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Qcells FLEXRACK S Series Installation Manual

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S-SERIES TRACKER
Installation Manual
1
www.flexrack.com
Version – 2.4.4

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Summary of Contents for Qcells FLEXRACK S Series

  • Page 1 S-SERIES TRACKER Installation Manual www.flexrack.com Version – 2.4.4...

  • Page 2: Table Of Contents

    S-Series Tracker - Installation Manual Table of Contents Disclaimer/Clarifications ....................1 Handling and Storage Requirements: ................2 Safety Requirements ......................2 3.1. General Recommendations: ..................2 3.2. Mechanical Assembly: ....................2 3.3. Electrical Risk: ....................... 3 3.4. Tracker Operation: ....................... 3 Tracker Product Description ...................3 4.1.
  • Page 3 Updates to Landscape mounting, Construction Stow, Self Powered Cold Weather, and Pre-assembled Idler Bearings. 2.4.3 6.19.2024 Updates to Layout, Self Powered Cold Weather, and Pre-assembled Idler Bearings. Add Qcells Steel Frame module mounting details. 2.4.4 8.1.2024 Updates to pre-assembled bearing installation. Updated details to show cradle spacers www.flexrack.com...

  • Page 4: Disclaimer/Clarifications

    Please read and understand any additional installation instructions included in the project engineering drawings. Project specific installation tolerances and fastener torque values unique to the specific FLEXRACK by Qcells (FLEXRACK) product model are provided in the engineering drawings. This manual illustrates the most efficient method for installation. All sequenced instructions outlined in this manual must be followed in the correct order.

  • Page 5: Handling And Storage Requirements

    S-Series Tracker - Installation Manual FLEXRACK advises the installer to develop and implement an interim construction material stabilization contingency procedure in case a severe weather event occurs prior to the completion of the entire installation. 2. Handling and Storage Requirements: All components that are not shipped in weather sealed containers shall be stored in a dry environment to prevent damage.

  • Page 6: Electrical Risk

    S-Series Tracker - Installation Manual In addition, certain tools may generate high level noise, in such case, wear hearing protectors. 3.3. Electrical Risk: Beware of photovoltaic modules. They generate electricity as soon as they are exposed to sunlight. They must be treated as live components. Electrical operation must be carried out by qualified personnel according to the country regulation, wearing adapted protective equipment.

  • Page 7: Tracker Mechanical Components

    S-Series Tracker - Installation Manual 4.1. Tracker Mechanical Components The S-Series Tracker mechanical components consist of the following components. See Figure 4.1. 1. Drive system – One Slew drive with 24-v DC motor per row. Typically located at center of tracker. 2.

  • Page 8: Tracker Electrical Components

    S-Series Tracker - Installation Manual 4.2. Tracker Electrical Components The S-Series Tracker electrical components consist of the following components. See Figure 4.2 below. 1. Network Control Unit (NCU) – Connection point to Tracker control system and Coordinates interactions between all devices. NCU manages system alarms, communicates with TCU to verify date and time synchronization, manages safe positions.

  • Page 9: Tool List

    S-Series Tracker - Installation Manual 5. Tool List Colored Mason Line • Drill will adjustable clutch • 8 ⁄ ”, 2 ⁄ ”, ⁄ ”, 3 8 ⁄ ”, 9 16 ⁄ ”, 1- 1 16 ⁄ ”, 1- 1 4 ⁄ ” and sockets, wrenches, & ratchet •...

  • Page 10: Post Installation Tolerances

    S-Series Tracker - Installation Manual 7. Post Installation Tolerances Step 7.1: Install the drive post. After installing the drive post to the drawing specifications, install the idler posts using the installation tolerances below. W-section flanges always face the East-West direction. The drive post has a Post height Above Grade (PAG) that is higher than the idler posts (3”...

  • Page 11: Slew Drive Installation Procedure

    S-Series Tracker - Installation Manual 8. Slew Drive Installation Procedure Step 8.1: Install drive post angle mounting brackets to the flanges of the drive post. Install hardware loose. Verify hardware size with the engineering drawings. Step 8.2: Place drive post mounting top cap channel on drive post angle mounting brackets, aligning slots.
  • Page 12 S-Series Tracker - Installation Manual Step 8.3: Place slew carefully on top of drive post top cap channel and install hardware loose. Notes: Slew drive motor to face East • Motor electrical connection shall remain sealed until connection is made to TCU •...

  • Page 13: Idler Post Bracket And Sector Plate Installation Procedure

    S-Series Tracker - Installation Manual 9. Idler Post Bracket and Sector Plate Installation Procedure Predrill 1 2 ⁄ " thru-hole with hole facing North-South. Install Step 9.1 (Round Post Only): idler round post converter bracket to the top of the idler post. Step 9.2: Install pre-assembled sector plate assembly on post.

