Annex I-5 Manual

TracSmart
Generic Installation Manual Rev.3
GENERIC INSTALLATION MANUAL

TRACKSMART PROJECTS
Rev.3
Document GSS-MI- 2018-01

Document: GSS-MI- 2018-01 Página 1 de 42
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DOCUMENT UPDATES RECORD

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INDICE
1. SUMMARY OF CONSTRUCTION TASKS AND KEY WARNINGS.................................................................... 4
2. GENERAL INFORMATION RESPONSABILITIES, SAFETY AND TRANSPORTATION ....................................... 4
3. TRACKSMART’S INFORMATION ................................................................................................................. 6
4. STORAGE OF THE STRUCTURE ................................................................................................................... 9
5. UNLOAD OF STRUCTURE ......................................................................................................................... 10
6. LIST OF TOOLS.......................................................................................................................................... 12
7. ASSEMBLY STEPS AND WARNINGS .......................................................................................................... 13
1. TIGHTENING SCREWS .......................................................................................................................... 13
8. ASSEMBLY OF STRUCTURE ...................................................................................................................... 14
2. PILLARS STAKEOUT AND INSTALLATION.............................................................................................. 14
3. ASSEMBLY AND LEVELLING OF SUPPORTING ELEMENTS. ................................................................... 18
a. MARKING AND CUTTING ......................................................................................................................... 21
b. MINIMUN DISTANCES.............................................................................................................................. 22
c. SECURITY ................................................................................................................................................. 23
4. ASSEMBLY OF MOTOR. ........................................................................................................................ 26
5. ASSEMBLY AND ALINGMENT OF SHAFT SUPPORT AND MOTOR. ....................................................... 27
6. ASSEMBLY OF MAIN BEAMS ................................................................................................................ 29
7. ASSEMBLY OF SECONDARY BEAMS AND ELECTRICAL WIRE................................................................ 32
8. ASSEMBLY OF PV-MODULES................................................................................................................ 34
9. ASSEMBLY OF CONTROL SYSTEM ........................................................................................................ 35
9. CHECK LIST QUALITY ................................................................................................................................ 37
10. SURVEYOR REPORT .............................................................................................................................. 37
11. ANNEX 1. REFERENCE VALUES FOR TIGHTENING TORQUES ............................................................... 38
12. ANNEX 2. DRAWINGS .......................................................................................................................... 39
13. ANNEX 3. CHECK LIST QUALITY............................................................................................................ 40
ANNEX 4. REQUIREMENTS AND INSTRUCTION TO INSTALL THE CONTROL .................................................... 41

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1. SUMMARY OF CONSTRUCTION TASKS AND KEY WARNINGS
Solar Steel recommends that construction steps be carried out in the following order:
CONSTRUCTION STEP KEY WARNING
Surveyor to mark the exact

To keep the same reference point
position of piles
Pile’s installation According to the foundation designed
Slew drive’s installation To check the orientation
Torque tubes’s installation Refer to project site plan
Align and secure row Check security of all fasteners after installation
Secondary beam’s installation
Modules’s installation According to manufacturer’s manual
Align and Secure modules
To check the metric and estándar in order to

To apply the torque
use the proper tools
To install controller Self powered or external power
To perform the steps to install the

Important to follow the order
controller
To fill the check list 100% of the structure
2. GENERAL INFORMATION RESPONSABILITIES, SAFETY AND

TRANSPORTATION
This manual is intended as a guide for the correct assembly of the Solar Tracker. Please, read it
carefully before starting assembly. The team undertaking the assembly of the solar tracker must be
qualified and specialized in this type of work.

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SOLAR STEEL manufactures different models of TrackSmart ; in each case the customer will
choose the option agreed for the particular project.
SOLAR STEEL is only responsible for the items it supplies.
SOLAR STEEL recommends the exclusive presence of authorized personnel for the installation of
the TrackSmart. Workers must be equipped with the required clothing and personal protective
equipment (helmet, gloves, harness, safety shoes, etc.) and take preventive measures such as not
standing under suspended loads, wearing gloves to avoid injury from irregularities in the surfaces of
ferrous materials, checking the moorings of the pieces, making sure that slings and cables have sufficient
strength to withstand the weight of the pieces to be raised and any other measures that are applicable
to the work being performed at all times.
It is strictly forbidden to commission the trackers without the approval of SOLAR STEEL; the
placement and verification of an anemometer is also mandatory. The wind control network
(anemometer) shall be designed according to the needs of each installation.
It shall be the responsibility of the customer to supply power to the trackers. SOLAR STEEL shall
not be liable for damages that may occur, for example, in a power outage in which the trackers are in
working position.
SOLAR STEEL supplies structure and fasteners according to the project. Customer will be
responsibility to replace the fasteners lost during the construction steps.

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3. TRACKSMART’S INFORMATION
TracSmart structure is composed of two sets of symmetrical main beams with respect to a
central slew drive, aligned in north-south direction. Above the main beams are placed a series of
secondary beams on which ultimately photovoltaic modules are installed. The whole structure is
supported by a series of pillars, ground embedded by means of the foundation solution chosen for each
project.
Real tracker could be different from 3D image
Fig.1 3D View
Every morning at sunrise, the drive starts the axis rotation, pointing the modules to the east, up
to the tilt angle limit for that day. Following the control algorithm included in the solar tracking system,
the drive is varying the angle of inclination, thus the orientation of the modules, ending at the end of the
day at its tilt angle limit westward.
A solar field will consist of several TracSmart settled according to designed layout. The different
trackers are independent of each other from the structural point of view, and have the ability to adapt
to slopes of up to 12% towards the north - south axis.
The structure is available in two versions with identical main dimensions and two different
structural rigidities, depending on the tracker location regarding its exposure to the wind. Each project
design may define combination of both versions for a solar field or just one of them.

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Several foundations are available for this tracker according to the site:
DIRECT RAMMING
PREDRILLING + RAMMING
MICROPILE
GROUND SCREW

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It is important to comply with the distances (maximum 300 mm) N/S and E/W between trackers
according to the slope of the soil.
Fig.2 Front view
Fig.3 Top view
Fig.4 Lateral view
To install the structure must be carried out with the proper tools. Take into account the
standard of the screws in order to have the proper tool to tight. Screw’s standard will be marked for
each specific project.

