Installation Manual.

Tracker Control Box 3C SPS1.2 V51 150 OAD

MA-EN-3005_en

Change control
Revision Date Section involved Issued Reviewed Approved
1 17/12/21 All J.Castejón
2 17/12/28 Installation criteria J.Castejón F.Luque J.A.Teruel
3 18/02/26 Section 4 and 5 J.Castejón F.Luque J.A.Teruel
4 18/02/28 5.1 add rating table J.Castejón F.Luque J.A.Teruel
5 18/03/01 All. Review and update J.Castejón F.Luque J.A.Teruel
6 18/03/26 Changes in index order J.Pérez J.Castejón J.A.Teruel
7 18/05/03 5.1 add PV cable adaptor J.Pérez J.Castejón J.A.Teruel
8 18/05/22 4.2, 5.1, 5.5, 6.1, 6.3 J.Castejón J.Pérez J.A.Teruel
9 18/05/28 3 and 5.5 J. Pérez J.Castejón J.A.Teruel
10 18/07/24 3.1 and 5.2 J.Castejón J. Pérez J.A.Teruel
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Table of Contents

1 Safety recommendations ........................................................................................... 3

2 Purpose of the document........................................................................................... 4
3 Description of Tracker Control Box ............................................................................. 4
3.1 Main control internal components ..................................................................... 5
3.2 Electronic components distribution .................................................................... 6
3.3 Types of Tracker-Controllers ............................................................................... 6
3.4 Tracker field distribution ..................................................................................... 7
4 Mechanical assembly of the Tracker Control Box ....................................................... 8
4.1 Assembly of TCB’s Support Plates ....................................................................... 8
4.2 Assembly of TCB to Torque Tube ........................................................................ 8
4.2.1 Installation process...................................................................................... 9
4.2.2 Installation criteria....................................................................................... 9
5 Cabling ..................................................................................................................... 10
5.1 Self-Powered cabling ........................................................................................ 10
5.2 Communications cabling ................................................................................... 12
5.2.1 RS-485 cable .............................................................................................. 12
5.2.2 Radio ......................................................................................................... 14
5.3 End-Limit Switch ............................................................................................... 14
5.4 Motor cabling ................................................................................................... 14
5.5 Battery power bank installation ........................................................................ 15
6 Connections ............................................................................................................. 19
6.1 Components ..................................................................................................... 19
6.2 TCB External connectors ................................................................................... 19
6.3 Internal connections ......................................................................................... 20
6.4 Electrical risk ..................................................................................................... 20

Soltec
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1 Safety recommendations
1. Before beginning installation of the tracker, read this manual
thoroughly.
2. The installation will be carried out by qualified personnel and trained
in accordance with the safety regulations in force in the country.
3. The working area must be well lit.
4. Keep work area tidy. Keep the work environment clear of objects
that could cause injury. Clutter in the work area can cause accidents.
5. Check before the start of the installation whether it does not
interfere with other work.
6. Strictly follow the instructions given in this manual.
7. No manipulations or modifications to the tracker are permitted if
they are not described in this manual.
8. The tools and machines used to maintain the tracker must be used
in accordance with their instruction manual.
9. Stay alert, pay attention during work and use the assembly tools
wisely. Do not use tools if you are tired, or after using alcohol, drugs
or medications. A moment of carelessness when using the tool could
lead to severe injury.
10. Avoid forced postures. Make sure the posture is stable and always
be in balance.
11. While working, keep other people away from the tool's range of
action
12. Use the right tool. Do not use a tool for unintended purposes, but
only in a regulation and in perfect condition.
13. Always unplug or unload a tool before cleaning, repairing or
servicing, before stopping work and before storing
14. Keep tools, both manual and electrical, dry, clean and free of oil or
grease.
15. Never use a tool if the protective devices are damaged or have
been removed.
16. In the installation of the tracker you can be exposed to risks of
knocks, cuts, particles or burns, do not forget to use your personal
protective equipment: hard hat, safety goggles, hearing protectors,
protective gloves and safety footwear.
17. And remember, when in doubt, STOP AND ASK. Your safety and
that of everyone is most important.
18. Pay special attention to electrical risk described in this manual and
safety procedures.

