array) route ▪... - Page 37 WIRING ARRAY Use SS wire clips where wire crosses panels and PV wires cannot ▪ be tied into a rail ▪ Check polarity of strings and land DC leads in the inverter disconnect DO NOT trim DC leads, coil excess wire as show along back of ▪...
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Page 38: Installing Anemometer
INSTALLING ANEMOMETER DIRECTIONS: • While frame is tilted back, install anemometer boom with White + flat side against trim using (2) 1/4” U bolts has shown; Black - torque to 8 ft-lbs • Install anemometer boot and anemometer onto boom and insert cotter pin through boom, tighten setscrew •... -
Page 39: Installing Dc Guard
INSTALLING DC GUARD Required Parts: SERIES 20 SERIES 24 Coroplast sheets Coroplast sheets Screw anchor (12) Screw anchor Required Tools: Hand drill #2 Phillips driver bit Sliding coroplast panels Wire management DIRECTIONS: • Slide coroplast panels down from above, between the second and third rails from the end, prior to the third row of PV panels being installed. -
Page 40: Load Center Installation
LOAD CENTER INSTALLATION: 240/208V Sites Required Parts: Square D load center 40 amp breaker 15 amp breaker Self drilling screws Tooth lock washers ½ ” Strap connector Required Tools: 3/8" Battery impact driver 3/8” Drive, 3/8” socket Wire stripper up to 8GA ¼... - Page 41 LOAD CENTER INSTALLATION: 240/208V Sites Mount the load center to the mast by installing 4 self drilling screws ▪ into the mast through the mount bracket Install the 40amp breaker into the leftmost space in the load center ▪ and the 15amp breaker into the rightmost ▪...
- Page 42 LOAD CENTER INSTALLATION: 277V Sites Required Parts: Cooper Bline Enclosure 40 amp breaker 15 amp breaker Self drilling screws Ring terminals ½ ” Strap conector Strap connector installation Required Tools: 3/8" Battery impact driver 3/8” Drive, 3/8” socket Wire stripper up to 8GA ¼...
- Page 43 LOAD CENTER INSTALLATION: 277V Sites Wire L2 into the top of the terminal blocks to the left of the breakers ▪ as shown Crimp the 8GA ring terminal onto the ground and install on the left ▪ stud as shown ▪...
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Page 44: Power Up
POWER UP Voltage Jumper Setting voltage jumper Remove cover on control box ▪ Set voltage jumper to match grid voltage ▪ ▪ Use the 15 amp breaker in the load center to power up the tracker Use the 40 amp breaker in the load center to power up the inverter ▪... -
Page 45: Calibration
CALIBRATION BEEP CODES: 2) All OK 3) No anemometer. LE3 blinks when anemometer is spinning Align shadow with vertical lines 4) Inverter not connected or DC off Calibration on module button 5) Dongle missing or faulty 6) No GPS fix 7) Windhold active 8) Motor cooling West... -
Page 46: Installing Allsun Plaque
INSTALLING ALLSUN PLAQUE Required Parts: AllSun Plaque #2 3/4” Self Drilling Pan Head Stainless Steel Screws Required Tools: Battery Drill #2 Phillips Bit for drill DIRECTIONS: Locate as shown in the picture and attach using the supplied screws ▪ IMPORTANT: Do not over-tighten or you will strip the sheet metal ▪...
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