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4. STORAGE OF THE STRUCTURE

About the structure, the follow point shall complied on site:
 Once the components are unload on site, the packages must be opened to avoid
the white rust. The components should be stored inside a warehouse to avoid the white
rust or defect on the surface due to the water (rain, dew….).
 In case that the structure is mounted in a short time (not more than 4 days from
the unload on site), it is not necessary that the structure is stored in the warehouse.
 Fasteners should not be stored outdoors.
 To check if the good unloads is according to the packing list. If not, to notice by
written to Solar Steel
About the motors y controllers, the follow point shall complied on site:
 Motors and controllers (including modules) will be stored in a dry place (cover)
and only 1 level of height.
 To check if the good unloads is according to the packing list. If not, to notice by
written to Solar Steel.

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5. UNLOAD OF STRUCTURE
Structure is supplied in containers. All the structure is packaging on wood. Maximum dimensions
and weight are ( 12 x 2 x 2 meters – 2.500 kg). Machinery to unload the structure should be used
according to the dimensions and weight of the structure described above. Take measures for the follow
points:
 To store the structure in a clean storage area.
 To avoid cause damage in the palets, boxes, etc
 To check the packing list with the real structure unload on site.
 The handling of the load will be done by the length and not by the width of the load.
 Weights per package do not exceed 2.5 tons
 The wooden blocks have an opening in the base, which allows their manipulation.
 The packages carry slings of no return and each package goes on wooden skids, with straps on the
product and straps on the wooden blocks.
 All wood used in packing according to IPPC / NIMF-15 standard
 The handling of the packages during the loading and unloading of the container must be done on the
"nails" of the telescopic manipulator or any other used tool, which must exceed the center of the load
using the wooden blocks that allow the access of the Nails or useful, to keep the load
 Palletized material, loading / unloading is recommended using a telescopic manipulator.
 Beams loading / unloading is recommended with two telescopic handlers. Due to the length of the pieces
they must slide on the wooden chocks until they are outside the container, long enough to be removed in
the next maneuver; avoiding at all times damaging the floor of the container / platform. For this the load
must be fixed to the manipulator in a safe way, by means of slings, chains or similar.
 It is advisable to cover the "nails" / useful to avoid damaging the material in the loading / unloading, and
avoid affecting the galvanized or deform the structure, as well as the container (floor, sides and roof). You
must provide photographic report.
 The packages must be stored properly covered with wood, preventing the material from coming into
contact with the ground and its subsequent damage and deterioration.
 At the end of the discharge, it is advisable to clean the container: sweep the dirt and collect the remains
of the slings from the floor of the container, to avoid possible stoppages of the return of the container to
the yard of the terminal.
 The container / equipment must not be damaged during loading / unloading, if so, photographic report
must be provided as soon as possible to the shipper.
 Torque-tubes with rivets, controls, motors and piecerío, must be unloaded and stored with special care,
preserving the integrity of the packages and their contents. Photographic report must be submitted

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 The displacement inside the work of the materials will be carried out by vehicles and / or machinery
suitable for that purpose. Once arrived at the assembly and installation site, they will be transported by
manual means, taking at all times the adequate security measures for such task.

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6. LIST OF TOOLS
Below is a list with the tools needed for assembly of the structure, for both the electrical side
and the mechanical side:
 Markers
 Laser meter
 Digital lever
 Impact wrench
 Hammers
 Torque wrench
 Manitous
 Riveter

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7. ASSEMBLY STEPS AND WARNINGS
UNCOMPLIANCE to these installation instructions may cause void all warranties and
IRREPARABLE DAMAGES AND MAY RESULT IN PROPERTY DAMAGE, PERSONAL INLURY, AND/OS LOSS OF
LIFE. Therefore, any modification introduced by the assembly contractor must be approved by Gonvarri
prior to its execution.
All instructions in this manual are general. Each project may include particular instructions.
In order to ensure a successful outcome, these assembly steps should be conducted in the order
below related:
1 Pillars stakeout and installation
2 Assembly and leveling of supporting elements on central and general pillars
3 Assembly of motor
4 Assembly and alignment of shaft support and motor
5 Assembly of main beams
6 Assembly of secondary beams
7 Assembly of PV-modules.
8 Assembly of control system
9 Installation of controller
10 Check list quality
1. TIGHTENING SCREWS
In order to prevent that the fasters are seizure when torque is applied, it is important to comply
with the follow instructions, as stainless as HDG fasteners. It should be noted that if the threads are
used when there is dust, dirt, gravel or sand, the probability of seizure during the assembly increases
significantly.
1. Do not use high speeds of tightening, those do not have more than 20 rpm.
2. Do not apply a tightening torque above the recommended maximum. An excess of

tightening torque increases the probability of seizure. The fixing elements should be
adjusted to the proper torque using a torque wrench.
3. Use a lubricant or antifriction coating on the threads. In critical applications or that

require bolting at higher speeds, it is highly recommended to reduce the coefficient
of friction by applying the threads to the special antifriction coating, using lubricants
or treatments on the threads. In this way the friction between the threads decreases

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a lot and this reduces the risk of seizure.
4. Keep the threads clean of dust, especially dirt, gravel and sand.
8. ASSEMBLY OF STRUCTURE
2. PILLARS STAKEOUT AND INSTALLATION.
The installation of pillars will be made according to specifications of Engineering department.

The methods of implementation and the specific dimensions of the pillars will be specifically defined for
each project.
Motor pile cannot be regulated in height, so it has to be the first pile to ram in order to get the
reference for the extreme piles
For the direct ramming, it is necessary to take the same point of the pile. For example:
For any foundation, motor pile will be the first pile to be installed in order to be a reference for the rest
of the piles within tracker.
Nevertheless, some common topics are below related:
Tolerances
The proper installation of pillars, complying with design TOLERANCES is a must in order to
enable a proper assembly of the tracker.
Accurate stakeout of pillars coordinates, height & leveling, and proper performance of jobs
checking up vertical and twist deviation angles, should be committed in order to achieve maximum
quality. Otherwise, next assembly steps will be more difficult to do or even DISABLED.
Generally, tolerances to be fulfilled will be defined for each project. Otherwise stated:

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MOTOR PILE EXTREME PILES
β= 2º β= 2º
α= 1º α= 1º
MOTOR/EXTREME PILES HEIGHT PILES
MAX ± 5º H= Max ± 20 mm
Fig.5 Tolerances for pillars installation
The tolerances indicated in the drawings are those generated during the design phase to
facilitate assembly works and ensure the correct operation of the tracker.