Soltec
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2 Purpose of the document

The main purpose of this document is to describe step by step the installation procedure of the
Tracker Control Box and its electrical connections. Table 1 summarizes the version and type of
the elements conforming the Tracker Control Box.

Box Type Pw. Supply Tracker Controller Motor Type End Switch
MK III SPSv1.2 V5.1 DC 150 W OAD
Table 1: Version or type of the elements conforming the Tracker Control Box.

3 Description of Tracker Control Box

The SF7 Tracker Control Box integrates all the power electronics and control electronics to
perform the following tasks:
• DC/DC Power conversion
• Pitch and Roll angle position
• Real Time Clock
• DC motor driver
• RS-485 communication
• 2.4 GHz Radio communication
• Battery back-up
• Battery temperature monitoring
• Limit switch
• NFC Interface
• External reset
• Status Indicator LED
• Emergency Stop

Figure 1– Tracker Control Box

Soltec
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Tracker Control Box ratings and environmental conditions are shown in table below:
Input configuration PV String Series Connection
Rated input voltage (Vdc) 2V
Operating output voltage range (Vdc) 16-32 V
Range of input operating current (Idc) 3 – 12 A
Maximum continuous output current (Adc) 10 A
Maximum input current (Idc) 12 A
Maximum input voltage (Vdc) 6V
Environmental range -20° to +55°
Humidity range 10 - 100 %
Enclosure environmental rating IP 65
Maximum Altitude 2000 m
Box dimensions (each) 192 x 397 x 190 mm
Weight 6.4 kg
Table 2: Ratings – SF7 Tracker Control Box

3.1 Main control internal components

Figure 2 – Control diagram

Soltec
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3.2 Electronic components distribution

Temperature sensor Series Power Supply

Battery Bank

Tracker-Controller Over-Angle Detector

Figure 3 – Electronic circuit distribution

3.3 Types of Tracker-Controllers

There are two types of Tracker-Controllers depending on their location in the Layout. Their main
difference is their communication role and interface.
• HEAD-TRACKER1:
Features two communication ports. One RS-485 communication port, isolated from the
rest of the circuit and a Radio communication module.
First port connects input and output RS-485 cables of this port physically to do not
interrupt communication in case of Tracker-Controller failure. This port is connected in
series to ‘Head’ bus.
Second port consist on a radio communication module. This radio module allows Tracker-
Controller to join the multi-hop network. It acts as a communication bus starter of the
channel named ‘Sub’. This port works as a repeater of the information that device receive
by any of their communication port to the other.
• SUB-TRACKER2:
Features only one communication port consisting on a radio communication module. This
radio module allows Tracker-Controller to join the multi-hop network in ‘Sub’
communication channel.

Color code for identifying Tracker-Controllers:

1
Head-Tracker-Controller has a black enclosure with logo in orange and green Tracker-Controller PCB
inside.
2
Sub-Tracker-Controller has a black enclosure with logo in black and blue Tracker-Controller PCB inside.

Soltec
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Reference Description Reference Description

SF7-EL-00-000 Head Tracker Control Box SF7-EL-01-000 Sub Tracker Control Box

3.4 Tracker field distribution

Typically, Head Trackers bus is vertical in the N-S

axis, from the Head-Tracker that is closest to the
communications cabinet.
Sub-Trackers communicate with their Head-
Tracker over the air, by radio. There is no RS-485
cabling from the Heads to the Sub-Trackers.
Communications between the GW and Head-
Trackers still uses RS-485 cabling.
An example is shown in Figure 4.

Figure 4 – Tracker field distribution

Soltec
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4 Mechanical assembly of the Tracker Control Box

Tracker Control Box (TCB) is installed under the rotation axis beside the gear train.
TCB do not be installed until all cabling of each Tracker is finished. RS-485, RF antenna, PV lines,
DC motor. Connectors are IP67 only in lock condition, previous exposure of inside connector
could damage them and generates mal functioning.

