Technical

tracker
Specification
Project:

Customer:
 Revisión Autor Descripción Fecha
R01 AJC Emisión inicial de documento 15/12/17
R02 A.A Alimentación por panel 9/1/17
R03
R04
R05
R06
R07
R08
R09
R10

Contenido

1. SCOPE .................................................................................................................................... 3
2. STI H-250 TRACKER DIMENSIONS ......................................................................................... 4
3. SERVICE CONDITIONS .......................................................................................................... 5
4. SITE CONDITIONS .................................................................................................................. 5
4.1. Tolerances slopes allowed in terrain slope .............................................................. 5
4.2. Support tolerances ...................................................................................................... 6
4.2.1. Ramming depth ................................................................................................... 6
4.2.2. Supports Verticality ............................................................................................. 6
4.2.3. Supports Rotation ................................................................................................ 6
4.2.4. Supports Deviation .............................................................................................. 6
5. TRACKER MECHANICAL COMPONENTS ............................................................................. 7
5.1. Foundations.................................................................................................................. 7
5.1.1. Direct ramming .................................................................................................... 7
5.1.2. Predrill + ramming ............................................................................................... 7
5.1.3. Micropile .............................................................................................................. 8
5.2. Aerial structure ............................................................................................................ 9
5.2.1. Drive Set................................................................................................................ 9
5.2.2. Rotation and a regulation part. ....................................................................... 11
5.2.3. Torque Tube and arm........................................................................................ 12
5.2.4. Rods .................................................................................................................... 14
5.2.5. Belts ..................................................................................................................... 15
5.3. Module and module joints ....................................................................................... 16
5.3.1. Bolted Joint (Does apply to this project) ........................................................ 16
5.3.2. Fastened Joint (Does not apply to this project) ............................................. 16

1
6. CONTROL & COMUNICATION SYSTEM.............................................................................. 17
6.1. General facts; key elements ................................................................................... 17
6.1.1. Tracker Control Unit (TCU) ............................................................................... 17
6.2. Innovation and technology ..................................................................................... 18
6.3. Communication Wireless: ........................................................................................ 19
6.3.1. Why ZigBee ........................................................................................................ 19
6.3.2. Site Analysis ....................................................................................................... 20
6.4. Quick commissioning; four steps ............................................................................ 21
6.5. Power supply, self-power from PV panel ............................................................... 22
6.5.1. System features ................................................................................................. 22
6.5.2. Operation mode................................................................................................ 23
6.5.3. Battery life time .................................................................................................. 23
6.6. Back tracking ............................................................................................................ 24
6.7. Remote Monitoring & Predictive Maintanance ..................................................... 24
6.8. Remote Monitoring & Predictive Maintenance (optional) ................................... 25
6.8.1. System overview ............................................................................................... 25
6.8.2. Site and TCU´s status -Alarms .......................................................................... 26
7. GALVANIZED REPAIR PROCEDURE AND ZM ..................................................................... 27
7.1. Rust Cleaning ............................................................................................................. 27
7.2. Surface Sanding ........................................................................................................ 27
7.3. Surface Cleaning ...................................................................................................... 27
7.4. Surface Painting ........................................................................................................ 28
7.5. Tears,burrs and zinc residues ................................................................................... 28
7.6. Pregalvanized parts .................................................................................................. 29
7.7. Bolts and joints ........................................................................................................... 29
7.8. Others ......................................................................................................................... 30

2
1. SCOPE

This document has been elaborated by STI NORLAND SL. It summarizes all the relevant
technical information of the STi-H250 horizontal tracker.

Disclaimer: This publication is intended only for a specific product, not generic, on demand, project number
1038. Pictures and illustrations, technical info, annexes, data and descriptions were right at time of emission. STI
NORLAND accepts no responsibility for any inaccuracies or omissions that may appear in this publication,
although great care has been taken to make it as complete and accurate as possible.

STI NORLAND reserves the right to make the necessary changes resulting from continuous development and
improvement without notice. In this sense, some of the parts can be modified, and therefore, thickness, steel
grades, standards, corrosion protection, control and communication features, may evolve in the life of the
product. Always consult STI NORLAND for the latest version of this publication.