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It is important to respect the tolerances on the distance between piles according to the
following:
c ± 20 mm
b ± 20 mm
d ± 30 mm
Pillars layout
The tracker is supported by a series of pillars following north-south direction.

- Central pillar: Galvanized steel profile
- Type pillar: Galvanized steel profiles. Symmetric with respect to the central pillar
Fig 6. Pillars layout
Pillars height leveling
The tracker may fit on terrains with north-south slope up to 12%. In order for final success,
leveling of top pillars during this stage should be set parallel to terrain average slope.

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Fig 7. Pillars Leveling
Central pillar – warning
Central pillar will support the motor. Final position of this will determine the real direction of
main beams. Therefore, any deviation should occur during this pillar erection will translate a big
impact for next assembly stages, and maximum assembly jobs quality must be provided.
NOTE: During the installation of the piles, damaged could be occur in the galvanizing cover.
Piles must be repair according to the UNE EN 1461. Paint, tools, etc are not supply by Gonvarri.
Galvanization Reparations
Clean the area of rust or dirt to

avoid residues, leaving a fairly
clean surface, free from flaking
of zinc or of any element which
would cause difficulties
adhesion.
Apply the zinc rich paint in the

affected area, following point 6.3
in the standard UNE EN ISO
1461.
Galvanization Finishing Touches

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In some cases, burr-free areas

appears in the structure.
Accumulations of zinc are not a
cause for rejection while they do
not interfere with normal
operation for the assembly of
galvanized parts.
Uncoated Areas
Release of the Zinc coating is

produced by hits on the
structure during transportation,
handling, storage or assembling.
To repair these uncoated areas,
instructions established in EN
1461, item 6.3, must be used:
1- Cleaning the area that is going to be
repaired (rust removal if any).
2- Applying zinc-rich paint according to
ASTM A780, until the average zinc coat
in the repaired zone is 100 microns.
3. ASSEMBLY AND LEVELLING OF SUPPORTING ELEMENTS.
The supporting elements will be placed on the pillars: motor supports on central pillar, and
regulation elements for shaft support on type pillars.
During operations on site, be aware of possible dimensional differences of elements to be
installed in different version of tracker (wind exposed vs wind hidden), should it be the case.
Fig 8.Motor supports and regulation/shaft support
Take into account, that there are a gap (50mm – specific for each project) between central pile
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and extreme piles.
In the event that the foundation (direct ramming and/or predrillin+ramming) does not reach the
depth indicated in the assembly drawings, the following procedures of action are established for all the
rejections.
FOUNDATION VALIDATION
Validation
% theoretical depth achieved Affectation What to do? Loads to apply
Criterion
Puntual 1 NA 1
L ≥ 100% Concentrated 1 NA 1
Global 1 NA 1
Puntual 1 NA 1
100% > L ≥ 90% Concentrated 1 NA 2
Global 1 NA 2
Puntual 4* 1,2*ELS 3
90% > L ≥ 80% Concentrated 3* 1,4*ELS 3
Global 2* 1,6*ELS 3
Puntual 5* 1,2*ELS 3
80% > L
Concentrated 6 1,3*ELS 3
The minimum length of L shall be 1 m
Global 6 1,4*ELS 3
Specific Area.
Soil surface with more or less homogeneous geotechnical characteristics with a maximum
dimensions of 1Ha.
Affectation
 Puntual: concrete points distributed uniformly by a specific area of the project or by the
whole area. Affection less than 5% of the pillars of the concrete or global area.
 Concentrated: concrete points distributed uniformly by a specific area of the project.
Affectation between 5% and 15% of the pillars of the specific area. In the event that the
affectation is greater than 15% in a particular area it will be considered as a global

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affectation.
 Global: Numerous points distributed evenly across all specific areas of the project.
Affection greater than 15% of the pillars.
What to do?
Nothing. The nominal design conditions of the foundations have been reached, which
1
guarantee a safety factor close to 2 with respect to ELS.
2 Extra pull out test will be performed. 5% of the piles affected will be tested.
5 Extra pull out test will be performed. 25% of the piles affected will be tested..
Look for an alternative foundation solution or increase the foundation depth achieved. Alternatively, all pillars
6
that do not reach the indicated depth of foundation can be tested individually.
In any case the number of additional pull-out tests shall be greater than the number of tests
*
performed to determine the nominal foundation
Validation Criterion
1 The foundation is validated through the pull out tests carried out before the execution of the project
The foundation is validated through the pull out tests carried out before the execution of the project taking
2 into account that the safety factor is slightly less than 2 with respect to ELS. In addition, the new safety factor
will be justified by theoretical calculation.
The foundation is validated if at least 90% of the tests performed are positive. In addition it will be necessary
3
that the other compliments comply with at least ELS charges
Once the validation criterion is clear and the pilles is ok with the depth ramming reached, the
follow steps should be carried out:
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 Marking and cutting the profile.

 Hot dip galvanizing recovery
For the pull out test, Pull Out Test Procedure will be applied in order to validate or not the
results:
Traction/Compression Test
After the driving pillar into the ground, the first step is to do the traction test according to the following summary:
· @ 50% of the maximum load has to be applied during 3 minutes or until verifying that the displacement of the pillar
with a constant load applied is zero.
After this time, we need to measure the displacement produced in the pillar (M1).
· @ 100% of the maximum load has to be applied during 3 minutes or until verifying that the displacement of the
pillar with a constant load applied is zero.
After this time, we need to measure the displacement produced in the pillar (M2).
The traction test will be considered valid provided that the following two conditions are met:
· The displacement after the measurement M1 is less than 10mm.
· The displacement after the measurement M2 is less than 20mm.
Once we finish Traction Test, next step is to do Compression test with the same procedure as we did Traction Test.
Horizontal (shear) Test

