Wattsun AZ-225 Installation Manual

Dual-axis, azimuth drive solar tracker

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INSTALLATION GUIDE

Guide for your AZ-225 Dual-Axis, 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 Eight-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.

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

WARNING:

Tel: 505-881-7567

Fax: 505-881-7572

URL:

www.wattsun.com

Table of Contents

Summary of Contents for Wattsun AZ-225

Page 1 The tracker comes complete with all the hardware necessary for assembly and mounting the PV modules. The Wattsun™ Tracker requires a length of Eight-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.
Page 2 Copyright © Array Technologies, Inc. All rights reserved. Wattsun™ is a trademark of Array Technologies, Inc. Sixteen, BP 150 watt modules mounted on a Wattsun AZ-225 Tracker Drive. AZ-225 Installation Guide: Revision 6 Aug 2009...
Page 3 ♦ 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.
Page 4: Table Of Contents
Orient the Azimuth Gear Drive Assembly Install the Drive, Elevation Actuator & Torque Tube Installing the Module Support Frame Installing a Wattsun Solar Tracker Controller Power Connection to the Elevation Actuator Power Connection to the Tracker Controller Setting Preferences and Operating the Tracker Controller...
Page 5: Installation Of The Tracker Pipe Mast And Foundation
1.4) Use the appropriate length of 8" 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.
Page 6: Orient The Azimuth Gear Drive Assembly
Locate ‘magnetic north’ or ‘magnetic south’ using a compass and adjust your tracker setting accordingly. Your Wattsun Tracker Dealer can provide you with the Magnetic Declination for your area. The Array Technologies web site (www.wattsun.com) has links to geomagnetic data. You can find, or calculate, the magnetic declination for any place on the globe.
Page 7 VERY IMPORTANT! “OUT OF THE BOX” DRIVE ORIENTATION The AZ-225 Drive orientation is preset at the factory and referenced to Solar Noon. The drive should be mounted facing due South, (Due North in the Southern Hemisphere.). The four set bolts “dig in” to the mounting pipe and secure the drive to the pipe mast.
Page 8: Install The Drive, Elevation Actuator & Torque Tube
You will have to be able to lift the AZ-225 Drive up, over and down on top of your mounting pole. Placing the drive on top of the pipe is at least a “two person” job. The drive...
Page 9 ELEVATION ACTUATOR ASSEMBLY FOR DUAL-AXIS OPERATION: Do not unscrew the inner tube of the elevation actuator! This destroys the factory pre-set mechanical upper and lower limit switch settings. Install the elevation actuator. Center both the eyelet end (the top) of the elevation actuator inside the forks and the elevation actuator clamp eyelet (the bottom).
Page 10 AZ-225 HORIZONTAL TORQUE TUBE INSTALLATION FOR THE SMALLER 4” X 4” TORQUE TUBE Consult the diagrams below for the bolt connections. Tighten the U-bolt Nylock nuts to 70 Ft-Lbs of torque TIGHTEN NYLOCK 5/16” U-BOLT NUTS EVENLY. TIGHTEN EACH NYLOCK NUT TO 70 FT-LBS OF TORQUE.
Page 11: Installing The Module Support Frame
Each rail is u-bolted onto the horizontal “steel spine” of the tracker called a torque tube. If the rails they are longer than ten feet then an additional support under-angle is included – one for each rail. Wattsun Trackers come with all the hardware to assemble the tracker and mount the modules.
Page 12 BUILDING THE FRAME AND RACKING THE MODULES: DO YOU MOUNT ONE PIECE AT A TIME OR BUILD SUB-ARRAYS? Module Rail & Support Angle Detail One installer, one piece at a time approach. From the bottom up the Procedure is: Modules are being used to “square-up: the frame. Bolt >...
Page 13 Each manufacturer has unique hole patterns. Your mounting holes are made to accommodate either 1/4” or 5/16” module mounting bolts. The bolts are supplied with your Wattsun Tracker. Step 2 Identify your module mounting bolts and nuts from the hardware kit. The module bolts are labeled and are either 1/4”...