Total or partial reproduction of this publication and / or its attachments, as well as its storage in a word
processing system, transmission by electronic, mechanical, photographic or otherwise, or recording,
translation, editing, compact or extended, is prohibited without prior written permission of STI NORLAND.

The STI NORLAND items, spare and / or accessories have been specially designed for this product and specific
project. The non-original items, parts and / or accessories have not been examined or approved by STI
NORLAND, so their adequacy and / or safety cannot be certified, whether they are already installed or to be
installed in the product. STI NORLAND do not accept, therefore, liability for damages caused by the use of items,
spare parts and / or non-original accessories.

3
2. STI H-250 TRACKER DIMENSIONS

Typical general dimensions on 30 string/module.

N-S length A m 60
Distance between Lines B m 4-8.
Distance East - West C m 6 - 10 .

Module Height D m 1,25

The STi-H250 tracker has been designed to place 63 Modules per Torque Tube disposed
DIRECTIVES AND STANDARDS COMPLIANCE

2006/42/CE Machinery directive

2006/95/CEE Low Voltage Directive
2004/108/CE Electromagnetic Compatibility Directive
UNE-EN ISO 14121-1: 2008 Machinery security
UNE-EN ISO 12100-1 Machinery security
UNE-EN ISO 12100-2 Machinery security
UNE-EN ISO 15609-1 Welding procedure specification

4
3. SERVICE CONDITIONS

Operating Range:

- ±55º with backtracking option.

*If E-W slope is higher than 5% this operating range will be reduced.

Environment:

- Temperature range: -10º / +50º.

- Wind: The tracker will be calculated depending on wind conditions for each
project.
- Category: The tracker will be calculated depending on category conditions for
each project.
- C2/ C3 according to ISO 12944-2 standard

4. SITE CONDITIONS

4.1. Tolerances slopes allowed in terrain slope

The STi-H250 can be allocated on a terrain with this maximum slopes;

 E-W Direction:

Maximum slope allowed up to 10% between the two consecutives lines of the tracker.
There is not any mechanical restriction between slopes changes on consecutives
trackers.

 N-S Direction:

Maximum slope allowed of up to 15%. Local slope changes between 2 lines Torque Tube
(VIT) allowed of ±2%.

Please remind that the torque tube creates a straight line in N-S. Therefore, earth
movements or additional heights in the supports shall be considered to compensate
uneven terrains.

5
 4.2. Support tolerances

4.2.1.Ramming depth
Please note that the supports (SOP001, SOP002 and SAC001) shall be buried onto the
ground according to their minimum and maximum ramming depths defined in the
project.

4.2.2.Supports Verticality
In case of any Support (SOP001, SOP002 or SAC001) is inclined more than 2º from its totally
vertical position on N – S direction, or more than 1º on E – W direction, the affected Support
shall be extracted and replaced with new one.

 Maximum Vertical Deviation N – S: ± 2º

 Maximum Vertical Deviation E – W: ± 1º

4.2.3.Supports Rotation
In case any Support (SOP01) was rotated more than 3º from its theoretical position, the
affected Support shall be extracted and replaced with new one.

 Maximum Rotation Deviation: ± 3º

4.2.4.Supports Deviation
Drive Support (SAC001) support-head is considered as the origin point (0,0,0) of the
tracker. All deviations described above are referenced to this point.

In case of any Support (SOP001, SOP002) was deviated more than its theoretical position,
the affected Support shall be extracted and replaced with new one.

 Axis X (E – W) Deviation, Maximum on Support Head (SOP001± 40 mm ; SOP002± 50 mm)

 Check Procedure: Deviation on Base based on verticality for Maximum on Head:

[º] 0 0,25 0,5 0,75 1

[mm] 50 45 40 35 30

 Axis Y (N – S) Deviation, Maximum on Support Head (SOP001± 40 mm ; SOP002± 50 mm)

 Check Procedure: Deviation on Base based on verticality for Maximum on Head:

[º] 0 0,25 0,5 0,75 1 1,25 1,5

[mm] 50 45 40 35 30 25 20
In case of any SOP002 Support exceeded its ramming depth above or below 30 mm from
its theoretical position, rejected or not, it shall be rammed the missing length or extracted
and rammed again till correct one.