After we have passed traction and compression test, we need to continue with horizontal test. The process is summarized
here:
· @ 50% of the maximum load has to be applied during 3 minutes or until verifying that the displacement of the pillar
with a constant load applied is zero.
After this time, we need to measure the displacement produced in the pillar (M1) · @ It stops to apply some load and
displacement is measured regarding to the starting position of the test (M2).
· @ 100% of the maximum load has to be applied during 3 minutes or until verifying that the displacement of the
pillar with a constant load applied is zero.
After this time we need to measure the displacement produced in the pillar (M3) · @ It stops to apply some load and
displacement is measured regarding to the starting position of the test (M4).
The test will be considered valid provided that the following two conditions are met:
· The displacement after the measurement M2 is less than 10mm or M2 <1/2M1 · The final displacement of the pillar
(M4), once stop applying the loads and 3 minutes after it, can’t be bigger than 20mm or M4 <1/2M3.
a. MARKING AND CUTTING
This part describes the steps to cut the piles in order to ensure the quality of the final pile and the
security of the workers.
Due to the conditions on site, the piles will be cut on site, in its final position and in vertical position.
Cutting tools will be appropriate to be used on site ( batteries or electric tools through generator) and
according to the thickness and dimensions of the piles to be cut (grinder with disc of suitable diameter, or
equivalent tool)
In order to ensure the proper execution of the cutting in relation of the final quality, it is recommended
the follow:
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1. To mark the teoric heigh of the pile along to the all longitudinal section where the cut will be carried
out.
2. To cut using the tool (cutting element) in perpendicular position to the profile.
3. Using the cutting element continuously traverse the entire longitudinal section, progressively
deepening in each passes of the tool.
4. To pay attention in the last cutting pass, when the separation of the pieces is near, in order to avoid
sudden movements between both pieces of the profile. It is recommended for this stage:
a. In C profiles, the two cornes corresponding to the open area of the profile
5. To remove the leftover part and to apply cold galvanized procedure (shaving and brushing) according
to Hot DIP Galvaning Procedure.
b. MINIMUN DISTANCES
According to the reference standard, the minimum distances, taking into account that d is the nominal
diameter of the screw, will be:
 HOLES DRILLS ROUND
o Distances to edges: Between drills centers, 1,5d
o Distances to drills: Between drilling centers, 3d

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 HOLES DRILLS ROUND OVERHEAD AND COLOSSUM

o Distances to edges: Between edges of drills and end, d
o Distances to drills: Between edges of drills, 2d
c. SECURITY
In order to make the cut with the proper safety conditions for the operators, the following guidelines
should be followed:
a) Handling of the cutting tool can only be done by operators who are properly qualified and experienced
in their use.
b) The appropriate Personal Protective Equipment must be used for this tool. Special mention is made at
this point to the use of eye protection and gloves.
c) During the operation, no person is allowed within the range of the cut projections.
d) Under no circumstances will the tool be operated with the protective housing removed.
e) Attention shall be given to the condition of the disc and its anchoring to the tool before use. In the case
of not offering guarantees (worn disc, loose anchor) will not make the cut.
f) Pauses will be made between the different cuts of the cut to protect both the tool and the cutting disc.
g) Prior to the removal of the remaining part, sufficient time should be allowed before touching it to cool
the part.

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Motor supports:
The joint to the pillar will use M16 fasteners,

according to drawings.
Fig 8. Motor supports
Regulation element for shaft support
The joint to the pillar will use M10 fasteners, according to

drawings.
Fig 10. Regulation element for shaft support

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Supports levelling
In order to enable further leveling of main beam, both

motor supports and regulation elements for shaft support
should be leveled in this step.
- First, the motor supports tilt angle will be regulated
following average slope of terrain.
- Then, regulation elements for shaft supports will be

regulated in two dimensions: tilt angle (following
average slope of terrain), and height level searching
a continuous line (this will be parallel to main beam
axis, enabling these to be properly leaned on every
shaft support).
In order to enable further leveling of main beam, both motor supports and regulation elements for shaft
support should be leveled in this step.
- First, the motor supports tilt angle will be regulated following average slope of terrain.
- Then, regulation elements for shaft supports will be regulated in two dimensions: tilt angle
(following average slope of terrain), and height level searching a continuous line (this will be
parallel to main beam axis, enabling these to be properly leaned on every shaft support).
Tilt angle tuning (motor supports and regulation element) and height level (only in the regulation
element for shaft support) can be done by means of provided slots.
Once leveling references are achieved, all fasteners will be partially tightened. Fine leveling adjustment
will be done on further stage, according to main beam real position requirements.

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4. ASSEMBLY OF MOTOR.
In this stage motor will be placed on its supports in the central pillar.
The joint to the supports will use M16

fasteners, according to drawings.
Before rising the motor to its final height,

flange faces parallelism should be checked, as well as
relative position of bores, in order for the main beams
to be properly positioned on both sides. Should any of
previous check points fail, this single motor will not be
installed, and detailed analysis will be done.
Fig 12. Motor assembly
The motor will arrive at site with the position

0º . Confirm that the motor is fixed at 0º

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5. ASSEMBLY AND ALINGMENT OF SHAFT SUPPORT AND MOTOR.
Shaft supports
Shaft supports will be placed on the regulation

elements, and joined together with M10 fasteners,
according to drawings. Bottom half of every shaft
bushing will finally be placed inside shaft supports.
Fig 13. Shaft support and bushing
Shaft supports and motor alignment
In order to achieve proper alignment for main beams, shaft supports and motor positions
need to be regulated. Thus:
- Motor flange and shaft support center points have to define an axis (north- south
direction)
- Motor flange and shaft supports have to be perpendicular (west-east
direction) to such an axis
Laser is recommended in order to minimize the deviations in the installation.

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Fig 14. Shaft supports and motor alignment
Regulation can be made by means of provided slots. Joint between motor and supports allow,
as well as those for shaft support and regulation element, allow displacement in west-east direction and
axis z rotation.
Proper alignment should start with the motor, placing it in best position searching both
alignment with each of the 6 shaft supports and orientation of main beams towards north-south axis.
After that, every shaft support will be moved to match the defined axis.
Once alignment references are achieved, all fasteners will be partially tightened. Fine alignment
tuning will be done on further stage, according to main beam real position requirements.

