Assembly Instructions for the InteliTrack 3000 Rail Tracking System

Transcription

1 Assembly Instructions for the InteliTrack 3000 Rail Tracking System InteliTrack is a trademark of Sedona Solar Technology. Sedona Solar Technology 16 April

2 1. Before you begin WARNING Safety equipment needed: Hard hat Safety goggles Ear plugs Work gloves Tools and other equipment needed: Torque wrench SAE socket set The frame array has moving parts that can cause injury if handled improperly during assembly and operation. Use appropriate safety equipment including gloves, hard hats, and eye protection, and keep hands clear of areas where unsecured components may move. Follow the directions in this manual for safe, proper setup of the tracking system. SAE open-end wrench set Pliers lineman s, needle-nose, and channel-lock Figure 1: Safety equipment Laser level or string line 4 ratchet straps 8 foot length, minimum working load 500 pounds Rubber mallet Socket adapters and extensions Tape measure at least 25 feet Impact driver or cordless drill* * Optional but highly recommended. List of parts: See Bill Of Materials included with individual packages. Sedona Solar Technology 16 April

3 2. Posts 2.1 Posts are customer-supplied parts. 2.2 The minimum length of 48 inches includes 6 inches of clearance. Adjust length accordingly if more clearance is needed for snow, grass, etc. Length increase must meet local codes and wind loads. 2.3 Posts can be pounded posts, helical piles, ground screws, or set in concrete, depending on soil conditions and local codes, and must be engineered. 2.4 Engineering can be done locally or by Tower Engineering Professionals ( which provides this service to Sedona Solar Technology customers. 2.5 Recommended post material: 4-inch diameter schedule 40 galvanized steel pipe. 2.6 Post spacing see Figure 2. Number of frames Spacing west-to-east Configuration W W-E W-C-E W-C-C-E W-C-C-C-E W-C-C-C-C-E 2.7 Install the ground posts in a secure foundation. 2.8 The posts must be installed to within ± 1 inch in all directions. Figure 2: Post spacing Sedona Solar Technology 16 April

4 3. Overview of assembled tracking system 3.1 Axes of motion Assembly Instructions InteliTrack 3000 System The system is configured to move in two axes to track the sun. The motion around the elevation axis (Figure 3) tilts the array toward the north in winter (in the northern hemisphere) and more nearly horizontal in the summer. Figure 3: Elevation axis Sedona Solar Technology 16 April

5 The motion of the radial axis moves the panels to track the sun from east to west through the day. Figure 4: Array at summer position Figure 5: Array at winter position Sedona Solar Technology 16 April

6 3.2 Array configuration Up to six frames can be joined together to make a single array or rail. Each array will have one West frame (Figure 6), one East frame (Figure 7), and up to four Center frames (Figure 8). Note the differences in the corners where each rail meets a crossbeam. Figure 6: West frame Figure 7: East frame Figure 8: Center frame Sedona Solar Technology 16 April

7 3.3 Actuator placement Elevation actuators are placed as shown in Figure 9. Figure 9: Actuator placement Sedona Solar Technology 16 April

8 The radial actuator is placed near the center of the array, as shown in Figure Controller placement Figure 10: Radial actuator placement The controller is mounted on the west-most post in the array. 4. Frame assembly 4.1 Post clamp installation Locate all post clamps one for each frame plus one at the end of each array Mount one post clamp to each post in the array, with two ½ u-bolts to each post in the array, tightening all nuts evenly to finger-tight locate the highest post clamp in the array Set the laser level elevation to the center of the holes on the top of each post clamp. (See Figure 11.) Adjust the height of all the other post clamps to match that of the highest clamp, using the laser level Torque all the u-bolts. Note: When the post clamps are properly aligned, it will be possible to look through all the mounting holes. Sedona Solar Technology 16 April

9 Figure 11: Post clamp locations 4.2 Saddle bracket installation see Figures 12 and Locate the saddle brackets one for every post clamp Verify that all the bushings are fully pressed into the saddle brackets Install a saddle bracket over each post clamp with a clevis pin. Figure 12: Saddle bracket installation Figure 13: Saddle bracket installation Sedona Solar Technology 16 April

10 4.3 Crossbeam installation Figures 14 and Locate a crossbeam Install the crossbeam on the furthest saddle bracket to the west, using four bolts Install crossbeams on each remaining saddle bracket. Figure 14: Crossbeam installation Figure 15: Crossbeam installation Sedona Solar Technology 16 April

11 4.3.4 Locate four rail end angle brackets and four crossbeam end angle brackets Install four crossbeam angle brackets onto the crossbeams in the locations shown in Figure 16, with the orientation shown. 4.4 Rail installation Locate one top rail and one bottom rail. Figure 16: Crossbeam angle bracket installation Install grommets in all 1 holes in both rails Install the rail end brackets onto the rails as shown in Figures 17 and 18. Note: Rail end brackets will have different spacing for the crossbeams at both ends of the frames. Rails mating to end crossbeams install as shown in Figure 17. Rails mating to middle crossbeams install as shown in Figure Using two ratchet straps, secure the southern end of each crossbeam to the mounting posts to prevent crossbeams from moving during installation of the bottom frame rail Mount the bottom rail to the crossbeam using bolts as shown in Figures 19 and 20. Make sure the grommets face inside the frame Flip the frame so that the installed rail is now on the high side, and secure the frame with ratchet straps Install the top rail in the same way Using a tape measure and a square, check to make sure that the frame is square to within Sedona Solar Technology 16 April