Page 14 Step 3 There are four bolts and nuts per module. Pre- mount the module bolts so that the serrated nuts will dig into the underside of the module frame. Do not tighten the bolt fully. Leave it about one full turn loose so it will glide easily in the module track.
Page 15 Step 6 Pull the module rail u-bolts, washers and locknuts from the hardware kit. There will be one set of u-bolt hardware per module rail. If your module rail is longer than 10 feet then there will be a corresponding support angle in your frame bundle.
Page 16 Step 9 Carefully fold up the support angle so that it makes contact with the underside of the module rail. The hole in the side face of the angle should be aligned over the side track of the module rail. The support angle connection to the side of the module requires that you slide a 5/16”...
Page 17 Step 12 Continue populating the array with the rail assemblies and solar modules. Even out the spacing between the module frames (typically 1/4” in 1/2”) and square-up the frame assembly. Go back and tighten up all the bolts and nusts left intentionally loose.
Page 18: Installing A Wattsun Solar Tracker Controller
Controller input power specifications: The input voltage range is 23 to 50 volts DC. Use a Wattsun Voltage adapter to power the controller for nominal voltages other than 24 VDC. Tracker controller wiring and drive motor wiring: Do not connect the motor output wire harness to a power source! Connecting any of the controller output...
Page 19 THE TRACKER CONTROLLER IS PREINSTALLED ON THE AZ-225 DRIVE. WARNING! MAKE THE “POWER IN” CONNECTION LAST! DO NOT ENERGIZE THE WATTSUN SOLAR TRACKER CONTROLLER UNTIL YOU HAVE COMPLETED THE ENTIRE TRACKER INSTALLATION. TWO ADDITIONAL CONTROLLER CONNECTIONS THAT GET MADE BY THE INSTALLER: Sensor mounts on the top edge of the array.
Page 20 WATTSUN TRACKER CONTROLLER: FUNCTION AND FEATURES. OVERVIEW Wattsun™ Solar Trackers utilize a patented, closed loop, optical sensing system to sense the sun’s position and track it. The sun sensors are mounted on the remote chassis and feed information to the control electronics about the direct component of sunlight available, the diffuse amount of sunlight, the total amount of sunlight as well as the differential amount of sunlight on opposing sensors.
Page 21 Terminal Controller Output Motor White Azimuth Drive Green Azimuth Drive Elevation Actuator Black Elevation Actuator...
Page 22 East-West Azimuth movement. The second pair (Red & Black) “passes through” and controls the North-South elevation movement. The Elevation Actuator power lead exits azimuth motor cover through the strain relief and will be connected to the actuator motor by the installer. AZ-225 AZIMUTH MOTOR WIRE CONNECTIONS...
Page 23 AZIMUTH MOTOR: TERMINAL STRIP WIRING DIAGRAM (POWER CONNECTIONS ARE PREWIRED AT THE FACTORY) WARNING! THE LAST CONNECTION MADE IS FROM YOUR POWER SOURCE TO THE TRACKER CONTROLLER! DO NOT ENERGIZE THE WATTSUN SOLAR TRACKER CONTROLLER UNTIL YOU HAVE COMPLETED THE ENTIRE TRACKER INSTALLATION.
Page 24 5.2) MOUNTING THE REMOTE SENSOR MOUNT THE REMOTE SENSOR ON THE TOP OF THE ARRAY The sensor mounts on the TOP CENTER (or near the center) of the PV array. Most modules already have a hole in the frame that you can use. If your modules do not have an "end hole" then you will need to drill a 1/4"...
Page 25: Power Connection To The Elevation Actuator
Section Power Connection to the Elevation Actuator Warning! Never apply power to the actuator until it has been securely bolted into place. The linear actuator will tend to "unscrew" and will destroy the preset limit switch settings. 6.1) Loosen the cover screws and remove the actuator cover. The plastic strain relief might have been inverted to protect it during shipping and hidden inside the actuator cover.
Page 26 NOTE: The azimuth-tracking limit switches are preset at the factory to accommodate the maximum range of East-West azimuth tracking. Array Technologies recommends that you power your Wattsun Tracker Controller from a battery bank or grid-tied power source. The tracker will return to the East at sunset and the tracker has 270 degrees of azimuth tracking available.