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6. ASSEMBLY OF MAIN BEAMS
Before rise and assembly of main beams, the following considerations should be taken into
account:
- Every section of main beam (central and extreme) will be placed nearby the base of their
pillars. During material delivery, profile thickness and kind of tracker should be checked
(wind exposed vs wind hidden), in order to assign them properly.
- Main beams will arrive on site with the supports installed, so take into account that the main
beams should be handled carefully.
Fig 15. Main beams. Central and extreme sections
- Final torque will be applied to joints between motor supports and central pillar, and
between motor supports and motor.
- It will be checked that joints between shaft support - regulation element- type pillars are
tight enough to support punctual loads
- Scaffolding/rigging system for structure will be deployed in order to facilitate and make jobs
safer.
- Moreover, when operating on terrains with high north-south slope, additional actions will be
taken to ensure proper handling of main beam sections during assembly jobs
- Solar tracker bearing rotations will be aligned prior to be tightened. There are a tolerance
between the holes (on the beam) and the screws in order to align horizontally the bearings .

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Central main beam
They will be rigged and placed facing the

motor lateral flange bores. Fasteners M16 are to
be used, according to drawings.
Fig 16. Flange and central main beam assembly
Relative position of main beam will be observed whit the holes in top position. It is necessary to
remark that motor is set on stall position, so it is not possible to make it spin to face the flange bores to
the main beam. Therefore, main beam is the element to be moved in order to achieve proper position.
While tightening bolts of flange-beam joint, crew located nearby closest shaft support (in the
opposite side of this central beam section) will focus on relative position between bushing and axis,
checking alignment and level in order for the bushing to receive the axis. Should any of these out of
range, fine tuning will be applied to the shaft support, following main beam requirements.
Same procedure will be committed to assembly central beam section in the other side of motor.
Proper relative position of both flat sides of main beams will be checked, validating previous check point
of flanges parallelism.

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Once both sections are installed, and shaft

supports perfectly aligned and leveled, final
torque for fasteners will be applied.
Fig 17. Shaft support top part
Finally, shaft support will be completed, assembling its top half (bushing and shell), applying
final torque (fasteners M10, according to drawings).
It is needed to remark the requirement of assembling both central beam sections before
proceeding to assembly any of the extreme beam sections.
Extreme beam sections
To respect this position (flat zona up)
They will be rigged and placed

facing the flange bores with central
beam section. Fasteners M16 are to be
used, according to drawings. Relative
position of flat side of extreme beam will
be placed following central beam
guidance.
Fig 18. Central and extreme sections joint

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While tightening bolts of flange-beam joint, crew located nearby shaft supports (two) will focus
on relative position between bushing and axis, checking alignment and level in order for the bushing to
receive the axis. Should any of these out of range, fine tuning will be applied to the shaft support,
following main beam requirements.
Once extreme section is installed, and shaft supports perfectly aligned and leveled, final torque
for fasteners will be applied, and safety scaffolding/rigging will be removed
Finally, shaft support will be completed, assembling every top half (bushing and shell), applying
final torque.
Should any difficulty showed up during fine tuning of leveling and alignment in this stage,
procedures being applied during supporting elements regulation should be carefully reviewed.
7. ASSEMBLY OF SECONDARY BEAMS AND ELECTRICAL WIRE
Secondary beams will be installed on main beams, perpendicular oriented. Number of items and
distances between them are specifically defined according to PV-modules dimensions
Fig 19. Secondary beams layout
Secondary beams will be placed on the support of the main beam, joining by means of
U- bolt, reinforcement plates and M10 fasteners, according to drawings. Gonvarri recommends to
tighten the U-bolt simultaneouslyin order to get a good fixation and alignment of the secondary
beams.
Secondary beams are installed on aluminum support. This element is riveted to the main
beam. In case that the support is damaged due to the transport and/or manipulation, it will be
riveted using the riveted machine provide.
Modules with and without frame is possible to be installed in TrackSmart

TracSmart
WITH FRAME WITH OUT FRAME
Fig 20. Secondary & Main beam
For both options, secondary beam have to be installed perpendicular (90º) to main bean.
Wire for electrical continuity will be installed according to the Gonvarri’s drawings

TracSmart
8. ASSEMBLY OF PV-MODULES
PV-modules will be hold by secondary beams. Layout, relative distances and joints will be
particularly defined for each project.
Fig 21. PV-modules. Top view
PV-modules will be placed and bolted using clamps or fasteners:

SCREWS CLAMPS
Fig 22. PV-modules joint

Take into account, that the modules could not be align from the assembly drawings. GAPs
between modules can be possible and this will not be a reason to reject the design of the tracker.
During PV-modules assembly, below considerations will be taken into account:
- Assembly according to module manufacturer.

- Delivery and handling of PV-modules have to be done safely, in order to avoid any damages to
material
- During delivery, special attention should be paid to dimension and electrical features of PV-
modules.
- PV-modules alignment and relative distances will comply with requirements.
- Every joint will be tightened right after PV-module is placed on secondary beam. It is not
allowed to keep unfasten bolts, providing the PV-module to be hazardously exposed.
Once alignment of modules is achieved, final torque will be applied.

TracSmart
9. ASSEMBLY OF CONTROL SYSTEM
There are two types of control to be installed in TrackSmart:

 Module Self powered motor. Tracker is selfpower through small module install above the
motor.
 Control TCU (Wire). Power is supply by customer according to the Gonvarri’s specification
WIRE SELF POWERED
TCU and slew drive orientation should be according drawing “FIXATION TCU”. Final torque for these
joints will be applied.
In case of discrepancy between this manual and the drawings included on it, the drawings have preference.
Once the structure, control and motor are installed, the follow steps must be carried out prior to do the
supervision and to fill the check list.
The steps to be followed in the installation of the control panel (TCU) must be performed, according to
steps 1 to 17. It is strictly forbidden to commission the trackers without the approval of Solar Steel. The
location and verification of anemometers is mandatory. The control system (anemometers) are designed
according to the needs of the installation.

TracSmart

TracSmart
Once the tracker is ready to move (check list approved and all steps mentioned above done), the
sequence to move the trackers will be:
 Exposed trackers
 Resguard trackers
9. CHECK LIST QUALITY
Gonvarri Structural CheckList must be performed (100% of the trackers) and approved by Gonvarri
(In case Gonvarri execute the supervision of the project) or Customer (Gonvarri will not be responsible for
the quality of the assembly works performed) previous the start of Commissioning works.
10. SURVEYOR REPORT
In order to a proper operation of the tracker, a document (in excel) have to be delivered to
Gonvarri with the height of each tracker ( Coordinates GPS X – Y – Z). It is important to get this information
with the maximum accuracy to fix the parameters proper to the backtracking. This report should be
delivered to Gonvarri according to ramming process during the execution of the project.

