PD-6-202 Installation Guide First Solar Single-Axis Tracker

7/21/2019 PD-6-202 Installation Guide First Solar Single-Axis Tracker

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Installation Guide:

First SolarSingle-Axis

Tracker

Global



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Table of Contents1 General Document Overview ...................................................................................................................... 4

1.1 Purpose ......................................................................................................................................... 4

1.2 Scope ............................................................................................................................................ 4

1.3 Notice ........................................................................................................................................... 5

1.4 Safety Symbols and Signal Words ................................................................................................. 6

1.5 Common Terms ............................................................................................................................ 7

1.6 Key Definitions .............................................................................................................................. 7

2 Tracker System Installation Overview......................................................................................................... 8

2.1 Tracker System Components Overview ........................................................................................ 8

2.2 Component Installation Sequence ............................................................................................. 10

2.3 Recommended Component On-Site Storage ............................................................................. 10

3 Tracker Assembly Installation ................................................................................................................... 11

3.1 Tracker Installation Drawings ..................................................................................................... 11

3.2 Tracker Assembly Images ........................................................................................................... 11



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5.1 Wire Management Drawings ...................................................................................................... 27

5.2 Controller to Actuator Cable Packaging...................................................................................... 27

5.3 Controller to Actuator Cable Labeling ........................................................................................ 28

5.4 Controller to Actuator Cable Connections to Tracker Controller ............................................... 29

6 Tracker Gateway Installation .................................................................................................................... 30

6.1 Tracker Gateway Physical Installation ........................................................................................ 30

6.2 Tracker Gateway Electrical Installation ...................................................................................... 31

6.3 Tracker Gateway Communication Installation ........................................................................... 31

7 Tracker Weather Station Installation ........................................................................................................ 32

7.1 Tracker Weather Station Physical Location ................................................................................ 32

7.2 Tracker Weather Station Electrical Installation .......................................................................... 34

7.3 Tracker Weather Station Communication Installation ............................................................... 34

8 Tracker Backup Power System Installation (optional) .............................................................................. 35

9 Commissioning .......................................................................................................................................... 36

10 Warranty Terms & Conditions .................................................................................................................. 37

11 Appendices................................................................................................................................................ 38



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1

General Document Overview

1.1 Purpose

This Installation Guide: First Solar Single-Axis Tracker (PD-6-202) is intended to provide information

concerning installation of First Solar’s single-axis tracker system in a photovoltaic power plant site. This

document may be used to plan installation of tracker system components, including developingresource estimates for installation of the tracker system components.

Failure to install, commission, operate and maintain First Solar’s tracker system in the manner described

below will void the applicable warranty (refer to the First Solar Single-Axis Tracker Warranty Terms And

Conditions (PD-5-120)).

1.2

Scope

This document is not intended to:

1.

Be a substitute for site specific drawings that details the installation.

2.

Provide details of the tracker system that may be required for permitting purposes.

3.

Suggest any unsafe installation practices.

4.

Provide guidance for designing a photovoltaic power plant incorporating the First Solar’s tracker

system. (See the Application Manual First Solar Single-Axis Tracker (PD-6-241) for design

guidance.)

5.

Provide guidance for commissioning the First Solar Tracker Product. (See the Commissioning



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1.3 Notice

Changes to certain Tracker System Components are common as First Solar continuously strives for

product improvements. All products within the same model classification remain functionally

equivalent and compatible with one another, even though there may be slight differences.

Modifications that do not impact product functionality may be made without notification.

First Solar reserves the right to make changes to design or specifications applicable to the First Solar

Single-Axis Tracker at any time without notice. Accordingly, the Buyer is responsible for verifying that

data sheets are current before placing orders or finalizing system permitting and/or design. Neither

First Solar nor its affiliates assume any responsibility for use of information furnished by First Solar or its

affiliates, nor for any infringements of patents or other rights of third parties that may result from the

use of such information. No license is granted by implication or otherwise under any patent or patent

rights of First Solar or its affiliates.

For information regarding First Solar and its products, please visit www.firstsolar.com. For technical

support, please contact [email protected].



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1.4

Safety Symbols and Signal Words

Indicates a safety hazard or unsafe practice.

Indicates an electrical shock hazard.

DANGER Indicates a hazardous situation that, if not avoided, will result in death

or serious injury.

