A.23.1. PDM-000176 NEXTracker NX Horizon 2.4.1 Short Rail Installation Manual Rev - B

Installation Manual
NEXTracker NX Horizon 2.4.1

Short Rail
PDM-000176 Rev. B
PDM-000176 Rev. B ©NEXTracker, Inc., 2019 CONFIDENTIAL/PROPRIETARY Contents subject to change without notice. Mar 2019
Installation Manual NEXTracker NX Horizon 2.4.1 Short Rail Page 2 of 57
Installation Manual
NEXTracker NX Horizon 2.4.1
Short Rail
PDM-000176 Rev. B
Copyright ©NEXTracker, Inc., 2018. All rights reserved.

NEXTracker provides this documentation without warranty in any form
either expressed or implied.
NEXTracker may revise this document at any time without notice.
This document may contain proprietary information and should be
respected as a proprietary document with permission for review and
usage given only to the rightful owner of the equipment with which this
document is associated.
No part of this document may be reproduced by any means without
written permission by NEXTracker.
FM18b
Foreword
About this Manual
This is the installation manual for NEXTracker products and applies to projects using
2.4.1 and 2.4.9. It presents detailed installation requirements and instructions,
safety reminders, key steps, and other information; best means and methods of work
may be determined by the installer.
Safety
The following notes, warnings, and critical items appear throughout this manual.
NOTE: This box contains information that makes assembly of NEXTracker

components faster and easier.
WARNING: This box alerts the reader to a condition that could lead to critical
consequences.
CRITICAL: This box gives urgent and important information. Disregarding it may
lead to accidental injury, loss of life, and damage to equipment, tools or
components; it may compromise the NEXTracker warranty. This information notes
steps that are critical to installing components so they meet quality requirements.
In addition to general construction best practices, appropriate use of personal

protective equipment (PPE) is essential when handling heavy components and
equipment that may be pressurized with hydraulic fluid or air. Eye protection and ear
protection must be part of the PPE.
Adherence to the safety instructions of all third-party vendors is recommended as

well. Please be aware of hazards resulting from projectiles, repetitive motion, noise,
vibration, and other aspects of using hydraulic, pneumatic, and power tools.
Scope Limitations
This is a universal manual covering a NEXTracker product; project-specific
configurations are covered elsewhere. Please see the Construction Set and Part
Number Reference List for project-specific details.
FM18b
Contents
Foreword .......................................................................................................................... 3
1. How To Use this Manual ................................................................................................ 5
Task A. Install Piers ....................................................................................................... 11

Task B. Install Slew Drive ...............................................................................................12
Task C. Attach Motor to Slew Drive ................................................................................ 15
Task D. Install Bearing Housing Assemblies .................................................................... 17
Task E. Torque Tube Installation ................................................................................... 20
Task F. Align and Secure the Row ................................................................................. 27
Task G. Install Dampers ................................................................................................ 29
Task H. Install Module Rails ........................................................................................... 38
Task I. Mount Module .................................................................................................. 42
Task J. Row Stowing .................................................................................................... 46
Task K. Install SPC ....................................................................................................... 47
2. Commissioning .......................................................................................................... 54
3. Operations and Maintenance ...................................................................................... 54
4. Key Definitions ........................................................................................................... 55
5. Revisions for this Manual ............................................................................................ 56
FM18b
1. How To Use this Manual

1.1 Callouts
This manual guides
references related product documentation; it is one part of a product documentation
family that includes the Construction Set and the Part Number Reference List.
References to these documents are color-coded throughout the installation manual:
• The Construction Set outlines the location of the tracker rows in the project
site, including identifying interior versus exterior tracker rows and related
parts. It also defines the specific mechanical tracker row configuration(s)
used on each specific project site, including dimensions, tolerances, and
elevation views.
• The Part Number Reference List outlines the project-specific part numbers,
names, and quantities that are referenced in this installation manual.
The images and dimensions in this manual are for general reference to guide field
assembly. The actual parts installed may vary. The Part Number Reference List and
Construction Set are the documents of record for project-specific, installed product
part numbers and location details.
• Number callouts in the installation manual construction tasks refer to parts

listed in the Part Number Reference List, as shown in Figure 1-1a, which
refers to Part Number Reference List item number 10 for project-specific
torque tube part numbers.
• Figure1-1b refers to Part Number Reference List item number 20 for the
project-specific assembly part number, and 20a for the referenced assembly
component in this case, the lower damper mount.
Figure 1-1. Numbered callouts that refer to part numbers and assembly components.
Intro1e
1.2 Module Specifications

This racking system may be used to mount a PV module complying with UL 1703
only when the specific module has been evaluated for grounding and/or mounting
in compliance with the included instructions. It is to be used with modules that
include this specific rack system in their installation manual.
This system has been certified and listed to UL 2703 for electric ground, electrical
bonding, fire resistance, and mechanical load testing. Certification loads are 5 psf
up, 10 psf down, and 5 psf downslope.
The maximum weight allowed on the back of the modules is 0.8 kg per meter
(0.53 lb per foot).
See the tables in each section for torque values for applicable fasteners used to
mount modules.
1.3 Grounding
Modules are grounded through tracker components to the piers when fasteners are
installed correctly. The overall grounding of the entire racking system is to be
investigated to meet the standards of the latest edition of the National Electrical Code,
NEC, to Article 690: Solar Photovoltaic Systems and Article 250: Grounding and Bonding.
The array pier is in direct contact with the earth and is to be installed based on the
requirements of a grounding electrode per Article 250. Any local electrical codes
must be adhered to in addition to the national electrical codes. Figure 1-2 shows the
grounding path for modules.
Figure 1-2. Grounding path for modules.
Intro1e
1.4 Summary of Tracker Operation

The NX Horizon is a self-powered solar tracker. Once a tracker is installed per this
manual and commissioned, the tracker will rotate to direct the photovoltaic (PV)
modules toward the sun as its position changes throughout the day. Tracker
movement is controlled by the self-powered controller (SPC). The tracker may be
turned on/off directly, if necessary, by the disconnect switch/button on the SPC box
(see Task K).
Refer to NX Horizon Operations and Maintenance Manual (MKT-000005) before

performing any operations or maintenance activities on the product. Failure to
comply with these instructions may void the NEXTracker limited warranty and may
result in property damage, personal injury, and/or loss of life.
1.5 Tracker Ratings

Tracker ratings are presented in Table 1-1. Direct current and grounding symbols are
shown in Figures 1-3 and 1-4.
Table 1-1. Tracker ratings.