TracSmart
11.ANNEX 1. REFERENCE VALUES FOR TIGHTENING TORQUES

TracSmart
12.ANNEX 2. DRAWINGS

FRONT VIEW
4 3 3 4
2 2 2 1 2 2 2
PLAN VIEW
LATERAL VIEW
Note: These data can be changed depending on the project.

6 * Or equivalent profile.
3D VIEW
Note: It is a reference view
DATE SCALE
22-01-2018
Format/Size Drawn Checked Approved - Replaces:
Measures in mm
A3
FRONT VIEW
PLAN VIEW
FRONT VIEW
LATERAL VIEW
* Reference to slope E-W of 0%, in case there is an outstanding slope, this level will be lower.
DATE SCALE
20-03-2018
Measures in mm
A3
ROWS
1 2 10 M 11 2 1
SOUTH COLUMNS NORTH COLUMNS
Note: configuration for 72 cells PV module

* One space free in last North Column
DATE SCALE
23-01-2018
Measures in mm
A3
DATE SCALE
23-01-2018
Measures in mm
A3
Front View
Top of the type pillar
Detail A
1. Between 6000-6500 mm depends on the project Detail A

Note:
Top of the type pillar
The dimension that marks the difference of height between the general pillars and
the central pillar with a square d must be respected rigorously.
Front View
(Maximun slope 12%)
type pillar
Top of the
N-S
slope 12%
Maximun
TOLERANCES
East-West
North-South
Height
Pillar Verticality East-West
Pillar twisting on axis Z
Maximum permited slope North-South in the structure assembly: 12% N-S. For slopes
North-South greater than 3% the distance between pillars shall be measured on the slope.
PLAN VIEW
Note:
Dimensions referred to absolute position of pillar.
DATE SCALE
23-01-2018
Measures in mm
A3
DETAILS FOUNDATION
Direct ramming - A Predrilling + ramming - B Concrete Micropile - C Ground Screw - D
Specific area.
Surface of soil with geotechnical characteristics more or less homogeneous with a

maximum dimensions of 1 Ha.
Affectation.
whole area. Affection less than 5% of the pillars of the concrete or global area.
Affectation between 5% and 25% of the pillars of the specific area. In the event that the
affectation is greater than 15% in a particular area it shall be considered as a global
affectation.
Global: Numerous points distributed evenly across all specific areas of the project.
Affection greater than 15% of the pillars.
Section Section What to do?
1 Nothing. The nominal design conditions of the foundations have been reached, which
guarantee a safety factor close to 2 with respect to ELS.
2 Additional pull out tests will be performed. 5% of all affected pillars shall be tested.
6 Look for an alternative foundation solution or increase the found foundation depth.
Alternatively, all columns that not reach the indicated depth of foundation may be tested
individually.
* In no case the number of additional pull-out tests shall be greater than the number of
tests executed to determine the nominal foundation.
Validation criteria.
Note: Layout shows the different foundation zones 1 The foundation is validated through the pull-out tests carried out before the execution of
the project
2 The foundation is validated through the pull out tests carried out before the execution of
the project taking into account that the safety factor is slightly lower than 2 with respect to
SLS. In addition, the new safety factor shall be justified by theoretical calculation.
3 The foundation is validated if at least 90% of the tests performed are ok. In addition it
shall be necessary that the rest comply with at least the SLS loads.
DATE SCALE
20-03-2018
-
Format/Size Drawn Checked Approved Replaces:
Measures in mm
A3
FRONT VIEW
Detail A Detail A Detail A Detail B Detail A Detail A Detail A
1x Motor Pillar
6x General Pillar
Detail A Detail B
Pillar type Motor Pillar
Set mounted Set mounted
Regulation element
Assembly process Assembly process
Regulation element
Top of the general pillar support

Top of the motor support
DATE SCALE
20-03-2018
Measures in mm
A3
Front View
Axis of rotation
Front View Detail A

(Maximun slope 12%)
Detail A
Detail A
Detail B
tion
Axis of rota
Detail A
slope 12%
Detail A Maximun
Detail A
Detail B
Detail A
slope 12%
Maximun
tation
Axis of ro
sl ope 12%
Maximun
tion
Axis of rota
Motor
Shaft support
Motor support
Pillar Motor
General
Pillar
Note:
Use slotted holes to a connect alignment and leveling.
DATE SCALE
23-01-2018
Measures in mm
A3
Front View
Motor
Motor Pillar
Assembly process
Set mounted
Motor
Orientation of motor
WEST
Motor support
Motor support
Motor
Motor support Motor support
Motor Pillar
Note: The view of the slewdrive is at reference.
Note: Use slotted holes to a correct alignment.
DATE SCALE
20-03-2018
TRACSMART Drawing Nº: 009

Measures in mm
A3 José Luis Castillo Abel J. Fernández Iván Arianes ASSEMBLY MOTOR Project Nº:
Front view
Shaft Support Shaft Support Shaft Support Shaft Support Shaft Support Shaft Support
6x General Pillar
Assembly process Set mounted

Note: Bushing part with cotter.
Bushing
Bushing
TS-155
TS-155
Shaft support
Shaft support (Bottom part)
(Bottom part) TS-154
TS-154
Regulation element
Regulation element
General Pillar
General Pillar
Note: use slotted holes to a connect alignment.
DATE SCALE
05-02-2018
Measures in mm
A3
FRONT VIEW
Cup Cup
Detail D Detail A Detail D

Detail B Detail B Detail B Detail C Detail B Detail A Detail B Detail B
Central Main Beam Central Main Beam
Extreme Main Beam Extreme Main Beam
Detail C
Assembly process Set mounted Detail B
Assembly process
Main Beam Motor
Shaft support
(Top part)
TS-057
Main Beam
Main Beam Main Beam
Motor Bushing
TS-058
Shaft support
(Bottom part)
TS-154
Bushing
TS-155
Main Beam
Note: See sheet 13 for assembly of
support of the TCU.
Detail A
Assembly process Set mounted
Top Main Beam Top