 Maximum Axis Z Deviation: ± 30 mm

SOP001 Support ramming tolerance it is related to the torque tube slope as shown in the table
below:

TT slope [%] 0 5 10 15
Tolerance [mm] ±30 ±25 ±20 ±15

6
5. TRACKER MECHANICAL COMPONENTS

The components of the STi-H250 tracker can be grouped in three parts.

 Foundation

 Aerial structure

 Modules and module joints

5.1. Foundations

The STi-H250 tracker needs 9 supports on its standard configuration, per Torque Tube. The
Drive foundation and its opposite uses IPE or HEA, while the rest the supports uses profiles
such as C profiles, square and rectangular tubes or IPE type profiles. There different type
of foundations:

5.1.1.Direct ramming
This kind of foundation consists on ramming machine onto the ground, following the next
steps:

 Place the profile in its correct position.

 Start ramming the pile till its correct height.

 Check the ramming tolerances several times along this process, with a gauge
meter and an inclinometer

5.1.2. Predrill + ramming

This kind of foundation is used to execute foundations with driven piles, when direct
ramming into natural soil is not possible (soil is too hard). The proposed solution consists
of pre-drilling the soil, filling with sand compacted in layers and driving the pile.

 First step is drilling the hole in the soil till the calculated depth.

 Second step is filling this hole with sand, compacted in layers, assessing a
minimum compactness.

 Finally, ram the profile in the new ground as described in 5.1.2.1.

7
 5.1.3.Micropile
This foundation consists of drilling the soil, placing the pile inside the hole and filling with
mortar. Is used ground conditions has not enough resistant capacity.

 First step is position the micropiling machine and start executing the micropile, till
reaching the nominal micropile depth.

 Introduce the support-pile inside the micropile.

 Fill with mortar, ensuring the complete filling of the hole.

8
 5.2. Aerial structure

5.2.1.Drive Set
The drive set is composed by a planetary gear box assembled onto the slewing Wheel.

With the following general characteristics.

Rated Voltage 24 VDC

Rated speed 1.500±10 % RPM

Motor-Gear Rated current 6,4 A

Rated Power 155 W

IP Class 65

Max Holding Torque 50 KNm

Tracking Time from 55º to 0º 6,2 minutes

Slewing Wheel
Lubrication Grease

IP Class 67

9
A foundation regulation part set is home to the slewing Wheel, with the following joints.

ITEM 1 ITEM 2 SIZE GRADE PROTECTION

Drive regulation plate (PRE002) I -BEAM (SAC001) 8 X M16 8.8 Zinc Nickel
Drive regulation plate (PRE002) Slewing Wheel 4 X M20 8.8 Zinc Nickel
Torque tube (VIT001) Slewing wheel 8 x M20 8.8 Zinc Nickel

Rotation and
regulation part

PART UNITS THICKNESS STEEL GRADE TREATMENT

S275JR-UNE-EN Hot Galvanized – UNE-EN-
Drive Regulation Plate 2 ≥10
10025 ISO1461

10
 5.2.2.Rotation and a regulation part.
The Torque Tubes are joined to the Foundation Supports by the Rotation and Regulation
System that allows movement to the tracker. At the same time, the Rotation and
Regulation System absorbs the possible deviations in the Support positioning.

Rotation and
regulation part

It is formed by different materials and is joined to the Supports with 2 x M20 DIN933 c10.9
bolts through a regulation part. The thickness, grades and treatments of the different parts
that form the Rotation and Regulation System are described in the following table:

UNITS
PART THICKNESS STEEL GRADE TREATMENT
per TT
Hot Galvanized – UNE-EN-
Regulation Part 8 ≥6 S275JR-UNE-EN 10025
ISO1461
Circular Housing 8 - Aluminum -
Rotation Cap Flange 8 - Plastic -
Top Rotation Cap 8 - Plastic -
Lower Rotation Cap 8 - Plastic -
S 275 JR – UNE-EN- Hot Galvanized – UNE-EN-
U Part 2 ≥2.5
10025 ISO1461
U Bolt 2 Ø8 Steel UNE 36066 Zinc Nickel

11
 5.2.3.Torque Tube and arm.
The Torque Tubes are formed by square tubes of different steel grades joined between
them by the Torque Tube Joint Clamps with 6 x M16 DIN980 c8.8 bolts. The Torque Tube is
the responsible for transmitting the movement to the PV modules and is formed by tubes
of hot-rolled steel S275JR and S355JR as standard UNE-EN 10025 and hot galvanized as
standard UNE-EN-ISO 1461.