4.1 Assembly of TCB’s Support Plates

Tracker Control Box will be provided with Support plates assembled.

4.2 Assembly of TCB to Torque Tube

TCB installation parts:

Item Reference Description Quantity
SF7-EL-01-000* Sub Tracker Control Box 1
1*
SF7-EL-00-000* Head Tracker Control Box 1
*One or another item would be installed according to layout distribution.

TCB installation fasteners and torque specs:

Torque
Item Metric Description Quantity
(Nm | ft-lb)
2 Flat washer M8, DIN 125 4
3 M8 U bolt M8 2 3-8 | 2.2-5.9
4 Hex nut M8, DIN 985 4

Head-tracker Sub-Tracker

Figure 5 – Exploded view of TCB assembly

Soltec
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4.2.1 Installation process

1. Installation of the TCB on the rotation axis beside the rotation axis
2. Coupling made via bolting of the clamps

Figure 6 – TCB assembly

4.2.2 Installation criteria

South North

US North
SI US
Fractional
Parameter Metric Decimal
(feet-
(mm) (inch)
Inch)
a
Figure 7 – Position of TCB
South

Parameter SI Metric (mm) US Decimal (inch) US Fractional (feet-Inch)

a 200 ± 100 7.9 ± 3.9 7 13/16" ± 3 7/8"

Soltec
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5 Cabling
Any cable connected to Tracker Control Box must be installed considering adequate cable relieve
to avoid any possibility of tangling/pinching. Cable must be fixed to structure nearby TCB to
minimize mechanical stress on TCB connectors, also consider extra cable relieve to prevent water
accumulation in connectors.
As example, see Figure 21 - Cabling the motor in Section 5.4 (Motor cabling).
It is responsibility of the installer to guarantee that cabling installation is adequate
following all recommendation in this manual and good practices procedure standards.

5.1 Self-Powered cabling

• The Series Power Supply (SPS) must be connected in series with panels. It can be
connected at any point of the string, but it is recommended to connect to the point of
the string with less voltage to ground, for further durability.
• The TC can be grounded, as the SPS is input to output isolated.
• The short circuit current (ISC) of the string must be lower than the maximum input current
specified for the SPS.
• The maximum power point current (IMPP) of the string must be close to the rated current
specified for the SPS.
• In case of low current panels, the SPS must be connected in series to a branch of strings
in parallel, to ensure rated current specifications.
• In general terms, the current operation range of the DC line must match the current
operation range of the SPS, to ensure operability in a wider radiation range and to
maximize the system availability.
The SPS is a load to the power line. At a DC power load, the current enters through the positive
terminal and exits through the negative terminal, and the voltage is positive between the positive
terminal and the negative terminal. In this sense, the PV+ terminal of the SPS must be connected
to the positive of the previous panel, while the PV- terminal of the SPS must be connected to the
negative of the next panel.
For Self-power connexion please see drawing of “Wiring_Tracker Control Box Power Connection”.

Series Power Supply - Input Ratings

Maximum input continuous current (IIN) 12A
Input rated current (IIN) 6–8A
Input operating current range (IIN) 3 – 12A
Maximum Input operating voltage (VIN) 6V
2V With cycle battery charge
Rated Input operating voltage (VIN)
0.5V With floating battery charge
Table 3 – Electrical ratings

Soltec
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High voltage may be present inside the TCB. The TCB must be completely disconnected
from the PV string for manipulation. Self-powered Tracker-Controller gets power from
DC strings. It is connected in series with the PV modules, becoming a part of the DC
string. Safety procedures must be followed to connect/disconnect the TCB to/from the
DC string. Safety procedure for disconnection of the TCB from the PV string is described
in Annexe 1.
.

Figure 8 – Series Power Supply installation diagram.

Figure 9 – PV connectors

In order to ensure the compatibility between Tracker Control Box PV connectors and PV
connectors of the cables which come from photovoltaic panels, Soltec provides a pair of
photovoltaic cables as adapter. These cables have one ending terminated with a PV connector
compatible with the TCB connector, and the other will end in cut cable. Installer must terminate
this cable with a connector, compatible with installation PV connectors.
This is standard solution supplied, but it is subject to changes. Soltec reserves the right not to
supply it in case it is not deemed necessary, or to modify the lengths due to agreements with the
client or its own installation criteria.