WARNING Indicates a hazardous situation that, if not avoided, could result in

death or serious injury.

CAUTION Indicates a hazardous situation that, if not avoided, could result in

minor or moderate injury.

NOTICE Indicates information considered important, but not hazard-related

(e g messages relating to property damage)



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1.5

Common Terms

Terms Found In Site Drawings (colloquial) Equivalent Meaning (proper name)

actuator control cable controller to actuator cable

anemometer weather station

anemometer control panel weather station enclosure

battery backup power backup power system

cable wire, wiring

gateway controller gateway enclosure

gateway control panel gateway enclosure

gateway tracker control panel gateway enclosure

longitudinal retention plates longitudinal retainers

MIB module interface bracket

post pile

TIB table interface bracket

tracker anemometer tracker weather stationtracker control unit tracker controller

tracker main beam torque tube

Table 1.List of items that may be found in site design drawings and their corresponding correct definitions or equivalents.

1.6

Key Definitions



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2

Tracker System Installation Overview

2.1 Tracker System Components Overview

A high level overview of the Tracker System Components can be found in Figure 1. A description of the

Tracker System Components’ functions and typical quantities can be found in Table 2.

Figure 1. Diagram of Tracker System Components.



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Component Function Typical Quantity

Trackerassembly

Structure and mechanism that hold and point modules in thedirection of the sun (includes the actuator, table, bearings and

torque tube). Each tracker assembly holds 60 First Solar

modules.

270 to 360tracker assembliesper array. Example: 326

tracker assemblies in a 1.956

MWdc array (assuming 100 W

First Solar module)

tracker

controller

The system “brain”. The tracker controller positions trackers at

the appropriate angle based on local conditions (time, date,

wind, and user input), and provides status of trackers to the

gateway.

24 to 39tracker controllers per

array.

Tracker

gateway

The main communication hub to tracker controllers, weather

stations, backup power system, and SCADA system. The tracker

gateway aggregates data for tracker controllers of each array

and converts this data into information that is comprehensible

to the SCADA system. The tracker gateway will receive and

process information from the tracker weather stations and the

backup power systems.

1 to 3tracker gateways per

array.

Tracker

weatherstation

Collects weather information from the anemometer sensors

and broadcasts weather information over the network to thetracker gateways.

2 to 8 tracker weather stations

per project site.

(optional)

backup

power

system

(BPS)

The backup power system passes grid supplied power through

to trackers until a power outage occurs, at which time it

switches to battery backup. Included in the system are the

necessary inverters/charger and batteries. This system is

optional.

0 to 1 backup power system

per array.

Table 2. Overview of Tracker System Component function and typical quantity. See Application Manual First Solar Single-

Axis Tracker (PD-6-241)for more information about quantities.



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2.2

Component Installation SequenceInstallation of tracker assemblies involves following the general sequence of steps described in Section

3. Other system components (such as the tracker controllers, the tracker gateways, the backup power

systems, and the tracker weather stations) may all be installed in parallel to the tracker assemblies.

Once tracker assemblies are structurally complete, and the tracker controllers are installed, complete

installation of the controller to actuator cables is possible.

CAUTION Trackers shall not be considered commissioned and released for operation

until they are able to communicate with an active tracker weather station. Until that

time, trackers may generate power but must remain near or at a flat orientation

(±7.5°).Without an active tracker weather station, the trackers may not be able to

accommodate the design wind loads at extreme tilt angles.(See the Commissioning

Manual: First Solar Single-Axis Tracker (PD-6-234).)

2.3 Recommended Component On-Site Storage

First Solar recommends storing the following items indoors (prior to installation): node assembly

SD card



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3

Tracker Assembly Installation

3.1 Tracker Installation Drawings

Any drawing set for tracker assembly provided by First Solar will specify torques ranges for fasteners,

and tolerances for component locations, and will remain subject to updates. For the remainder of thisdocument, such drawing set will be referred to as the “Tracker Installation Drawings”. It is the Buyer’s

responsibility to obtain the most current drawing set for accurate information and ensure the most

current version is used.

3.2 Tracker Assembly Images

Figure 2 through Figure 10show photo images of the major tracker assembly components.

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Figure 2. Bearing assembly with view of adjustment capability. The torque tube fits into the square slot.



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(picture redacted)

Figure 3. Torque tube highlighted in red; pile highlighted in green; bearing assembly circled in yellow.