Torque Tube

The thickness, grades and treatments of the different parts that form the Torque Tube are
described in the following table:

UNITS
PART per THICKNESS STEEL GRADE TREATMENT
Tracker
Central Torque Tube Section 1 Hot Galvanized – UNE-EN-
2 ≥5 S 275 JR – UNE-EN-10025
(motor) ISO1461
Central Torque Tube Section 1 Hot Galvanized – UNE-EN-
1 ≥4 S 275 JR – UNE-EN-10025
(sister) ISO1461
Hot Galvanized – UNE-EN-
Torque Tube Section 2 2 ≥3 S 275 JR – UNE-EN-10025
ISO1461
Hot Galvanized – UNE-EN-
Torque Tube Section 3 2 ≥3 S 275 JR – UNE-EN-10025
ISO1461
Hot Galvanized – UNE-EN-
Torque Tube Section 4 2 ≥3 S 275 JR – UNE-EN-10025
ISO1461
Hot Galvanized – UNE-EN-
Torque Tube Joint Clamp 12 ≥4 S 275 JR – UNE-EN-10025
ISO1461
The equivalent on Brazilian manufacturing:

UNITS
PART per THICKNESS STEEL GRADE TREATMENT
Tracker
Central Torque Tube Section 1
2 ≥5 USI CIVIL 300 – TUB 260 Hot Galvanized – NBR 6323
(motor)
Central Torque Tube Section 1
1 ≥4 USI CIVIL 300 – TUB 260 Hot Galvanized – NBR 6323
(sister)
Torque Tube Section 2 2 ≥3 USI CIVIL 300 – TUB 260 Hot Galvanized – NBR 6323

Torque Tube Section 3 2 ≥3 USI CIVIL 300 – TUB 260 Hot Galvanized – NBR 6323

Torque Tube Section 4 2 ≥3 USI CIVIL 300 – TUB 260 Hot Galvanized – NBR 6323

Torque Tube Joint Clamp 12 ≥4 USI CIVIL 300 – TUB 260 Hot Galvanized – NBR 6323

12
In the middle of the Torque Tubes are placed two arms, keeping its symmetry. Those Arms
are the responsible of transmitting the movement of the Rod to the Torque Tubes. The Arms
are joined to the Torque Tube with the help of a Clamp and 4 x M16 DIN980 c8.8 bolts.

Arms

The thickness, grades and treatments of the different parts that form the Arms are
described in the following table:

PART UNITS per TT THICKNESS STEEL GRADE TREATMENT

S 275 JR – UNE-EN- Hot Galvanized – UNE-EN-
Arm Clamp Plate 1 ≥5
10025 ISO1461
Arm Tube (with half S 275 JR – UNE-EN- Hot Galvanized – UNE-EN-
1 ≥5
clamp plate) 10025 ISO1461

13
 5.2.4.Rods
The Rod is the system that transmits the movement between the Drive Arm and the Arms
of the Torque Tubes. The Rod is formed by Two square tubes of hot-rolled steel S275JR as
standard UNE-EN 10025 and hot galvanized as standard UNE-EN-ISO 1461. The rod is
joined to the arms with Stainless Steel Pins.

Rods

The thickness, grades and treatments of the different parts that form the Rod are
described in the following table:
PART UNITS THICKNESS STEEL GRADE TREATMENT
2 between S 275 JR – UNE-EN- Hot Galvanized – UNE-EN-
Rod ≥3
2TT 10025 ISO1461
S 275 JR – UNE-EN- Hot Galvanized – UNE-EN-
U Joint Profile 4 per TT ≥5
10025 ISO1461
S 275 JR – UNE-EN- Hot Galvanized – UNE-EN-
Outer U Joint Profile 4 ≥5
10025 ISO1461
Pin Tube 1 per TT - Stainless Steel AISI 304 -

The equivalent on Brazilian manufacturing:

PART UNITS THICKNESS STEEL GRADE TREATMENT
2 between
Rod ≥3 USI CIVIL 300 – TUB 260 Hot Galvanized – NBR 6323
2TT

U Joint Profile 4 per TT ≥5 USI CIVIL 300 – TUB 260 Hot Galvanized – NBR 6323

S 275 JR – UNE-EN-
Outer U Joint Profile 4 ≥5 Hot Galvanized – NBR 6323
10025

Pin Tube 1 per TT - Stainless Steel AISI 304 -

14
 5.2.5.Belts
The Omega Belts are the direct support for the PV modules on the STi-H250 Tracker. The
Belts are formed by hot-rolled steel S275JR as standard UNE-EN 10025 and hot galvanized
as standard UNE-EN-ISO 1461 or hot-rolled steel S 250 GD / S 280 GD / S 350 GD as
standard UNE-EN 10346 or the equivalent Brazilian.

Belts

The Belts are joined to the Torque Tube with M8 steel U Bolt. The thickness, grades and
treatments of the different parts that form the Belts are described in the following table:

PART UNITS per TT THICKNESS STEEL GRADE TREATMENT

S 280 GD– UNE-EN

Omega Belt 38 ≥1,5 Pregalvanized steel
10346

U Bolt 42 Ø8 Steel UNE 36066 Geomet 500-B / Zinc Nickel

S 275 JR – UNE-EN-
U Part 42 ≥2,5 Hot Galvanized – UNE-EN-ISO1461
10025

Or the equivalent on Brazilian manufacturing

PART UNITS per TT THICKNESS STEEL GRADE TREATMENT

Omega Belt 38 ≥1,5 ZAR 280 –NBR 7008 Pregalvanized steel

15
 5.3. Module and module joints

The STi H-250 tracker has been designed to place 63 PV Modules per Torque Tube, being
able to accommodate many other numbers of PV Modules. It is important to point that
all modules must have holes in its frames to allow binding with belts. The joint between
PV modules and the STi H-250 Belts will be made with bolt or with fasteners.

5.3.1.Bolted Joint (Does apply to this project)

The bolted joint consists in lock the PV module to the Belt with 4 x M6 DIN 6921 A2-70.

5.3.2.Fastened Joint (Does not apply to this project)

The fastened joint consists in lock the PV module to the Belt with a fastener using a
pneumatic gun. This system is very fast and secure, and provides the PV module the
stability that needs.

16
6. CONTROL & COMUNICATION SYSTEM.

6.1. General facts; key elements

6.1.1.Tracker Control Unit (TCU)

 Power supply, self power from the External PV panel

 Power supply from the grid AC (OPTIONAL)

 NCU (Network Control Unit)

 RSU (Remote Sensor Unit) (OPTIONAL)

17
 6.2. Innovation and technology

1.- keyboard with LED codes. Avoids computers

2.- 3 different products in one platform
General Benefits 3.- 3 different power supplies in 1 platform
4.- 1 assembly piece.
5.- PWM motor drivers

1 2
Wireless Quick
Communications Commissioning &
Bactracking tools
Robust, cheap & easy Parametrization and
to install commissioning are now
easy to perform.
Offsets set-up

Wireless
1.- modbus over zigbee
2.- network design tools & consultancy
3.- encryption safe
4.- power auto selection
5.- NCU upgraded to 200 TCUs
Sw tools
1.- 1 commissioning tool=scanner
2.- automatic network setup
3.- zero adjustment
4.- motor direction self detection
5.- PV panel irradiance estimation
6.- motor current monitor
7.- 3 dimmension back tracking algorithm

3 4
Self Powered Remote
systems Monitoring &
Predictive
Li FePO4 chemistry long maintenance
life & safe battery for
Avoids stops &
Self powered from PV
increases availabilityic
string

Operation modes Battery, LiFePO4 chemistry:

1.- 4 different modes: 1.- health monitor
- sleep 2.-. Self sleep mode
- auto 3.- self tracking freq adapter
- Low irradiance 4.- smart switch PV –Battery
- freezing 5.- research chemistry advantages

18
 6.3. Communication Wireless:

6.3.1.Why ZigBee
Reliable & Safe: Encryption available, mesh routing, Modbus protocol over air.