Soltec
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Figure 10 - PV connector assembly

5.2 Communications cabling

5.2.1 RS-485 cable

The RS-485 communications cable will connect in a line of Head Tracker communication bus all
Head Tracker associated to a specific Gateway. The connector is field attachable, and the
assembly is described in Figure 12 to Figure 16.
Depending on the layout of the Trackers in each plant, the controller will have a specific
communication cabling configuration. There are two possible configurations:
Intermediate Head-Tracker
There are two communication cables connected to this Tracker Control Box:
1. RS-485 head-input line: 1 Twisted Pair + 1 Conductor + drain wire, shielded cable
2. RS-485 head-output line: 1 Twisted Pair + 1 Conductor + drain wire, shielded cable

End-of-line Head-Tracker
There is one communication cable connected to this Tracker Control Box:
1. RS-485 head-input line: 1 Twisted Pair + 1 Conductor + drain wire, shielded cable
2. An end-line connector will be assembled in the RS-485 Out connector highlighted in
Figure 17.

Figure 11 - End-of-line Connector

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RS-485 Connector Assembly

Figure 12 – Connector parts Figure 13 – Connector pin number

Figure 14 – Introduce cable thought the connector parts Figure 15 – Screwed wires

Figure 16 – Connector finished ready to installation

Overall outside diameter (OD) of RS-485 cable must be in the range: 4-8mm [0.157”-
0.315”]. Overall jacket cable must be stripped 25mm [1”] and the wires (AWG 22)
must be crimped with wire ferrule, with a length of: 10mm [0.4”].
Connector Gland must be tighten enough to guarantee IP68 protection.

Figure 17 – RS-485 connector assembly

Soltec
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5.2.2 Radio

Two antenna radio cables ended in a SMA

connector, will be screwed to their
respective SMA antenna radio connector in
the box.

Figure 18 – SMA connector assembly

Antenna radio + cable should be assembled and fixed to structure previous to Tracker
Control Box cabling. For mechanical assembly procedure, see “SF7 Assembly Manual”.

5.3 End-Limit Switch

The end-limit switch integrated in Tracker Control Box provides redundancy to the angle
measurement, acting as an angular position limit switch independent from the control, that cuts
motor power when the angle measured in the Over Angle Detector (OAD) exceed the limit angle
settled.
No cabling is required during installation for this safety End-limit switch option.
The PCB with Limit Switch functionality (OAD) should only be operated by Soltec
technicians.

5.4 Motor cabling

The DC motor comes already provided with a cable with optimum length and motor cable
connector, ready to assembly with motor connector at the Tracker Control Box. The motor must
be mechanically installed according to ‘SF7 assembly manual’ before proceeding with the cabling.

Figure 20 – Motor connector Figure 19 – DC Motor

Soltec
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Motor cable must be fixed using special outdoor cable ties that match all
environmental requirements of the project (Temperature, saline environment
resistance, etc.)
The cable should be fixed with enough cable relief to ensure wires run without
possible tangling/pinching between motor tie and torque tube tie, and among torque
tube tie and box to prevent water accumulation in connector entrance.
The following figure is only a graphic representation, it is responsibility of the installer
to guarantee that cabling installation is adequate, and any cable will not suffer any
damage or stress.

Cable tie to
torque tube

Cable tie to
DC Motor
Cable relief to prevent
water intrusion into the box

Figure 21 - Cabling the motor

5.5 Battery power bank installation

With the Tracker Control Box assembled in its correct position under torque tube, we can proceed
to install the battery power bank inside the box. To do it, is necessary a torque limitable electrical
screw driver with Tip Allen Key 4 to open the box. And two gel lead batteries3 12V@7.2Ah,
connected in series (the positive terminal of Battery 1 with the negative terminal of Battery 2) by
a cable with a fuse.

3
Gel battery must be approved by Soltec to ensure all requirements are fulfilled. TCB guaranty may be
compromised if not approved batteries have been installed.