Page 27 If the installation is for a 48-volt system, then you should use a Wattsun Voltage 48 to 24 VDC ♦ Converter to reduce the voltage to the tracker controller and motors.
Page 28 CONTROLLER DIAGRAM, COMPONENTS, SWITCH SETTINGS AND FUSING Interior View of a Dual-Axis Controller for Azimuth Trackers DIP SWITCH SETTINGS Default Up Position Down Position Down Freeze Tracker - Temporary off only Normal: Auto Track Normal: Energy Integration ON: Energy Integration OFF: Lowers the voltage input threshold to power from a low state of Allow for low current sources to power the charge 24 VDC battery.
Page 29: Setting Preferences And Operating The Tracker Controller
Setting Preferences and Operating Section the Tracker Controller OVERVIEW: OPERATING THE TRACKER CONTROLLER AND SETTING THE DIP SWITCH OPTIONS. Your tracker controller is preinstalled and “ready to go” as soon as you connect power it. The following procedure tests the controllers operation, the full range of motion of the tracker and to set some field selectable options. You can turn the tracker on and off or choose to bypass the Energy Integration Circuit.
Page 30 VIEW OF A DUAL-AXIS CONTROLLER with V3.3 Sensor...
Page 31: Setting The Az Motor Limits
Section Setting the AZ Motor Limits KEEP YOUR FINGERS AND TOOLS AWAY FROM THE GEARING BENEATH THE PROTECTIVE COVER OF THE DRIVE! The limits for your tracker are preset at the factory. Please contact Array Technologies if you want to change your settings.
Page 32: Manual Control Option
Array Technologies. However it is available as an upgrade kit that can be installed in the field. The Manual Control Option requires that power be available to the Wattsun Tracker Controller. If the controller is connected to the main battery bank, then you can use the manual controls day or night. If you power the tracker controller from the array, then you will be limited to the daylight hours.
Page 33: Periodic Maintenance
Elevation Actuator: Spray the inner tube (telescoping part) of the linear actuator with a lubricating rust inhibitor. ♦ (We use LPS-3) NOTE: YOUR AZ-225 GEAR DIVE MAY HAVE THE 4 GREASE ZERK LOCATED ON THE BOTTOM OF THE GEAR HOUSING RATHER THAN THE TOP AS SHOWN IN THE PICTURE.
Page 34: Suggested Methods For Grounding A Tracker
Array Technologies does not assume any liability for your failure to adhere to the NEC. • Failure to ground your tracker may void your Wattsun Warranty and may result in damage to your Wattsun • Solar Tracker Controller or motors.
Page 35 FIG 1: GROUNDING THE MODULES, TRACKER FRAME, DRIVE AND MOUNTING PIPE The array equipment-grounding conductors, for the modules, tracker frame, drive and mounting-pipe, should terminate at one location—probably a grounding terminal strip in the junction/combiner box. Then, there should be a conductor from this point to the grounding electrode (ground rod).
Page 36 FIG 2: TYPICAL GROUNDING OF A TRACKER TO THE BATTERY BANK/POWERCENTER. The modules, Wattsun Tracker, and mounting pipe are grounded as shown in Figure 1. • The normal, (primary bond) negative-to-ground bonding is required in the power center or ground-fault •...
Page 37 FIG 3: ALTERNATIVE GROUNDING FOR A TRACKER THAT IS DISTANT FROM THE BATTERY BANK/POWERCENTER. The modules, Wattsun Tracker, and mounting pipe are grounded as shown in Figure 1. • The PV array is ground mounted some distance (perhaps over 30 feet) away from other PV components •...
Page 38: Array Technologies, Inc. Limited Warranty
Array Technologies, Inc. warrants its Wattsun™ Solar Trackers to the original consumer purchaser that it will repair, or replace, at Array Technologies Inc.’s option, any Wattsun™ Tracker component that is determined to be defective in material or workmanship for the following terms: Two years from date of purchase on all components including tracker controller, frame, azimuth drive assembly, and actuator.