Figure 4. Torque tube interface bracket.



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(Image Redacted)

Figure 5. Actuator arm.

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Figure 6. Actuator highlighted in red, and lower actuator mount highlighted in green. The linear actuator is shown in full

extension. The lower actuator mount attaches to the pile and connects to the linear actuator’s trunnions.



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Figure 7. Torque tube and table interface brackets (TIBs); TIBs highlighted in red. TIBs and tables (Configuration A) are an

alternative to MIBs.

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Figure 8. Table highlighted in red. TIBs and Tables (Configuration A) are an alternative to MIBs.



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Figure 9. Module interface brackets (MIBs). MIBs (Configuration B) are an alternative to TIBs and tables.



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3.3

Tracker Assembly Installation Warning, Caution and NoticeStatements

WARNING Wear electrically rated PPE when working on interconnected

modules or other electrical system components.

WARNING Wear appropriate safety helmets and safety glasses (ANSI Z87.1-

2003) during installation of tracker assembly. Take appropriate precautions

when reaching overhead during torque tube installation.

CAUTION Installation is to be performed only by qualified personnel.

CAUTION First Solar’s Single-Axis Tracker should be installed according to

project site drawings.

CAUTIONDO NOT disassemble any of the bearing assemblies; assemblies are

pre-assembled and tightened to factory-specified torque, and are to be fixed

to vertical posts AS-IS. Lateral adjustments are acceptable where necessary.

CAUTIONDO NOT use bolts that have been previously tightened or pre-stressed bolts that are structurally compromised and will not retain their

strength if recycled.



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NOTICE

For maximum performance, the actuator will arrive pre-calibrated from the factory

and must be installed AS-IS to allow the First Solar’s Single-Axis Tracker to track the

sun within its specified range of motion. Install top actuator bolt first and bottom

mount last.

DO NOT remove the seal from the actuator shaft. DO NOT rotate the

actuator shaft.

DO NOT modify the actuator in any way.

Failure to comply with the above will result in voiding of the applicable

warranty, i.e., warranty provided pursuant to the First Solar Single-Axis

Tracker Warranty Terms And Conditions.

3.4 Tracker Assembly Installation Tips

Alignment of posts and bearings is a priority (slots allow precise install). Torque fasteners to proper specifications and orientation. (See relevant Tracker Installation

Drawings).

Lubricated nuts (indicated by blue or green colored wax) and non-lubricated nuts have different

torque specifications. (See relevant Tracker Installation Drawings).

The shorter of the two torque tubes must be paired with the actuator on any given tracker.

Each tracker has two torque tubes and four bearings. The two torque tubes must be situated in the

same orientation across the four bearings. If the orientation is clocked incorrectly, the tracker will

not operate correctly. See the Figure 11, section (a), for incorrect installation and Figure 11, section(b), for correct installation of torque tubes in bearings.



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3.5

Suggested Material Staging for Tracker AssemblyFigure 12shows suggested staging of materials for tracker assembly installation. In Figure 12, “Core”

refers to the lower actuator mount, actuator, bearing assembly, and actuator arm, collectively. “Drive”

refers to a path that may be taken by a skid steer or forklift in distributing components prior to

installation. The diagram only shows a portion of an array. The remainder of the array could follow a

similar staging pattern.



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3.6

Suggested Workflow for Tracker AssemblyFigure 13, Figure 14, and Figure 15 provide a suggested workflow for assembly of the tracker. As shown

in each figure, steps such as installation of the bearings with or without the lower mount can be done in

parallel. Figure 14 and Figure 15 contain details for installation of configurations A and B.

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Figure 13. Suggested workflow for tracker assembly.



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(Image Redacted)

Figure 14. Suggested workflow for tracker assembly. Configuration A uses TIBs and tables. Configuration B uses MIBs.



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3.7 Specialized Tools for Tracker Assembly Installation

Several tools are useful and recommended to render tracker assembly installation more efficient and/or

safe. These tools are summarized in Table 3. Figure 16 through Figure 20provide some images of these

tools.

Tool Purpose

lower mount spacer Locates lower actuator mount relative to the bearing.

joystick Control of the actuator without a tracker controller.

MIB installation jig Spacing tool that enables proper positioning of MIBs on torque tube.

actuator arm installation tool Proper centering of actuator arm around the bearing assembly.

actuator replacement kit Enables safe replacement of an actuator.