Rating Type NX Horizon
Maximum input voltage 30 VDC
Range of input operating voltage 10 25 VDC
Maximum input current (DC) 2A
Operating frequency range or single frequency N/A
Normal operation temperature 30°C to 50°C

( 22°F to 122°F)
Figure 1-3. Direct current symbol. Figure 1-4. Grounding symbol.
Intro1e
1.6 Blind Rivet Grip Sizing

Blind rivets of various grip sizes are installed depending on the row location and the
wall thickness of the torque tubes. Interior and exterior rows may use different
torque tubes. Table 1-2 specifies the grip sizing of the blind rivets for varying torque
tube wall thicknesses and types of connections along the tracker row. When
installing blind rivets, check the Construction Set to verify torque-tube thickness
and see Table 1-2 for the blind rivet grip sizing to use.
Table 1-2. Blind rivet grip sizing.

Tracker Location Task Installed 2.5 mm 3 mm 4 mm
Torque tube to torque tube adapter E.1 Grip 4 Grip 4 Grip 6
Torque tube to torque tube E.2 Grip 4 Grip 4 Grip 4
Torque tube to upper damper mount without G.1 Grip 6 Grip 6 Grip 6
additional torque tube (end of row)
Torque tube to torque tube with upper G.1 Grip 6 Grip 6 Grip 6
damper mount
NOTE: Apply cold galvanizing spray to all blind rivets once installed.
CRITICAL: All blind rivets should be in place before any blind rivets are swaged.
CRITICAL: SPC bracket location is project-specific.
NOTE: A correctly installed blind rivet must be flush or have up to three rings
remaining on the broken stem, as shown in Figure 1-5. A correctly installed blind
rivet should have a smooth swage on the head of the fastener. Excessive scoring
on the swaged head is a sign that tool maintenance is required.
a. Unfastened b. Securely fastened
Figure 1-5. Correctly installed blind rivets are flush or protrude up to 6.3 mm (¼ in.).
Grip2d
1.7 Tools Needed for Installation

See Table 1-3 to review the tools needed to assemble the NEXTracker NX Horizon.
Table 1-3. Tools needed for assembly.

Socket Wrenches
Hex bolt size M4 M6 M10 M12 M20
Socket wrench size, mm 7 10 15 18 30
Deep socket No Yes Yes Yes No
Hex Keys in the Following Sizes

Socket head cap screw size M8 M10 M12
Hex key size, mm 6 8 10
Rivet Tools
Application Installation Installation Installation Power Power Power Pull Return
Gun Option Gun Option Nose Source Source Source Pressure Pressure
1 2 Option Option Option Required Required
1 2 3 (psi) (psi)
½-in. blind rivet 2624PTD 2624 913F 940 HPU 5000 1800
(torque tube)
Site specific,
M12 pin and collar confirm with NX
SF-20 N/A 913F 940 HPU 4200 2200
(pier and BHA)
¼-in. pin and collar Standard Air
A1100 PB2500N Compressor 20V Battery N/A 90 90
(module)
Other Required Tools Optional Tools

,1 6
Self-leveling laser and tripod, 2 7
orque wrenches needed with a range of 5 in.-lb to 200 ft-lb, 3 en
,4
old galvanizing compound, 5 Leverage bar
1 2 3 4 5 6 7
Tools1g
1.8 Torque Marking Procedure

Torque fasteners must have torque markings, as shown in Figure 1-6.
• Torqued marks are made only after the fastener has been tightened with
the specified torque designated in the appropriate torque table for each
task.
• Torqued marks should be applied with a clearly visible marking pen or paint
pen.
• For a through-bolted connection, a continuous marking line should be
applied that covers the nut, bolt, and the part in contact with the nut, as
shown in Figure 1-6.
• For a blind connection, the marking should be applied to the head of the
bolt and the part in contact with the head.
• For quality control (QC) checks, a measured torque value within a

tolerance range of ±10% applies to all fastener torque values and is
acceptable with no re-work required.
Figure 1-6. An example of a properly torque-marked fastener.
Tools1g
Task A. Install Piers
WARNING: Refer to the Construction Set for motor pier placement tolerances.
A.1 Install Motor Piers

 Motor piers can be identified by the six holes in each flange.
 Motor pier design details are project specific. Install motor piers as
specified by the Structural Engineer of record and refer to the
Construction Set for motor pier placement tolerances.
A.2 Install Array Piers

 Array piers can be identified by four vertical slots in each flange, as
shown in Figure A-1.
 Array pier design details are project specific. Install array piers as
specified by Structural Engineer of record for the project and refer to the
Construction Set for array pier placement tolerances.
a. Sample motor pier b. Two sample array piers
Figure A-1. Sample motor pier and array piers.
A1a
Task B. Install Slew Drive

B.1 Install Slew Drive Brackets to Motor Pier
1. Place the slew drive brackets on the motor pier as shown in Figure B-1.
Insert the M12 pins.
2. Hand tighten the M12 pins and collars do not swage these fasteners at
this point. M12 pins and collars will be swaged after row alignment in
Task F.
Figure B-1. Install slew drive brackets to motor pier.
B1c
B.2 Install Slew Drive Assembly