  • Page 14: Tube Installation And Alignment Procedure

    S-Series Tracker - Installation Manual 10. Tube Installation and Alignment Procedure * Steps 10.1 -10.5 may be completed simultaneously* Step 10.1: Install horizontal tubes starting at the Motor and moving outward. See connection detail below. Step 10.2: Install splice clamp connections at each tube splice location. See connection detail below.
  • Page 15 S-Series Tracker - Installation Manual Step 10.3: Install sector plate assembly such that it is centered between the inside faces of the sector cradle channel in the North-South direction. Orient the sector cradle channel so that the sides are parallel to the sector plate assembly. The shoulder bolt sleeves must be parallel with the slope of the horizontal tube.
  • Page 16 S-Series Tracker - Installation Manual Step 10.4: Use slots in the top bracket connection to the post and bearing cradle to finalize alignment of the horizontal tube. Note: Please refer to Appendix B for Bearing Installation/Inspection guidance. 23000 Harvard Road, Ste B Cleveland, OH 44122 • 216.998.5988 www.flexrack.com...
  • Page 17 S-Series Tracker - Installation Manual Step 10.5: Use the adjustment within the slew drive connection to the post to align the tube along the tracker length. Step 10.6: Once the slew drive is aligned and in the final location, tighten all slew drive fasteners (torque tube to slew drive, slew drive to post brackets, and post brackets to posts) Refer to the engineering drawings for the required torque values.
  • Page 18 S-Series Tracker - Installation Manual Step 10.7: Once the torque tube is installed and final alignment is complete, remove both cradle spacers at all idler posts. The cradle spacers are located on either side of the sector plate and are bright orange in color. 23000 Harvard Road, Ste B Cleveland, OH 44122 •...

  • Page 19: Vertical Rail Installation Procedure

    S-Series Tracker - Installation Manual 11. Vertical Rail Installation Procedure *Steps 11.1 & 13.1 may be completed simultaneously* Step 11.1: Starting at the drive post of the tracker, install vertical rail using hardware shown below. Refer to engineering drawings for vertical rail spacing and tightening instructions.

  • Page 20: Damper Installation Procedure

    S-Series Tracker - Installation Manual 12. Damper Installation Procedure Step 12.1: Dampers shall be installed on the 2 outermost posts on both ends of the tracker. Each end of the tracker shall have (1) damper attached on the west side of the tube, and (1) damper attached on the east side of the tube.
  • Page 21 S-Series Tracker - Installation Manual Step 12.1 (Cont.): Damper is attached to the torque tube using the damper tube bracket. Notes: Distance from face of sector plate assembly to center of carriage bolts on torque • tube to be 6 1 4 ⁄ " ± 1 4 ⁄ ". The lock nut between the damper and bracket must be installed snug tight prior to •...
  • Page 22 S-Series Tracker - Installation Manual Step 12.2: Damper is attached to the idler post using the damper post bracket. Adjustments made for post installation tolerances in the slots for the top bracket should match those made for the damper bracket. Notes: Please refer to engineering drawings for critical dimension between top of damper •...

  • Page 23: Direct Bolt Module Installation Procedure

    S-Series Tracker - Installation Manual 13. Direct Bolt Module Installation Procedure Step 13.1: Slide modules onto vertical rail to align the vertical rail slots to panel mounting slots. Attach module to vertical rail using module mounting hardware. Refer to engineering drawings for vertical rail positioning, spacing, and tightening instructions.

  • Page 24: Construction Stow

    S-Series Tracker - Installation Manual 14. Construction Stow Step 14.1: Trackers must be moved to stow position after tracker and module installation is verified as complete. See construction drawing for stow angle. 23000 Harvard Road, Ste B Cleveland, OH 44122 • 216.998.5988 www.flexrack.com...

  • Page 25: Tcu Installation Procedure - Grid Powered

    S-Series Tracker - Installation Manual 15. TCU Installation Procedure – Grid Powered *If tracker is self powered, skip to step 16* Step 15.1: For the grid powered solution, the tracker control unit (TCU) is to be mounted to the torque tube, underneath the nearest panel to the slew drive, on either the North or South side of the motor.

  • Page 26: Tcu Installation Procedure - Self Powered

    S-Series Tracker - Installation Manual 16. TCU Installation Procedure – Self Powered *If tracker is cold weather self powered, skip to step 17* Step 16.1: For the self powered solution, the tracker control unit (TCU) is to be mounted on the West side of the tracker, opposite the motor, to the self powered solar panel provided.
  • Page 27 S-Series Tracker - Installation Manual Step 16.2: Mount Z rails onto the torque tube on each side of the slew drive as shown. Notes: TCU buttons to face west. • Do not connect any cables unless certified. • Slew drive is shipped with the motor cable preinstalled. Motor cable can be connected to the •...