Table 3. Summary of tools useful for tracker assembly

Figure 16. Lower mount spacer dimensions dictated by Tracker Assembly Prints. This tool is not provided by First Solar but

can be fabricated by construction team.



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Figure 18. MIB installation jig (if configuration B is implemented).

Figure 19. Actuator arm installation tool (if configuration B is implemented).



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4

Tracker Controller Installation

4.1 Tracker Controller Physical Installation

NOTICE

If distance between top of tracker controller enclosure and the top of the pile the

tracker enclosure is mounted on is less than 8 inches, it may interfere with thetracker and movement and damage the tracker assembly.

NOTICE

If tracker controller enclosure is mounted below the 100-year flood level, then the

controller could become partially submerged during storm conditions and be

damaged.

The First Solar tracker controller is intended to be mounted on an I-Beam at a minimum of 1 ft above

grade (or 1 ft above 100-year flood level, whichever is higher). The top of the First Solar tracker

controller must be a minimum of 8 inches from the top of the pile to clear the tracker assembly. Follow

NEC 110.26 guidelines for working space around the tracker. In general this is 30 inches wide, 78 inches

high and 36 inches to 48 inches deep (76 cm x 198 cm x 91 to 122 cm).

See Appendix A and Appendix B for the two possible mounting configurations of the tracker controller.

Figure 21 shows a fully installed tracker controller.



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4.2 Tracker Controller Electrical Installation

DANGER Tracker controller enclosure must be properly grounded to avoid death or

serious injury due to electric shock.

At the end of physical installation, the tracker controller shall be provided by Buyer with an approved

conduit and shall be permanently connected to a protected branch main supply that is properly

grounded.

The wiring to provide power to the tracker controller shall comply with the national regulations of the

countries in which the appliance is to be sold.

The electrical supply provided by Buyer shall be equipped with a disconnect device to disconnect all

ungrounded AC lines. Buyer should follow standard lockout/tagout procedures for all servicing.

The tracker controller may be shipped without a cutout for AC mains input. It is the electrician’s

responsibility to cut the appropriate sized hole for the conduit in use and to plug unused cutouts with a

NEMA 4 approved hole plug.

Conduit fittings provided by Buyer shall be installed in the end-use application per local electrical codes.

Buyer will install such conduit fittings in such a manner as to not compromise the NEMA 4 ingress

protection rating of the system.

The AC input terminal block contains two each of Black, White, and Green terminal blocks. Black is for

the live voltage, white is neutral and green is earth ground. The pairs of terminal blocks are jumpered



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5

Controller to Actuator Cables (CTAC) Installation

5.1 Wire Management Drawings

Any drawing set for the tracker assembly wire management provided by First Solar will include specific

wire management component location detail on the tracker assembly and will remain subject to

updates. For the remainder of this document, such drawing set will be referred to as the “Tracker Wire

Management Drawings”. It is the Buyer’s responsibility to obtain the most current drawing set for

accurate information and ensure the most current version is used.

5.2 Controller to Actuator Cable Packaging

The CTACs will be delivered to Buyer in kits containing up to 12 cables. The CTACs will connect thetracker controllers to the actuators. One tracker controller may control up to 12 actuators. Each tracker

assembly will have one actuator. Some tracker controllers will control fewer than 12 actuators. For

such cases, extra cables not used in the kits can be set aside as spares. In some instances, it may be

possible to use a longer cable to replace a shorter one. For example, a 90 foot long cable can be used as

a spare for a 60 foot long cable if the extra slack can be appropriately looped and attached properly.

Figure 22 shows the typical numbering scheme for actuators found in the site design drawings. The

specific numbering scheme is found in the site design drawings.



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5.3 Controller to Actuator Cable Labeling

The CTACs will be labeled on each end with part number and suffix. The suffix which is the last two

numbers on the label will provide information about the cable length. Multiplying the number by 15 will

provide the length of the cable (see Table 4). For example: the cable labeled 20-00528-07 will be 105

feet long (7 × 15 = 105).

length (ft.)