WARNING: The slew drive assembly weighs 99 kg (218 lb). Lift the assembly
close to the slew drive to ensure stability.
NOTE: Ensure correct slew drive assembly is installed. Interior slew drive
assemblies are visually smaller and installed on specific rows depending on site
conditions. See Figure B-2 for the two slew drive assembly types. Refer to
Construction Set for where each type will need to be installed.
1. Place the specified slew drive assembly on the slew drive mount so that
the motor mounting location points east, as shown in Figure B-3.
2. Insert and hand tighten the M20 bolts, flange nuts, and washers.
Fasteners will be secured after row alignment in Task F.
NOTE: Torquing of the bolt head is acceptable when securing the slew drive to the
slew drive mount. See Table B-1 for torque values.
Standard slew drive assembly
Interior slew drive assembly
Figure B-2. Ensure correct slew drive assembly is installed.
B1c
Figure B-3. Install the slew drive.
Table B-1. Torque values for applicable fasteners.

Construction Joint Description Fastener Type and Torque, Torque, Torque,
Task Part Number Reference in.-lb ft-lb N-m
B.2 Slew drive bracket to M20 bolt (1d), flange nut (1b), 175 240
slew drive washer (1c)
B1c
Task C. Attach Motor to Slew Drive
1. Ensure proper motor mounting orientation shown in Figure C-1 and place
the antenna on the motor with the antenna flange facing the slew drive.
2. Attach the motor and antenna mount to the slew drive using M12 SHCS, as
shown in Figure C-2. Figure C-2 shows a motor O-ring. See Table C-1 for
torque values.
CRITICAL: Ensure correct motor mounting orientation as shown in Figure C-1.

For Gen 2 motors, the protective vent will be above the motor connector head
For Gen 2.5 motors, the protective vent will be left of the motor connector head.
CRITICAL: The exposed motor connector head must always be covered with a
weatherproof cap until the self-powered controller cable connector is attached.
Protective
vent above
Protective
vent on left Connector Connector
head head
31 Gen 2.5 Motor 31 Gen 2 Motor
Figure C-1. Motor connector head with vent on left for Gen 2.5 versus vent above for Gen 2.
33
SPC Antenna 32
Mount
M12 SHCS
(2 total)
Gen 2.5 Motor Gen 2 Motor
Figure C-2. Attach the motor to the slew drive.
C2b
WARNING: Ensure the O-ring maintains a proper seal on the motor adapter
plate before installing the motor.
Figure C-2. Motor O-ring.
Table C-1. Torque values for applicable fasteners.

C Motor to slew drive M12 SHCS (32) 45 60

assembly
C2b
Task D. Install Bearing Housing Assemblies

CRITICAL: Ensure correct BHA type is installed depending on row location. Light
BHAs are used on only interior rows. See Figure D-1 for the two BHA types and refer
to the Construction Set for row distinction.
1. Place the bearing housing assembly (BHA) brackets on the array pier;
loosely insert the M12 pins and collars, as shown in Figure D-1.
There are two pairs of slots on the pier. The installed position of the pier
determines which holes are used for bracket installation. If the pier is
offset to the north, the southern slots should be used; if the pier is offset
to the south, the northern slots should be used.
NOTE: Determination of slots in the pier is defined by the installed position of the
pier (i.e. if pier offset is to the south, place brackets on northern slots).
8a 8a
BHA handle Light BHA
handle
5 toggles 3 toggles
8d 8d
BHA bracket Light BHA
bracket
Figure D-1. Standard BHAs (left) will be installed on exterior and edge rows while light BHAs
(right) are used on interior rows.
NOTE: Standard BHA handles have 5 toggles and thicker brackets marked with a
red stripe. Light BHA handles have 3 toggles and thinner brackets with no marking.
CRITICAL: Exterior row BHAs require the use of M12 washers in the foot of the
BHA. Two M12 washers are used per BHA. See the Construction Set for exterior,
edge and interior row distinction.
D3b
3 8d
M12 collar
BHA
(4 total)
bracket
(2 total)
2 M12 pin
(4 total)
Figure D-2. Brackets must be installed on the same side of the pier.
2. Level the brackets in the east west direction; see Figure D-3. Visually
align the brackets relative to one another, north to south, and ensure the
flat upper surfaces form a plane; see Figure D-4. Hand tighten the M12
pins and collars do not swage these fasteners yet. M12 pins and collars
will be swaged after row alignment in Task F.
3. Insert the M12 pins through the slots of the BHA handle and mount on top
of the brackets, as shown in Figure D-4. Exterior rows require M12
washers to be installed with the pins; see Figure D-5. Hand tighten the
M12 pins and collars do not swage these fasteners yet. M12 pins and
collars are swaged after row alignment in Task F.
Side view
Figure D-3. Level the brackets. In the east-west direction.
NOTE: Ensure that the flat upper surfaces of the brackets form a level plane along
the row from north to south. It is acceptable if the brackets do not line up front to
back of the pier.
D3b
Top view
ACCEPTABLE
Figure D-4. Align the brackets north to south.
2
8a M12 pin
BHA handle
3
M12 collar
Figure D-5. Attach the BHA handle to the brackets. Interior and edge row BHAs do not use
the M12 washers.
7
M12 washer
(2 per BHA)
Figure D-6. Exterior row BHAs require M12 washers to be installed with the pins.
D3b
Task E. Torque Tube Installation

E.1 Attach Torque Tubes to the Slew Drive Assembly
NOTE: Torque tube type and location are project specific. Refer to the Construction
Set for locations and to Table 1-2 for correct associated blind rivet sizes.
1. Starting at the slew drive, insert swaged ends of the torque tubes into the
slew drive assembly, as shown in Figure E-1. Ensure that the module rail
alignment holes on the torque tubes face up.
2. See Table 1-2 for blind rivet sizing and fasten the torque tube to the slew
drive assembly (Figure E-2). Apply cold galvanizing spray after the
fastener has been installed.
Slew drive assembly