Top
Detail D Set mounted
Main Beam
Main Beam
Main Beam
Main Beam Shaft support
Cup
Bottom Main Beam

Bottom
DATE SCALE
05-02-2018
Measures in mm
A3
FRONT VIEW
Central Main Beam Central Main Beam Extreme Main Beam

Extreme Main Beam
1.- MODULE WITH FRAME 2.- MODULE DUAL GLASS

ASSEMBLY MODULE WITH SCREW ASSEMBLY MODULE WITH CLAMP
FIXATION OF THE SECONDARY BEAM FIXATION OF THE SECONDARY BEAM
Secondary Beam
PLAN VIEW
Secondary Beam
TS-349
Reinforcement
TS-264/TS-277
Reinforcement
Support
TS-151a Support
TS-151a
Rivet
Rivet
Main Beam Main Beam
Note:The torque shall be done after

alignment of all secondary beams.
SECONDARY BEAM MOUNTED SECONDARY BEAM MOUNTED
* Turn the Locknut to finger-tight and then
tighten 14 or 12 a turn whit fixed wrench.
Secondary Beam Secondary Beam
TS-149 TS-264/TS-277
Reinforcement plate Reinforcement
Support
TS-151a Support
TS-151a
Main Beam
Main Beam
DATE SCALE
06-06-2018
TRACSMART Drawing Nº: 012

Measures in mm
A3 Abel J. Fernández Iván Arianes SECONDARY BEAMS ASSEMBLY Project Nº: 2018-GSS-0105D
FRONT VIEW
Module of
Self-Powered
Motor or Control
TCU (wired)
1.- Module of Self-Powered motor 2.- Control TCU (wired)

PLAN VIEW PLAN VIEW
3D ASSEMBLY 3D ASSEMBLY
Support element
Control Support
Support element
SOLAR MODULE ASSEMBLY Note: Note: Control Support

Main Beam
Solar Module
The control module must be oriented to the East. The control must be oriented to the East.
CONTROL ASSEMBLY
Control Support
Support element
Motor
TCU
3D VIEW
Control Support
Orientation keyboard display
3D VIEW
Note:
More information about power and comunication line see page:
Communication: Sheet 22 and 23.
Power supply: Sheet 20.
Orientation keyboard display
DATE SCALE
18-04-2018
Measures in mm
A3
FRONT VIEW
Detail B
Detail A
4 Fixation points per module PLAN VIEW
LATERAL VIEW 1.-MODULE WITH FRAME 2.-MODULE DUAL GLASS

ASSEMBLY WITH SCREW ASSEMBLY WITH CLAMP
SOLAR MODULES ASSEMBLY SOLAR MODULES ASSEMBLY SOLAR MODULES ASSEMBLY

EXTREME CLAMP INTERMEDIATE CLAMP
Solar Module
Solar Module
Intermediate clamp
Extreme clamp
Solar Module
Secondary Beam
Solar Module
Secondary Beam
Secondary Beam
Secondary Beam
Detail A Detail A
ASSEMBLY WITH SCREW ASSEMBLY WITH CLAMP
SOLAR MODULE
(Q.POWER L-G5 315-335)
Fixation points of the module Fixation points of the module
Detail B
Distance between modules. Distance between modules.
Solar Module
DATE SCALE
20-03-2018
Measures in mm
A3
FRONT VIEW
Detail A Detail A
Note: Electrical continuity between tracker is not included.
DETAIL A ASSEMBLY
2 units per tracker
Solar Module
GROUNDING HOLES POSITION
General Pilar
Note: The motor pillar don't

include this hole.
Secondary Beam
DETAIL A
Assembly Process
Note: Earthing cable in two pillar per tracker

Note: Electrical continuity cable between trakcer is not included
DATE SCALE
20-03-2018
Measures in mm
A3
CONCRETE SLAB
RSU Assembly
Note:
Reinforcement steel minimum yeild strength 4200 kg/cm
Concrete C25/30, f 'c = 25N/mm2
Elements supplied by Gonvarri:

Anemometers
Anemometer support
RSU
Anchors
RSU Mounted
A Elements not supplied by Gonvarri:
Concrete
Steel reinforcement
Recommendations:
Detail D Detail B 1.- Minimum 20m to the structure.
C C 2.- Near to NCU.
3.- Peripheral to the implantation.
4.- Area most exposed to the wind.
5.- Uniformly distributed.
Detail D
Note: More information about anemometer location in layout

More information:
-Communication: Sheet 23, 24 and 25.
-Power supply: Sheet 20 and 21.
View from A
Detail B
DATE SCALE
20-03-2018
Measures in mm
A3
Plate NCU Assembly NCU Assembly NCU Mounted
Note:
1- This mounting system is exclusively for outdoor mounting.
2- In the case of NCU is installed inside, the communication antenna must be placed outside (only in the case of zigbee comunication)
3- The mounting system for other boxes are simillar.
DATE SCALE
05-02-2018
Measures in mm
A3
DATE SCALE
23-01-2018
Measures in mm
A3
Auxilary Services
L1
N
PE
Max. 35 Units.
TCU TCU TCU TCU
PJB PJB PJB PJB
Detail C
NCU
TCU TCU TCU TCU
Detail D
RSU
Snow Sensor
PJB PJB PJB PJB

20m
Anemometer
Detail E
TMS
Max. 4 Units.
TCU: Tracker control unit.