20-00528 -01 15

20-00528 -02 30

20-00528 -03 45

20-00528 -04 60

20-00528 -05 75

20-00528 -06 90

20-00528 -07 105

20-00528 -08 120

20-00528 -09 135

20-00528 -10 150

20-00528 -11 165

20-00528 -12 180

20-00528 -13 195

20-00528 -14 210

20-00528 -15 225

20-00528 -16 240

20-00528 -17 255

Cable part number label



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5.4 Controller to Actuator Cable Connections to Tracker Controller

The CTACs are connected to the tracker controller on the outside of the tracker controller (see Figure

21). Figure 23provides a closer view of where the controller to actuator cables connect to the tracker

controller. On the inside of the tracker controller enclosure, the surge suppressor board (the blurred

out portion of the image) has the actuator channels numbered from A0 to A11, with the first actuator

starting at A0 or “Actuator 1” as shown in Figure 23. The site specific prints may have actuators

numbered according to Figure 22and therefore should be connected according to Figure 23.



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6

Tracker Gateway Installation

6.1 Tracker Gateway Physical Installation

NOTICE

If tracker gateway is mounted below the 100-year flood level, then the tracker

gateway could become partially submerged during storm conditions and be damaged.

The tracker gateway is intended to be mounted on an I-Beam at a minimum of 1 ft above grade (or 1 ft

above 100-year flood level, whichever is higher) using provided mounting kit.

See Appendix C for mounting configuration.

Figure 24 shows a fully installed tracker gateway.



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6.2 Tracker Gateway Electrical Installation

DANGER Tracker gateway enclosure must be properly grounded to avoid death or

serious injury due to electric shock.

At the end of physical installation, the tracker gateway shall be provided by Buyer with an appropriately-

sized conduit and shall be permanently connected to a protected branch main supply that is properlygrounded.

The electrical supply wiring to the tracker gateway shall comply with the national regulations of the

countries in which the appliance is to be sold.



The tracker gateway may be shipped without a cutout for AC mains input. It is the electrician’s

responsibility to cut the appropriate sized hole for the conduit in use and to plug unused cutouts with aNEMA 4 compliant hole plug.




The AC input terminal block contains two each of black, white, and green terminal blocks. Black is for


together to facilitate continuing AC wiring to the next device on the circuit (if any).

6 3 T k G t C i ti I t ll ti



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7.2 Tracker Weather Station Electrical Installation

DANGER Tracker weather station enclosure must be properly grounded to avoid

death or serious injury due to electric shock.

At the end of physical installation, the tracker weather station shall be provided by Buyer with an

appropriately-sized conduit and shall be permanently connected to a protected branch main supply that

is properly grounded.

The electrical supply wiring to the tracker weather station shall comply with the national regulations of

the countries in which the appliance is to be sold.



The tracker weather station may be shipped without a cutout for AC mains input. It is the electrician’s

responsibility to cut the appropriately-sized hole for the conduit in use and to plug unused cutouts with

a NEMA 4 compliant hole plug.




The AC input terminal block contains two each of black, white, and green terminal blocks. Black is for




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8

Tracker Backup Power System Installation (op-tional)

Details for installation of the Tracker Backup Power Systems can be found in the installation sections of

the User Guide: First Solar Single-Axis Tracker Backup Power System (PD-6-205).

Figure 26 shows a typical installation of the BPS. This system is optional.



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9

Commissioning

Detailed guidance for commissioning the tracker system is found in Commissioning Manual: First Solar

Single-Axis Tracker (PD-6-234). Commissioning activities with the Tracker System may begin prior to

module installation or delivery of grid power to the project site.



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10

Warranty Terms & Conditions

Please refer to, First Solar Single-Axis Tracker Warranty Terms and Conditions (PD-5-120) for warranty

terms, limitations, and product return policies.



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11

Appendices

Appendix A. Interface, Tracker Controller with Channel to Pile Flange 38

Appendix B. Interface, Tracker Controller with Channel to Pile 39

Appendix C. Kit, Interface, Gateway to Pile 40

Appendix D. Kit, Tower, Weather Station 41



www.firstsolar.com © Copyright 2014, First Solar, Inc. | PD-6-202 | REV 1.0 | Installation Guide: First Solar Single-Axis Tracker | of 42

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Appendix A. Interface, Tracker Controller with Channel to Pile Flange




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Appendix B. Interface, Tracker Controller with Channel to Pile




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Appendix C. Kit, Interface, Gateway to Pile.




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Appendix D. Kit, Tower, Weather Station



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Appendix D. Kit, Tower, Weather Station (continued)

PD-6-202 Installation Guide First Solar Single-Axis Tracker

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