10
Torque tube
(swaged end)
Figure E-1. Insert torque tube.
NOTE: All torque tubes will use 8 blind rivets for each torque-tube to torque-tube-
adapter connection (16 total per row).
See Construction Set for torque tube locations and Table 1-2 for correct
associated blind rivet sizes.
NOTE: Ensure the rail alignment hole is clear from torque tube adapter to torque
tube. Use a pry bar for the alignment hole positioning.
NOTE: Apply cold galvanizing spray to all blind rivets once they are installed.
E8b
Figure E-2. Insert blind rivets into the torque tube adapter holes.
WARNING: See Table 1-2 for correct associated blind rivet sizes.
WARNING: All blind rivets should be in place before any blind rivets are swaged.
E.2 Install Torque Tubes

NOTE: Torque tube type and location are project specific. Refer to the
Construction Set for type and location details.
NOTE: Torque tubes weigh between 67 105 kg (148 232 lb), depending on length
and wall thickness.
1. Moving from the slew drive outward, slide the swaged end of the torque
tube into the non-swaged end of the adjacent torque tube (Figure E-3).
Ensure that the module rail alignment holes on the torque tube face
upward.
2. See Table 1-2 for blind rivet sizing and fasten the torque tubes using the
appropriate blind rivets (Figure E-3). Apply cold galvanizing spray to each
blind rivet after the fastener has been installed.
3. Continue steps 1 to 3 until the row is complete.
E8b
10
Torque tube
(non-swaged end)
Figure E-2. Slide the torque tube into the adjacent torque tube.
Blind rivet
(6 total)
Figure E-3. Fasten torque tubes using the appropriate blind rivets.
NOTE: Apply cold galvanizing spray to all blind rivets once they are installed.
E8b
E.3 Install BHA Module Rails

NOTE: Assembled BHA module rails can be placed onto torque tubes before torque
tube fastening.
1. Using the rail alignment tab and the torque tube alignment hole as guides,
place the alignment tab of the BHA module rail into the alignment top hole.
Slide the BHA pin through the BHA handle, as shown in Figure E-4.
2. Insert the U-bolt into the BHA module rail from under the torque tube and
align the module rail. Hand tighten the nut and the jam nut, shown in
Figure E-5. Do not fully torque until BHA module rails are aligned.
NOTE: Use a digital level across the length of the BHA module rail. Ensure that each
rail is level (within 1.0 degree) relative to the rail that it shares a module with. This
applies to all rail types module rail, BHA module rail, and first module rail.
8b
BHA module rail
Front view BHA pin
Pin notch facing

downward
Figure E-4. Install BHA pin and rail.
E8b
8e
M10 serrated
flange
8c
U-bolt
Figure E-5. Securely fasten the BHA rail.
3. Ensure that the notched ends of the BHA pin are fully inserted and
protruding from the rail, as shown in Figures E-6.
4. Align each rail so that they are parallel within ±1°. See Figure E-7 for
details.
5. Once the BHA rails and pin have been aligned, see Table E-1 for torque
values. Once serrated flange nuts are secured, place and torque the jam
nut according to Table E-1. See Figure E-8.
NOTE: The jam nut is shipped separately from the BHA.
CRITICAL: Ensure that both notches of the BHA pin are fully inserted through their
respective BHA rails before fully fastening BHA rails. See Figure E-6.
E8b
ALIGNED NOT ALIGNED
Pin end
recessed
Figure E-6. Ensure that each end of the BHA pin is fully inserted and protruding from rail.
CRITICAL: Visually check that BHA rails are installed perpendicular to the torque
tube as shown in Figure E-7.
E8b
Top view
BHA rails ⊥ to torque tube
Figure E-7. Visually ensure that the BHA module rails are installed square to the torque tube.
11
Jam nut
Figure E-8. Install BHA rail.
Table E-1. Torque values for applicable fasteners.

Task Part Number Reference in.-lb ftb N-m
E.3 Bearing housing rail to M10 serrated flange nut (8e), 18 24.4
U-bolt jam nut (8f)
E8b
Task F. Align and Secure the Row

F.1 Align the Torque Tubes and Secure the Row
1. Align all BHAs and torque tubes in the north-to-south, east-to-west
directions and vertically down the row. Adjust components as needed to
achieve alignment within the tolerances defined in the Construction Set.
2. Ensure each BHA handle is correctly positioned relative to the slew drive
and the end of the row, as shown in Figure F-1. Placement must fall within
±6.3 mm (0.25 in.) of the stated distances. Ensure that the minimum
space between the BHA handle and the module rail is maintained. Do not
push the BHA handle all the way up to the rails.
Figure F-1. The measurements shown are used for all temperature ranges to determine
accurate BHA placement and correct handle position.
F.2 Secure Fasteners

1. Once the row has been aligned, swage all M12 pins and collars.
2. Secure all previously hand-tightened fasteners; see Table F-1 for a
checklist of items to confirm proper procedure.
3. Torque all fasteners according to values given in tables at the end of each
task.
4. M12 fasteners are semi-permanent and require specialized tools to
uninstall. Confirm proper alignment before swaging.
Table F-1. Checklist to confirm proper procedure.
Task Fasteners
F Secure M12 pins and collars.
B.2 M20 bolt, washer, and nut; see Table 1-2 for torque requirements.
B.1 Secure M12 pins and collars.
F1c
CRITICAL: Ensure that both ends of the BHA handle are resting flush on the BHA
bracket, without gaps, before swaging. If there is a gap, adjust the brackets as
needed. Never use the rivet tool to pull a gap closed. Ensure the rivet tool nose is
at a 90-degree angle to the bracket before swaging. If swaging is performed while
there is a gap between hoop and bracket, or when the nose is misaligned (as
shown in Figure F-2), components and tools may be damaged.
Figure F-2. Examples of when it is okay to swage and when you should not swage.
WARNING: If M12 pins and collars need to be removed, use a grinder or hydraulic
cutting tool.
WARNING: Check security of M12 pins and collars after installation via visual
indicators that show proper swaging, as shown in Figure F-3.
a. M12 collar unswaged b. M12 collar swaged
Figure F-3. Visual indicators of proper swaging: an M12 collar unswaged and swaged.
F1c
Task G. Install Dampers