  • Page 28: Tcu Installation Procedure - Self Powered (Cold Weather Configuration A)

    S-Series Tracker - Installation Manual 17. TCU Installation Procedure – Self Powered (Cold Weather Configuration A) Step 17.1: For the self powered solution, the tracker control unit (TCU) is to be mounted on the West side of the tracker, opposite the motor, to the self powered solar panel provided.
  • Page 29 S-Series Tracker - Installation Manual Step 17.2: Mount Z rails to the torque tube, to one side of the slew drive, as shown. Please see structural drawing when determining what side of slew drive is to be mounted. There will be a larger gap, in the modules, to the north or south of the slew drive.

  • Page 30: Tcu Installation Procedure - Self Powered (Cold Weather Configuration B)

    S-Series Tracker - Installation Manual 18. TCU Installation Procedure – Self Powered (Cold Weather Configuration B) Step 18.1: For the self powered solution, the tracker control unit (TCU) is to be mounted on the West side of the tracker, opposite the motor, to the self powered solar panel provided.
  • Page 31 S-Series Tracker - Installation Manual Step 18.2: Mount Z rails to the torque tube, to one side of the slew drive, as shown. Please see structural drawing when determining what side of slew drive is to be mounted. There will be a larger gap, in the modules, to the north or south of the slew drive.

  • Page 32: Bonding Strap Installation Procedure

    S-Series Tracker - Installation Manual 19. Bonding Strap Installation Procedure Step 19.1: The bonding strap must be installed to provide a bonding path across the polymer bearings. The bonding strap comes supplied with the required hardware pre-installed on one end only. The bonding strap is to be connected to the drive post top cap channel using either the 3 8 ⁄...

  • Page 33: Logo Sticker Installation Procedure

    S-Series Tracker - Installation Manual 20. Logo Sticker Installation Procedure Apply one logo sticker per tracker. The sticker must be applied so to be clearly identified and not obstructed. The logo sticker shall be applied to the West side of the torque tube on the South side of the slew drive.

  • Page 34: Appendix A - P4Q Components

    S-Series Tracker - Installation Manual 21. Appendix A – P4Q Components Grid Powered Cable Grid & Self Powered Antenna Cable 23000 Harvard Road, Ste B Cleveland, OH 44122 • 216.998.5988 www.flexrack.com...
  • Page 35 S-Series Tracker - Installation Manual Self Powered Panel Self Powered Panel (Cold Weather) 23000 Harvard Road, Ste B Cleveland, OH 44122 • 216.998.5988 www.flexrack.com...
  • Page 36 S-Series Tracker - Installation Manual Self Powered Cable Extender Diverter Cables 23000 Harvard Road, Ste B Cleveland, OH 44122 • 216.998.5988 www.flexrack.com...

  • Page 37: Appendix B - Bearing Installation/Inspection

    S-Series Tracker - Installation Manual 22. Appendix B – Bearing Installation/Inspection Note: Steps B.1 and B.2 are required to assemble the sector plate, bearing cradle, and stamped cup brackets on site. Step B.1: Install sector plate assembly into sector cradle, making sure to extend the shoulder of the bolt through both holes on the cradle, such that weight is not applied to the threads.
  • Page 38 S-Series Tracker - Installation Manual Bearing Location Tolerance Sector plate assembly to be installed centered between inside edges of sector cradle • channel. If a distance of 5 16 ⁄ " or less is measured between plastic of sector plate assembly •...
  • Page 39 S-Series Tracker - Installation Manual Bearing Skew Tolerance Difference in distance between plastic of sector plate assembly and inside edge of • sector cradle channel at East and West shoulder bolt sleeves to be less than ± 1 16 ⁄ ". If a distance of 5 16 ⁄...
  • Page 40 S-Series Tracker - Installation Manual Bearing Slope Tolerance Slope variance measured between horizontal tube and shoulder bolt sleeves to be • no greater than ± 2° 23000 Harvard Road, Ste B Cleveland, OH 44122 • 216.998.5988 www.flexrack.com...

  • Page 41: Appendix C - Material Storage Guidelines

    S-Series Tracker - Installation Manual 23. Appendix C – Material Storage Guidelines All components are made from non-corrosive materials such as galvanized steel, stainless steel, aluminum or polypropylene or polyethylene. Galvanized components consist of zinc coating. When galvanized components are installed, air circulation over zinc creates a chemical reaction and forms a protective layer of zinc carbonate which protects the steel from corrosion.
  • Page 42 S-Series Tracker - Installation Manual What wet storage stain is not: Wet storage staining is not indicative of inferior galvanizing quality, steel corrosion, or compromised coating thickness. Wet storage staining is not an attack on previously weathered zinc surfaces which already have formed their normal protective layer.