 Zigbee gateway allows access to the controllers handling multiple connections

to different serial devices that are addressed with a Modbus ID converting into a
Zigbee MAC address.
 -Mesh routing capabilities, and automatic network reconfiguration
 -Frequency agility: changes the working channel if excessive interference is
detected
 -Uses of the ISM band, available worldwide for low power applications.
 -implements expanded spectrum (DSSS) modulation, with a base rate of 250kbit/s

Until 1km range direct sight seen.

All devices work as routers connecting through a gateway ->SCALABLE

19
 6.3.2. Site Analysis

Antenna selection Solar Field condition

Wavelength analysis, dipole
monopole for maximum gain and
radiation pattern study taking into
account the electromagnetic mirrors.
or The presence of big metallic
surfaces in movement with moving
fading zones due to multipath
interferences. RF spectrum
simulation tools are used

Range estimation Final RF lay-out

The RF link is modelized by different factors After all RF simulation , final lay-out
expressed in logarithmic scale (dB) . is proposed for a safe networking,
Preceived (dBm)= Ptransmitted (max18 dBm) with sub-network gateways
- Transmitter Cable Loss (dB) efficient locations.
+ Transmitter Antenna Gain
- Free Space Loss
- Polarization Loss
+ Receiver Antenna Gain
- Receiver Cable Loss

20
 6.4. Quick commissioning; four steps

Use GPS barcode reader File processor for network assignment.

Addressing plan programmer.

1 Scan LOC barcode 2 Upload data

3 Commiss. setup
4 Parametrization

Router addresses configuration

and final Modbus address Calibration and functional
assignment. verification of tracking
parameters
Broadcast command. Network
verification

21
 6.5. Power supply, self-power from PV panel

6.5.1.System features

 Autonomous solar tracking algorithm

 Backtracking algorithm (see next page)
 Battery monitoring :
- State of charge
- State of health
- Temperature
- Voltage & current monitor.
 PV panel monitoring: V-I curves
 Smart switch for PV power when VI tracking is possible. Minimizes Depth
of Charge.
 Solar radiation real time estimation
 DC motor smart driver
- Slow ramp up, ramp down (PWM)
- Motor current monitoring
 Programmable safety positions
 Programmable tracking frequency
 Battery safe priority algorithm

Backtracking from 0
Backtracking to 0

Max. DoC 20%

22
 6.5.2.Operation mode

Low battery mode:

- Sleep mode. !!! Only 3mAmp consumption!!!
- Enough energy for safety position calculation
- Movement disable algorithm
Low irradiance mode:
- Minimizes movements. Energy saver. -> Frequency self- reduction
- Sleep mode when stopped
Night mode:
- Sleep mode.
- Awake order checking timer.
Freeze mode:
- When below -10ºC battery can’t be charged.
- Safety algorithm

6.5.3.Battery life time

Facts:
1.- Battery lasts more than 1.000 hours in sleep mode. 40 “dark” days. (100% DoC).
2.- It is recommended working band between 60% and 40%. >40.000 cycles ensured.
More than 10 years at >90% capacity

65% 65%

Normal 55% Normal

50%
Endurance
Endurance 45%
40% Zen
Zen 25%
20%
Ultra-Sleep
Ultra-Sleep

Figure 1.- Power Modes

23
 6.6. Back tracking

ADAPTATIVE PROPIETARY BACKTRACKING ALGORITHM:

Panel width, row separation, slope, tracker height, etc configurable.

Case 1 (no bactracking): Efficiency without back-tracking: with shadows (area

between cosin of Eff and total Eff). Mismatches->reduce production & lifetime

Case 2 (backtracking ) : Efficiency with back-tracking (no shadows cos eff=total

eff) ->More efficiency

6.7. Remote Monitoring & Predictive Maintanance

Please note that difference slopes N-S among torque tubes may cause shadowing.

24
6.8. Remote Monitoring & Predictive Maintenance (optional)

6.8.1.System overview

Modbus Master
CPU
Tracker SCADA
Datalogger+Router
Ethernet Ethernet- GPRS

Ethernet Switch-gateway

NCU-1 NCU-2 NCU-3

Zigbee-Rs485

TCU sub-network
Site Inverter SCADA

25
 6.8.2.Site and TCU´s status -Alarms

1
Availability
Any time sites availability Radiation reference
report from anywhere

Key parameters monitor

Motor current vs tracker angle can be used as a behavior
3
pattern.
Battery load, temperature etc can be monitored and
predicted

26
7. GALVANIZED REPAIR PROCEDURE AND ZM

The procedure related is intended only for reparation on-site, on items damaged due
to handling, transport and/or assembly works, as well as maintenance works.