G.1 Install U-Bolt to Upper Damper Mount
NOTE: Damper placement is project specific. Interior and exterior rows have varying
damper quantities. See the Construction Set for details.
NOTE: Upper damper mounts are placed on the side of the pier closest to the slew
drive.
1. Dampers installed on a row are shown in Figure G-1.
22
Dampers
Figure G-1. Double damper after assembly is completed.
2. Place the upper damper mount under the torque tube on the side of the
pier closest to the slew drive, so that the arm is away from the BHA, as
shown in Figure G-2.
3. See Table 1-2 (in installation manual) for blind rivet sizing; place blind
rivets on both sides of the double upper damper mount into the torque
tube (Figure G-3). Do not fasten until U-bolt is securely attached.
G2a
Double upper damper

mount arm
Slew drive
Figure G-2. Place each double upper damper mount under the torque tube, on the side
closest to the slew drive, and at the correct distance from the pier.
Blind rivet
(2 total)
Figure G-3. Place double upper damper mount on the torque tube using blind rivets.
CRITICAL: Do not fasten blind rivets until after U-bolt is securely installed.
4. Insert and hand tighten the nuts to the U-bolt (Figure G-4). Torque only
after proper alignment is confirmed. See Table G-1 at the end of Task G
for torque values.
G2a
19b
U-bolt
19c
M10 serrated
flange (2 total)
Figure G-4. Insert and hand tighten the U-bolt.
5. Once the U-bolt has been installed, fasten blind rivets using the rivet
tool.
6. After the fasteners have been installed, apply cold galvanizing spray to
each blind rivet.
G2a
G.2 Install Lower Damper Mount to Pier

1. Install the lower damper mounts in the slotted holes on the bottom of
the pier. Measure the vertical spacing from the bottom of the BHA
bracket. Vertical spacing and orientation detailed in the Construction
Set and shown in Figure G-5. Figure G-6 shows proper mounting.
Measurement found in
the Construction Set
Figure G-5. Install the lower damper mounts with the correct vertical spacing.
CRITICAL: Ensure correct damper mount spacing. See Construction Set for
dimensions.
NOTE: Double damper piers require two lower damper mounts on the same pier.
Refer to Construction Set for details on damper mounting locations.
G2a
W-Beam / C-Channel Pier
20a
Lower damper
mount
2
M12 pin
3
M12 collar
Figure G-6. M12 pin and collar installation for both W-beam and C-channel piers.
2. Once the bracket has been aligned, secure with hardware and swage
M12 collars.
G2a
G.3 Install Damper to Damper Mounts
CRITICAL: Damper orientation in visuals is for reference only. Ensure the damper
orientation is correct as shown in Figure G-
1. Dampers are oriented based on type. Ensure damper orientation is

correct (see Figure G-7).
2. Attach the dampers to the upper and lower mounts (Figures G-8 and
G-9) by installing the spherical rod ends on the M10 carriage bolts
followed by the castellated nut torqued to snug tight.
• Snug-tight condition requires all plies in the connection to be
pulled into firm contact and the nut tightened sufficiently to
prevent removal without a wrench.
3. Tighten the castellated nut to align a slot with the carriage bolt hole
and insert the cotter pin (Figure G-10a). Bend the cotter pin prongs in
opposite directions to secure its fit (Figure G-10b).
CRITICAL: Ensure that there are no gaps between any components along the
carriage bolt.
CRITICAL: Hole in carriage bolt must be aligned with castellated nut slot to allow
for cotter pin installation.
Body up
Rod up
Or
Rod down
Body down
Figure G-7. Dampers oriented based on type.
G2a
22
Dampers
Figure G-8. Damper attachment at the BHA.
19d
Castellated nut
19d
Castellated nut
a. Attach damper to upper mount b. Attach damper to lower mount
Figure G-9. Torque castle nut to snug tight.
G2a
19d
Castellated nut
Hole for cotter pin
Cotter Pin
19e
a. Install cotter pin in carriage bolt hole prongs b. Spread cotter pin
Figure G-10. Cotter pin installation through the castellated nut and carriage bolt.
G2a
G.4 Place End Cap on the Torque Tube

1. Place the end cap on the torque tube. Ensure that the tabs snap into
corresponding holes, as shown in Figure G-11.
23
End cap
Figure G-11. Place end cap on the torque tube, making sure tabs snap into holes.
Table G-1. Torque values for applicable fasteners.