Soltec
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Figure 22 – Electrical screw driver Figure 23 – Two gel lead batteries connected with fuse

First step is to open the box. Unscrew the three screws on the top side of the box front view and
rotate the cover until the box is fully open as in Figure 24. Leave the cover that way.
With the box open we proceed to insert both batteries, with the fuse cable connected as shown
in Figure 22, in the reserved space for it. First insert the batteries half way inside the box, in order
to easily connect the positive terminal of Battery 1 to the red cord coming out from inside the
box, and the negative terminal of Battery 2 to the black cord coming out from inside the box. Hold
up the battery cords and insert the rest of the batteries.
Be careful while introducing the batteries inside the box, in order not to damage cables or
electronic components inside.

Figure 24 – Batteries ready to be inserted into the box

Before installing batteries check that Stop Emergency button is pressed.

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Figure 25 – Battery power bank already installed

When the battery installation is complete, the TCB must be closed using components listed below
and following torque recommendations:
Component Torque
Metric Description Quantity
no. (Nm | ft-lb)
1 Washer M5 DIN 125
2 M5 Screw M5 x 10 DIN 912 3 2 – 3 | 1.5 – 2.2
34 Threaded insert M5 Series 16

Figure 26 – TCB closing procedure

4
Item ‘Threaded insert’ is already inserted in the enclosure. No manipulation is required.

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Soltec´s batteries are charged in factory. However, some losses can occur due to storage or any
circumstances, and power requirements during installation and commissioning could exceed
batteries capacity. Then it is necessary to charge the batteries. The batteries can be charged
using one of the modules near to the Tracker Control Box. For it, you just connect the module
connectors to the TCB as shown in next illustration:

Figure 27 – Panel mode connection to charge batteries

Before making any movement of the Tracker make sure that no any tangling/pinching
will occur in cabling.

Main features of the rechargeable batteries are:

Nominal Voltage 12 V (6 cells per unit)
Nominal Capacity (25oC) 7.2 Ah @ 20HR-rate (to 1.80Vpc)
Dimension L151mm x W65mm x H101mm
Terminal Type Fasten Tab F2 6.3 mm
Table 4: Batteries main features

This symbol, which can be seen in the outer part of the TCB, means that, in case
it was necessary to replace the batteries, the new ones must be rechargeable
and have the same characteristics as those described in Table 4.

Soltec
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6 Connections
Electrical connection of the Tracker Control Box.

6.1 Components

Component Description Quantity

TCB full assembly
Tracker Control Box MK III
PCB Tracker-Controller V5.
Series Power Supply v .
5 Limit Switch. OAD v . _Rev b
6 Gel Battery V@7. A
7 Emergency Stop
8 Status Indicator LED
9 Vent Gore
0 Motor connector
RS- 85 connector (Head / Sub) /0
SMA connector
MC female connector
MC male connector

6.2 TCB External connectors

Side view: LED, Emergency Stop, Vent Gore, 2 SMA radio connectors, 2 Multi-contact connectors
for strings, 2 RS-485 connector and motor connector.

Reference: SRM-EL-00-000/ SRM-EL-01-000

Description: Tracker Control Box. Side view.

Soltec
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6.3 Internal connections

All internal connection of Tracker-Controller (TC), Connectors, Series Power Supply (SPS), Over-
Angle detector (OAD) and temperature sensor are made at Soltec factory. No manipulation of
any of this component is allowed without direct supervision of Sotec’s authorized technician.
No manipulation of any of the internal component of the TCB is allowed, except for batteries.
The box can only be opened during the installation / replacement of the batteries .

6.4 Electrical risk

Due to SPS is connected in series to the string, electrical risk is present in SPS primary side. Primary
and secondary stage of SPS are isolated. To forestall risk of an electrical exposure, a Lexan plate
is disposed to prevent any human contact with high voltage exposed circuits.
Electrical risk is signalized in Lexan plate by an electrical risk sticker.
It is totally forbidden to manipulate or remove Lexan plate from its support.

Soltec
Figure 28 – Electrical risk