12 Figure 17: Rail end bracket- end crossbeam Sedona Solar Technology 16 April

13 Figure 18: Rail end bracking - center crossbeam Sedona Solar Technology 16 April

14 Figure 19: Mounting the lower rail to the end crossbeam Figure 20: Mounting the lower rail to the middle crossbeam Sedona Solar Technology 16 April

15 4.5 Installation of middle frames Assembly Instructions InteliTrack 3000 System Locate one crossbeam for each saddle bracket, two middle rails per frame, four rail end angle brackets per frame, and four crossbeam end anble brackets per frame Install the crossbeams on all saddle brackets as shown in Figure 21. Figure 21: Crossbeam installation Install two crossbeam angle brackets on each crossbeam as shown in Figure Install two rail end angle brackets on each rail spacing holes as shown in Figure Use two ratchet straps to secure the West frame to the post clamps, with the bottom rail down Use the remaining two ratchet straps to secure the next two crossbeams in the array to their posts with their south ends down Install bottom rails, using two bolts at each end of each rail Move ratchet straps down the array as needed to secure the next crossbeam before installing the next rail When all the middle frame bottom rails are installed, flip the frame and use the ratchet straps to secure the array for top rail installation Install all top rails using two bolts at each end of each rail. Sedona Solar Technology 16 April

16 Figure 22: Rail end angle bracket installed 4.6 Installation of elevation actuators Sedona Solar Technology 16 April

17 4.6.1 Locate the elevation actuator bracket assemblies two per array Locate two post actuator bracket assemblies two per array Locate two actuators Position the actuators according to Figure Install post actuator bracket assemblies as shown in Figure Install the elevation actuator bracket assemblies as shown in Figure Install actuators on each post actuator bracket as shown in Figures 25 and Repeat for all other elevation actuators in the system. Figure 23: Post actuator bracket Sedona Solar Technology 16 April

18 Figure 24: Elevation actuator bracket assembly Sedona Solar Technology 16 April

19 Figure 25: Actuator installation Figure 26: Actuator installation on crossbeam Sedona Solar Technology 16 April

20 4.7 Installation of lever arms Locate lever arms four per frame Install lever arms into the frames as shown in Figures 27 and Check for free movement of each lever arm. Figure 27: Lever arm installation Sedona Solar Technology 16 April

21 Figure 28 Lever arm installation Sedona Solar Technology 16 April

22 4.8 Carrier arm installation Locate the carrier arms one for each frame Locate the carrier arm coupler kits one for each junction between carrier arms Locate the radial actuator carrier arm bracket assembly Locate radial actuator frame bracket assembly Locate actuators one for each array Install each carrier arm using clevis pins from lever arm, as shown in Figure 29. Figure 29: Carrier arm installation Sedona Solar Technology 16 April

23 4.8.7 Join the carrier arms using couplers as shown in Figure 30. Figure 30: Carrier arm coupler Install radial actuator carrier arm brackets as shown in Figures 31 and 32. Figure 31: Radial actuator carrier arm bracket installation Sedona Solar Technology 16 April

24 Figure 32: Assembled radial actuator carrier arm bracket Sedona Solar Technology 16 April

25 4.8.9 Install radial actuator frame bracket as shown in Figure 33. Figure 33: Radial actuator frame bracket Install the actuator as shown in Figure 34. Install the shaft end of the actuator to the carrier with clevis pin. Figure 34: Actuator installation on frame Note: You may apply 12 to 24 volts dc to the actuator to extend it to hold the lever arms in a level position. Sedona Solar Technology 16 April

26 4.9 Panel support bar installation Locate panel support bars two per lever arm Locate hat brackets two per lever arm Locate hat bracket fasteners four per lever arm Install panel support bars as shown in Figure 35. Figure 35: Panel support bar installation Mock up solar panel (if available) to determine correct positioning for panel support bars to center panel on lever arm Use laser level to guide positioning of all successive panel support bars Properly torque all panel support bars Frame checks Check all frames and verify that they are square Disconnect radial actuator at the carrier arm and ove carrier arm through its entire range of motion, checking for binding and collisions Check all fasteners for proper torque Install solar panels Install solar panels onto panel support bars, making sure that panels are oriented so that leads can feed into the wiring holes in the bottom rails of the frame Torque all fasteners to panel manufacturer s specifications. Sedona Solar Technology 16 April

27 4.12 Wire arrays according to NEC and local building codes Install controller Install control unit on the post furthest to the west using the controller mount kit Wire controller referencing documentation provided Follow setup procedure in controller documentation. 5. Final checks 5.1 Check frames Check that all fasteners are properly torqued Check that all wires have adequate lengths to allow for system movement Check that frames are not twisted Verify all grounding connections Verify all controller and actuator connections. 5.2 Check system function Check array range of motion to the north, using the controller in manual mode Check array range of motion to the south, using the controller in manual mode Check array range of motion to the east, using the controller in manual mode Check array range of motion to the west, using the controller in manual mode Check that the controller moves the panels to full south and centers them between east and west when in CLEAN mode Check that the controller moves the panels to be flat when in STORM mode Check that the controller points the panels at the sun when in TRACK mode by placing at least a six inch long rod, such as PVC pipe, on the panel and checking the shadow. Sedona Solar Technology 16 April

28 Sedona Solar Technology 16 April

29 2225 North Gemini Drive Flagstaff AZ Sedona Solar Technology 16 April