G.1 U-bolt to upper damper M10 serrated flange (19c) 20 27
mount
G.3 Damper to damper mount Castellated nut (19d) Snug tight
G2a
Task H. Install Module Rails

H.1 Install First Module Rails
NOTE: The first module rails on either side of the slew drive assembly (Figure H-1)
are different module rail types from the remaining row module rail. Refer to Part
Number Reference List for part specifics.
1. Insert the module rail alignment tab into the torque tube alignment hole
(Figure H-1).
2. Level the module rail and torque the through bolt to the torque value
shown in Table H-1. See Figure H-2.
CRITICAL: Do not use an impact gun to torque the bolt. An accurate torque value
must be measured.
NOTE: Use a digital level across the length of the module rail. Ensure that each rail
is level (within 1.0 degree) relative to the rail that it shares a module with. This
Torque tube
alignment hole
First module 27a

rail
Figure H-1. Insert the module rail alignment tab into the torque tube alignment hole.
H8b
M8 through bolt 27c
Figure H-2. Install first module rails.
NOTE: Bolt should be installed at the bottom of the tube and parallel (within ±10°)
to the rail.
H.2 Install Module Rails

CRITICAL: Ensure correct rail type is installed depending on row location. Light rails
are used only on interior rows. See Figure H-3 for the two rail types and refer to the
Construction Set for row distinction.
1. Move each module rail into place by inserting the module rail alignment
tab into a torque tube alignment hole (Figure H-4).
2. Once aligned, securely fasten the module rail through bolt. Refer to
Table H-1 for torque values (Figure H-5).
CRITICAL: Do not use an impact gun to torque the M8 through bolt. An accurate
torque value must be measured.
NOTE: Bolt should be installed at the bottom of the tube and parallel (within ±10°)
to the rail.
H8b
Heavy
25a Module rail module rail 25a
Corner tab
(4 per rail)
Figure H-3. The standard version (left) has no corner tabs while the heavy version (right)
has corner tabs.
25a Module rail, Wide Heavy module 25a

rail, Wide
End flange hole

(4 per rail)
End flange hole
(4 per rail) +
Corner tab
(4 per rail)
Figure H-4. The wide module rails feature end flange holes. Standard version (left) has no
corner tabs while the heavy version (right) has corner tabs.
Module rail 25a
Figure H-5. Align the module rail on the torque tube alignment hole.
H8b
M8 through bolt 25c
Figure H-6. Tighten the M8 through bolt of the module rail.
Table H-1. Torque values for applicable fasteners.

H.1 First module rail strap to TTA strap (27b), Through 13 17.6
torque tube bolt (27c)
H.2 Module rail strap to torque Torque tube strap (25b), 13 17.6
tube Through bolt (25c)
H8b
Task I. Mount Module

I.1 Install Module
1. Place the module on top of module rails so that the holes in the frame
align with the appropriate module rail holes; see Figure I-1.
2. Insert ¼-in. pin through the module frame and module rail; see
Figure I-2.
3. Swage collars onto the ¼-in. pin; see Figure I-3.
36
¼-in. pin
37
¼-in. collar
Figure I-1. Install modules on rails.
Figure I-2. Insert ¼-in. pin through the module frame and module rail.
I8b
CRITICAL: Do not attach cable trays or shields to the underside of the panels. The
maximum weight capacity attached to the back of modules is not to exceed 0.8 kg
per meter (0.53 lb per foot).
Before swaging After swaging

Figure I-3. Visual indication showing proper swaging for ¼-in. collars.
I.2 Module Wiring

CRITICAL: Installers must carefully and strictly adhere to the module manufacturer
safety information for the proper installation, maintenance, and handling of their
modules. All module manufacturer instructions and requirements must be read and
understood before attempting to install, wire, and operate and/or service the
module and accompanying electrical equipment.
CRITICAL: This procedure provides simplified, schematic examples of

recommended wire management configurations to avoid contact with tracker
mounting components. All wire management must comply with NEC/IEC standards
and local AHJ requirements for maintaining wires (service loops, cable trays,
raceways, etc.).
1. For half-cell module-to-module connections, wires can be routed

through the panel rails secured along module frames to ensure no
contact between wires and panel rails. Route wires outside of the panel
rail if length allows adequate clearance from components.
2. For full-cell module-to-module connections, connect wires along or near
the edge of modules depending on module technology.
I8b
3. For modules across the BHA gap, shorter leads may require a jumper
wire to bridge the BHA gap which spans approximately 200 mm
depending on selected module width. All wires must be secured a
minimum of 400 mm away from the center of the module to provide
adequate clearance from the BHA.
4. Secure cables as needed along module frames using wire clips and/or
supports through the unused mounting holes to avoid interference with
tracker components and shading on module rear side.
200-mm
BHA gap
Conductors
400 mm
MIN
Figure I-4. Half-cell monofacial and bifacial module wire schematic.
200-mm
BHA gap
Conductors
400 mm
MIN
Figure I-5. Full-cell monofacial module wire schematic.

I8b
200-mm
Conductors BHA gap
Figure I-6. Recommended bifacial full-cell wiring to minimize rear-side obstruction.
NOTE: Modules with split junction box configurations often have shorter leads and
may require a jumper wire to bridge the BHA gap.
I8b
Task J. Row Stowing

CRITICAL: Once modules have been securely installed, rotate the row to lockout
stow.
1. Plug the hand-held motor controller, shown in Figure J-1, into the tracker
motor and rotate the array to lockout stow.
2. Use a level on the PV panel closest to the motor to set the array angle,
as shown in Figure J-2.
NOTE: Lockout stow is within ±5° of maximum allowable tracker angle with the
leading edge of the module toward the direction called out in the Construction Set.
Maximum allowable angle is project specific but is within 5° of the torque tube
touching the BHA hoop.
Figure J-1. Gen 2 (left) and Gen 2.5 (right) hand-held motor controllers.
Leading edge of
module
Figure J-2. Set the angle of the array in site-specific construction stow direction.
J2e
Task K. Install SPC

K.1 Mount Smart Panel
1. Attach project-specific Smart Panel mount to the torque tube adapter
(TTA) using M10 serrated flange nut and U-bolt (Figure K-1). See Table K-1
at the end of this task for torque values.
• For the standard flat mount, use digital level to ensure panel
mounting bracket is module or first
module mounting rail if is not mounted yet.
• For angled mount, measure and mark relative mounting
location at 50 mm (2 in.) from the TTA. (Figures K-2 and K-3)
2. Place Smart Panel on the panel mount bracket. Insert M6 serrated cap
screw through both the panel frame and the bracket. (Figure 4). Secure
with M6 serrated nuts and torque to value in Table K-1.
NOTE (Project specific): Some projects use an angled panel mount as shown in
Figure K-2 and K-3. Installation instructions are the same for this mount.
NOTE: Smart Panel and SPC mounting locations depend on geography. Sites in the
Northern Hemisphere mount on the southern side of the slew gear facing west.
Sites in the Southern Hemisphere mount on the northern side of the slew gear
facing east.
13c M10 serrated nut