The procedure related is based on Standard ISO 1461, except for allowed repair area,
which will be determined by client criteria.

7.1. Rust Cleaning

Scrape rusty surface with a wire brush. Apply a firm pressure combined with a forward
and backward movement.

Wire brush can leave permanent marks and scrapes on the surface that must be covered
with painting later (see step 4).

Use eye protection such as safety goggles to prevent injuries from rust particles
projection.

7.2. Surface Sanding

Sand the surface to remove all minor rust areas. Apply a firm pressure combined with a
forward and backward movement. If the area is flat and extensive, we recommend the
use of a belt sander for a quicker rust removal.

7.3. Surface Cleaning

Clean the area of oxide powder and rust particles left, as well as rest of dirt, mud and/or
debris. Use a soft brush, and a cloth with water and neutral soap if needed.

Let the surface to get completely dry before next step 8.4.

27
 7.4. Surface Painting

Paint generously the surface, including the marked and scraped areas, with rich zinc
painting or cold galvanized spray (complying with Standard 3549 or equivalent, minimum
98% content of zinc).

Apply as many layers at needed, waiting manufacturer recommended drying time

between coats.

Check that new galvanized thickness is of at least 100μm.

7.5. Tears,burrs and zinc residues

Tears, burrs and zinc residues are not usually removed, except in case of usage
requirements, adjustment with another items, or safety hazards.

In case removal is needed, use a file or a radial grinder with a flexible disc. Wipe the
surface with the sander for a fine finish.

Do not bump tears, burrs and zinc residues with a tool such as a hammer for removal.
May peel off the surrounding coating.

28
 7.6. Pregalvanized parts

Some items of the STi H-250 tracker as PUA001 or COM 001 are manufactured using pre-
galvanized steel (Z / ZM). Due to the manufacturing process, a lack of cover could
appear on edges.

This absence could result in expected corrosion products that will be protected naturally
afterwards during curing process. This phenomenon does not imply a defect of the
covering nor a reduction in the expected life service.

This items therefore do not need any repair on edges.

7.7. Bolts and joints

The manipulation of bolts, nuts and washers in assembly, overall in torqueing and contact
with tools and site dirty environment, can usually peel off the anticorrosion covering. In
this case, this detaching shall be repaired by the assembly or maintenance company by
using rich zinc painting or cold galvanized spray as described in previous paragraphs as
soon as noticed.

29
 7.8. Others

Most of the steel items of the Tracker STi H-250 are HDG (Hot Deep Galvanized) steel
manufactured. The HDG is an artisanal manual process, with random control according
to ISO1461 indications that cannot cover the 100% of the production.

Therefore, it is possible that some areas, specially the end of the tubes, profiles and wide
edges, may have minor naked zones. It MUST be repaired with rich zinc painting or cold
galvanized spray as described in previous paragraphs as soon as noticed.

As stated in the ISO1461 standard, the primary purpose of the galvanized coating is to
protect the underlying steel against corrosion. Considerations related to aesthetics or
decorative features should be secondary.

The occurrence of darker or lighter areas or some surface unevenness shall not be a
cause for rejection. The development of wet storage staining, primarily basic zinc oxide
(formed during storage in humid conditions after hot dip galvanizing), shall not be a
cause for rejection.

Lumps and zinc ash, that generally do not affect usage requirements or adjustment with
other items, shall not be a cause for rejection. Aesthetic effects (e.g. weld seepage)
resulting from the use of intermittent welds around overlapping surfaces in the fabrication
should not be a cause for rejection, but this minor defects are recommended to be
covered with zinc rich spray paint.

Additionally, all holes should be checked to be clean and without solid interferences
such as burrs or galvanized residues that could interfere with correct assembly of the
items. In such situation, proceed to pierce/file and correct, plus corresponding
galvanization repair with rich zinc paint or spray as described in previous paragraphs.

30