  • Page 43: Appendix D - Bonding

    S-Series Tracker - Installation Manual 24. Appendix D – Bonding Modules are connected with two methods – one method being Direct Bolt only, the other including a bonding washer. The serrations in the bolt head and nut head bite into the materials, allowing for an electrical path to be established between the module frame and the vertical rail.
  • Page 44 S-Series Tracker - Installation Manual The bond path created with the serrated hardware (and, if necessary, the bonding washer) is then carried through the vertical rail connection to the tube. 23000 Harvard Road, Ste B Cleveland, OH 44122 • 216.998.5988 www.flexrack.com...
  • Page 45 S-Series Tracker - Installation Manual All tubes are securely fastened, bonding all tubes to each other. This electrical path is then carried through the bonding strap mentioned previously, located next to the slew drive. The bonding strap then is installed to provide a bonding path across the motor. The bonding strap is to be connected to the drive post top cap channel using either the 3 8 ⁄...
  • Page 46 S-Series Tracker - Installation Manual Option A (Aluminum Frame): Option B (Steel Frame): Note: Refer to engineering drawings for any alternate bonding strap details. 23000 Harvard Road, Ste B Cleveland, OH 44122 • 216.998.5988 www.flexrack.com...

  • Page 47: Appendix E - Cast In Place(Cip) Installation

    S-Series Tracker - Installation Manual 25. Appendix E – Cast In Place(CIP) Installation Assembly below shows a single ballast form, drive, and idler assembly. Patent U.S. 10,125,506 23000 Harvard Road, Ste B Cleveland, OH 44122 • 216.998.5988 www.flexrack.com...
  • Page 48 S-Series Tracker - Installation Manual Note: Ballast Form c-channel will arrive on site flat with prefabricated holes and notches. 2 c-channels are required to create one ballast. Step E.1: Fold the ballast form c-channel at pre-notched location. Patent U.S. 10,125,506 23000 Harvard Road, Ste B Cleveland, OH 44122 •...
  • Page 49 S-Series Tracker - Installation Manual Step E.2: Bring forms together and attach corner brace at one corner leaving the opposite corner open. Step E.3: Install the flattened tab of transverse cross braces into the slots of the ballast form and bend tab to secure braces to form. Notes: The quantity of transverse braces is dependent on the length of the form.
  • Page 50 S-Series Tracker - Installation Manual Step E.4: Install the flattened tab of longitudinal cross braces into the slots of the ballast form and bend tab to secure braces to form. Step E.5: Attach corner braces using supplied hardware. Step E.6: Using a string line;...
  • Page 51 S-Series Tracker - Installation Manual Step E.7a: Install cast in place insert using required hardware. Notes: Series of holes provided in the post for vertical adjustment. • Slots in cross braces allow for supports to be installed plumb on uneven terrain. •...
  • Page 52 S-Series Tracker - Installation Manual Step E.7b: Secure both drive posts together using required hardware. Notes: Series of holes provided in the post for vertical adjustment. • Slots in cross braces allow for supports to be installed plumb on uneven terrain. •...
  • Page 53 S-Series Tracker - Installation Manual Step E.7c: Install completed drive post using required hardware. Patent U.S. 10,125,506 23000 Harvard Road, Ste B Cleveland, OH 44122 • 216.998.5988 www.flexrack.com...
  • Page 54 S-Series Tracker - Installation Manual Step E.8: Ballast forms should be positioned based on the site layout and Engineered Stamped Drawings Step E.9: After the concrete is poured and had proper time to cure, install the remaining racking components in accordance with the installation manual and Engineered Stamped Drawings.

  • Page 55: Appendix F - Landscape Orientation

    S-Series Tracker - Installation Manual 26. Appendix F – Landscape Orientation Step F.1: Starting at the drive post of the tracker, install vertical rail using hardware shown below. Refer to engineering drawings for vertical rail spacing and tightening instructions. Final torque shall be completed after all modules are installed. Both vertical rails nearest the drive post will have a bonding strap connected under (1) nut on each side.

  • Page 56: Appendix G - Steel Frame Module Attachment

    S-Series Tracker - Installation Manual 27. Appendix G – Steel Frame Module Attachment Step G.1: Variations of the Steel Frame Vertical Rails are available based on site specific load requirements. Rails may vary in length and may include reinforcement struts. All variations of the vertical rail attach to the tube and module the same way.
  • Page 57 S-Series Tracker - Installation Manual Step G.3: Install the first module. Slide the module onto the vertical rail under the pre- installed clamps. Align the module alignment slot to the vertical rail alignment tab. Tighten down module clamps. Verify that the clamp is properly aligned with the rib in the module rails.
  • Page 58 S-Series Tracker - Installation Manual Step G.4: Install next vertical rail on the torque tube. Slide the vertical rail into position to align with the module alignment slot. Tighten the vertical rail carriage bolt at the bottom of the torque tube. Do not tighten the module clamps. Step G.5: Install the next module following G.3.

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