13a
(4 total)
Smart Panel
mount
bracket
13d TTA saddle
13b
U-bolt
Figure K-1. Attach Smart Panel mounting bracket assembly to TTA.
CRITICAL: Ensure U-bolts are installed on the horizontal portion of the TTA and that
this portion is even and not deformed by the adjacent bent portion.
K5b
14a
First module
Angled Smart
Panel mount
14b U-bolt 50 mm ± 6 mm
(2 in. ± .25 in.)
Figure K-2. Project-specific angled Smart Panel mount.
M10 serrated nut 14c

(4 total)
14a
Angled Smart
Panel mount
U-bolt 14b
Figure K-3. Project-specific angled Smart panel mount.
13e Smart Panel 35

M6 cap screw
(4 total) First module
13f
M6 serrated nut
(4 total)
Figure K-4. Place Smart Panel on the bracket; the Smart Panel can be mounted with
¼-in. pin and collar or M6 cap screw and nut.
K5b
K.2 Install SPC

1. Remove plastic packaging and attach SPC to the SPC mount using M8
serrated flange cap screws. Hand tighten all M8 screws before torquing
(Figure K-5).
2. Measure and mark relative mounting location at 83 mm (3.25 in.) from the
TTA. Position the SPC mount next to the first rail under the first module
(Figure K-7).
3. Hand tighten the SPC mount to the torque tube using U-bolt, saddle, and
M10 nylon insert nut (Figure K-6). Adjust SPC mount within defined
mounting location (Figure K-7) from TTA. Do not torque M10 nuts yet.
• The SPC mount must be hand tightened to allow for adjustments and
proper leveling.
4. Apply a digital level against the leveling reference surface on the SPC
mount. Install the SPC and mount perpendicular to the first module
(Figure K-8).
• Center the digital level directly above the torque tube on the first
production module or first module rail, then press the reference
.
• After setting the reference surface on the digital level, set the digital
level on the SPC mount leveling surface. Adjust the SPC mount to
get a readout of 90 (+/-0.5) degrees.
• Keep the digital readout window always pointed away from the slew
drive to avoid any offset from the level.
5. Once SPC box and mount are properly positioned and leveled, torque the
M10 nuts to value in Table K-1.
WARNING: The battery used in this device may present a risk of fire or chemical
temperature limit, or incinerate. Replace battery with NEXTracker-approved battery

only. Use of another battery may risk fire or explosion.
CRITICAL: Hand tighten all M8 cap screws prior to apply final torque value in Table
K-1 when attaching SPC to SPC bracket. Do not use impact gun and do not over
torque.
CRITICAL: The SPC Mount must be installed perpendicular (90° ± 0.5° with a digital
level) to the first production module. Failure to do so will result in interrow shading
and reduced power production.
K5b
15a SPC mount

SPC 39
15e M8 cap screw

(4 total)
Figure K-5. Attach SPC to SPC bracket using M8 cap screw. Hand tighten all before torquing.
Torque tube saddle 15d

15b U-bolt
M10 nut 15c

(2 total)
Figure K-6. Hand tighten SPC bracket to torque tube using M10 nut. Do not torque.
83 mm ± 13 mm
(3.25 in. ± 0.5 in.)
First module
Figure K-7. Position SPC within defined mounting location.
K5b
Reference surface
First module
90° ± 0.5°
Leveling
surface
a. Set REF on digital level using center b. Set digital level on SPC leveling
of first production module/first rail. surface and adjust until 90° ± 0.5°.
Figure K-8. Level surface to level SPC box with first module,
K.3 SPC Wiring

1. Insert and screw in the antenna cable on the SPC box. Attach the PV
cables from the SPC panel to the SPC box. See Figure K-9.
2. Connect the antenna to the SPC antenna mount. See Figure K-10.
3. Connect the motor cable from the SPC box to the motor. See Figure K-11.
4. Use a drip loop to secure the motor cable and antenna to the motor.
Ensure that the cables have enough slack for tracker movement. See
Table K-2 for minimum bend requirements.
CRITICAL: Ensure correct motor orientation and connection. See Figure K-11.
For Gen 2 motors, the protective vent will be above the motor connector head and
the motor cable connection must be hand tightened.
For Gen 2.5 motors, the protective vent will be left of the motor connector head and
the right-angle connector of the motor cable must point down.
K5b
CRITICAL: Do not use any part of the SPC box (lid, battery door handle, etc.) to
secure cables. Do not route any cables through openings in the Smart Panel bracket.
Keep cables away from any sharp edges of mounting components.
NOTE: Cable management at SPC must consider the minimum bend radius
requirements shown in Table K-2.
NOTE: Secure motor, antenna, and PV cables (with zip ties or the equivalent) to
motor or Smart Panel mounting bracket so they are not loose but allow enough slack
for the full range of daily tracker movement. See Table K-2 for minimum bend radius
requirements for cables.
Antenna
connector
PV connectors
Motor cable
Figure K-9. Attach appropriate cables to the SPC box.
43
Antenna
43a
33 M3 screws
(2 total)
SPC antenna
mount
Figure K-10. Connect the antenna and insert into the SPC antenna mount.
K5b
Vent
Vent
Gen 2.5 Motor Gen 2 Motor

Connection Connection
Motor cable
Figure K-11. Motor cable connector heads depending on motor type.
Table K-1. Torque values for applicable fasteners.

K.1 Smart panel mount to U-bolt (13b/14b) and 15 20
TTA M10 nut (13c/14c)
Smart panel to bracket M6 cap screw (15e) and 75 8.5
serrated nut (13f)
K.2 SPC box to SPC mount M8 hex screw (15e) 90 10
SPC mount to torque U-bolt (15b) and M10 nut 15 20
tube (15c)
Table K-2. Minimum bend radius requirements.

Cable Connection Description Minimum Bend Radius
Motor cable 4.33 in. (110 mm)
SPC panel cables 2.56 in. (65 mm)
Antenna cable 2.36 in. (60 mm)
K5b
2. Commissioning
Prior to scheduling at NEXTracker commissioning team to arrive on site, the
mechanical installation contractor must complete, sign, and send the following
documents with photographs to the project manager:
 OPS-000054 Mechanical Checklist

 OPS-000023 Pre-Commissioning Checklist
3. Operations and Maintenance

Prior to performing any operations or maintenance on any components of this
system, refer to the O&M manual. Failure to comply with the following instructions
may void the NEXTracker limited warranty and may result in property damage,
personal injury, and/or loss of life:
 MKT-000005 NX Horizon Operations and Maintenance Manual
BkCh2-3 1e
4. Key Definitions
Term Definition
BHA Bearing housing assembly.
Blind rivet Blind oversized mechanical fastener. Blind rivet fasteners, or blind
rivets, are torque-less fasteners that are swaged using specialized
tools. Blind rivets come in various grip sizes according to use. Refer
to Table 1-3 for blind rivet grip sizing.
PV Photovoltaic.
SPC Self-powered controller.
Swage, Process of changing shape or diameter of material. Swaged end of
swaging torque tube is the end with the smaller diameter. Swaging fasteners is
done with a specialized tool that reduces the collar diameter to create
a clamping force.
Interior/exterior The project-specific Construction Set specifies the type and location
piers versus of each pier.
interior/exterior
row Symbols used for interior and exterior piers are shown here:
Interior rows are identified by the use of interior motor and array piers,
including those that use one or two exterior piers.
Exterior rows are identified as any row that uses all exterior motor and
array piers.
BkCh2-3 1e
5. Revisions for this Manual
Revision Notes Effective

Date
A Initial release. 06/21/2018
B Addition of 2.4.9 and updates made to Tasks C, D, E, H, I, J, K. 03/31/2019
Back18b
www.nextracker.com
NEXTracker, Inc., 6200 Paseo Padre Parkway, Fremont CA 94555
Phone: +1.510.270.2500 | Fax: +1.510.793.8388 | Email: info@nextracker.com
Back18b

A.23.1. PDM-000176 NEXTracker NX Horizon 2.4.1 Short Rail Installation Manual Rev - B

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A.23.1. PDM-000176 NEXTracker NX Horizon 2.4.1 Short Rail Installation Manual Rev - B

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Installation Manual

NEXTracker NX Horizon 2.4.1

Copyright ©NEXTracker, Inc., 2018. All rights reserved.

NOTE: This box contains information that makes assembly of NEXTracker

In addition to general construction best practices, appropriate use of personal

Adherence to the safety instructions of all third-party vendors is recommended as

1. How To Use this Manual ................................................................................................ 5

Task A. Install Piers ....................................................................................................... 11

3. Operations and Maintenance ...................................................................................... 54

4. Key Definitions ........................................................................................................... 55

5. Revisions for this Manual ............................................................................................ 56

1. How To Use this Manual

• Number callouts in the installation manual construction tasks refer to parts

1.2 Module Specifications

Figure 1-2. Grounding path for modules.

1.4 Summary of Tracker Operation

Refer to NX Horizon Operations and Maintenance Manual (MKT-000005) before

1.5 Tracker Ratings

Table 1-1. Tracker ratings.

Maximum input voltage 30 VDC

Range of input operating voltage 10 25 VDC

Maximum input current (DC) 2A

Operating frequency range or single frequency N/A

Normal operation temperature 30°C to 50°C

Figure 1-3. Direct current symbol. Figure 1-4. Grounding symbol.

1.6 Blind Rivet Grip Sizing

Table 1-2. Blind rivet grip sizing.

CRITICAL: SPC bracket location is project-specific.

a. Unfastened b. Securely fastened

1.7 Tools Needed for Installation

Table 1-3. Tools needed for assembly.

Deep socket No Yes Yes Yes No

Hex Keys in the Following Sizes

Hex key size, mm 6 8 10

Other Required Tools Optional Tools

1.8 Torque Marking Procedure

• For quality control (QC) checks, a measured torque value within a

Figure 1-6. An example of a properly torque-marked fastener.

Task A. Install Piers

A.1 Install Motor Piers

A.2 Install Array Piers

a. Sample motor pier b. Two sample array piers

Figure A-1. Sample motor pier and array piers.

Task B. Install Slew Drive

Figure B-1. Install slew drive brackets to motor pier.

B.2 Install Slew Drive Assembly

Standard slew drive assembly

Interior slew drive assembly

Figure B-2. Ensure correct slew drive assembly is installed.

Figure B-3. Install the slew drive.

Table B-1. Torque values for applicable fasteners.

Task C. Attach Motor to Slew Drive

CRITICAL: Ensure correct motor mounting orientation as shown in Figure C-1.

31 Gen 2.5 Motor 31 Gen 2 Motor

Gen 2.5 Motor Gen 2 Motor

Figure C-2. Attach the motor to the slew drive.

Figure C-2. Motor O-ring.

Table C-1. Torque values for applicable fasteners.

C Motor to slew drive M12 SHCS (32) 45 60

Task D. Install Bearing Housing Assemblies

Figure D-3. Level the brackets. In the east-west direction.

Figure D-4. Align the brackets north to south.

Task E. Torque Tube Installation