TCU TCU TCU TCU
PJB: Power juntion box.
TMS: Tracker monitoring system
Notes:
-Mandatory protect the power line in head against overcurrent and
overvoltage.
-Dimensioning of the feeding lines will depend on the layout and is not
PJB PJB PJB PJB within in the reach of Solar Steel.
-Power supply line not included in the delivery.
DATE SCALE
20-03-2018
Measures in mm
A3
L1
N
Conexion
PV module
PE Cables
TCU
Detail C
NCU
Detail D
RSU
Snow Sensor
20m
Anemometer
Detail E
TMS
Notes:
-Mandatory protect the power line in head against overcurrent and
Note: Details in sheet 22. overvoltage.
-Dimensioning of the feeding lines will depend on the layout and is not
within in the reach of Solar Steel.
DATE SCALE
20-03-2018
Measures in mm
A3
DETAIL A DETAIL B
TCU TCU
Weipu Weipu
Weipu Weipu
2 m length
PJB PJB
L1 L1
N N
PE PE
DATE SCALE
20-03-2018
Measures in mm
A3
RS 485 ZIGBEE
RS485 TCU TCU TCU TCU

NCU
TCU TCU
NCU TCU
RSU
TCU TCU
85
TCU TCU TCU TCU
4
RS
NCU NCU
TCU TCU TCU NCU line
RSU
TMS
TMS
TCU
TCU TCU TCU
NCU TCU
85
RSU
RS
4 TCU
NCU
TCU TCU TCU
RSU
NCU
Fiber optic or
ethernet ring
NCU
Fiber optic or
ethernet ring
Note: TMS - NCU communications , page 23 Note: TMS - NCU communications , page 23
Note: NCU-TCU-RSU communications , page 24 Note: NCU-TCU-RSU communications , page 25
DATE SCALE
20-03-2018
Measures in mm
A3
DATE SCALE
23-01-2018
Measures in mm
A3
OPTION 1
TCU TCU TCU Max. 50 Units. TCU

NCU
PROTEC
COM
LTR
TCU TCU TCU TCU

Max. 50 Units.
PROTEC
COM
LTR
GATEWAY
TCU TCU TCU TCU
Max. 50 Units.
PROTEC
COM
LTR
TCU TCU TCU TCU

Max. 50 Units.
PROTEC
COM
LTR
LTR: Line Termination Resistance
OPTION 2
NCU TCU TCU TCU Max. 100 Units. TCU

PROTEC
COM
LTR
GATEWAY
MAX. 200
TCU TCU TCU TCU

Max. 100 Units.
PROTEC
COM
LTR
LTR: Line Termination Resistance
DATE SCALE
20-03-2018
Measures in mm
A3
DATE SCALE
23-01-2018
Measures in mm
A3
TracSmart
13.ANNEX 3. CHECK LIST QUALITY

PEC-S0-03-04 Rev.1
Cliente
Ubicación
Proyecto
TRACKER
Checklist-Structure
The completation and Release of this CheckList implies the acceptance by Gonvarri of the Control Performed.
Measurement
Description OK NO OK
Structure installed according to the LayOut/Position of the Foundations (visual)
Verify Foundations are not damaged(Visual)
Structure and Structure Foundation not affected by corrosion(Visual)
All parts of the structure have been installed(Visual)
Structure elements have not been damaged(Visual)
Structure elements (aereal and fundations) are not affected by corrosion(Visual)
Galvanization of the Structure(Visual)
Settlement in Bolted Joints(Visual)
Installation of TCU - Step to install it
Installation and powering of RSU and NCU
Network finalized and operating
Flat Ground References(Measures to be done with all the elements installed)

Reference Description Tolerance Range Checkings
Drawing
General Pillar Height -20mm/+20mm - N/A N/A N/A N/A
Measure
Drawing
Central Pillar Height -20mm/+20mm -
Measure
Drawing
General Pillar Height(Not Leveled Terrain) +100/-300 1.240/1.640 mm N/A N/A N/A N/A
Measure
Drawing
Central Pillar Height(Not Leveled Terrain) +100/-300 1.190/1.590 mm
Measure
90º Pillar Verticality North-South Direction -2º/+2º - OK/NO OK
90º Pillar Verticality East-West Direction -1º/+1º - OK/NO OK
0º Pillar Rotation(Head of Pillar) -5º/+5º - OK/NO OK
10 Distance Between Modules - 5mm to 12mm
-55º/+55º Step 1 to 17 about TCU installation - - DONE/NOT DONE
Joints Torque
N.m Description Tolerance OK/NO OK (Maximun 10 checks)
10 Control with Support -10%/+10%
4 Anemometer -10%/10%
6 RSU/Plate -10%/+10%
8 NCU/Support -10%/10%
17 Modules/Clamp -10%/+10%
20 Plates NCU/Pillar NCU -10%/10%
40 Secondary support/secondary beam -10%/+10%
50 Secondaru Reiforcement with secondary beam -10%/10%
50 Support/General pillar -10%/+10%
50 Grounding wire/pillar -10%/10%
50 Closing shaft support -10%/+10%
50 Anemometer support/Plate RSU -10%/10%
190 Motor/beams -10%/+10%
190 Main beams -10%/10%
190 Central support/ pillar -10%/+10%
190 Motor/central support -10%/+10%
80 Anchor anemometer support -10%/10%
Comments
Reviewed by:
Date / /
The tolerances indicated in the drawings are those generated during the design phase to facilitate assembly works and ensure the correct operation of the structure. This does not imply that in
some specific case, where these are not met, suppose the non-acceptance of the structure as long as the functionality of the structure is not affected.
TracSmart
ANNEX 4. REQUIREMENTS AND INSTRUCTION TO INSTALL THE CONTROL

TracSmart
COMMISSIONING Rev.0
Solem – México
COMMISSIONING
Rev. 0
1
TracSmart
COMMISSIONING Rev.0
Solem – México
DATE REV UPDATE DONE CHECKED APPROVED

14/03/2018 0 Documento Inicial IDM JLRF JLRF
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TracSmart
COMMISSIONING Rev.0
Solem – México
INDEX
1. OBJECTIVE .......................................................................................................................................4
2. DEFINITIONS ...................................................................................................................................4
3. REQUIREMENTS ..............................................................................................................................4
4. CONTROL PRODUCT .......................................................................................................................5
4.1 MAIN COMPONENTS .............................................................................................................5
4.2 BASIC OPERATION .................................................................................................................7
4.3 COFIGURATION AND COMMISSIONING OF THE TCU ............................................................9
4.3.1 PRE-COMMISSIONING REVIEW .......................................................................................... 10
4.3.2 PROJECT PLANNING............................................................................................................ 10
4.3.2.1 NCU QUICK CONFIGURATION GUIDE ............................................................................. 12
4.3.2.2 RSU QUICK CONFIGURATION GUIDE.............................................................................. 13
4.3.2.3 TCU QUICK CONFIGURATION GUIDE ............................................................................. 14
4.3.2.3.1 DATA ACQUISITION ....................................................................................................... 16
4.3.3 CONFIGURATION AND VERIFICATION (PHASE 3…6) .......................................................... 17
4.3.4 COMBINATION OF MAPS (PHASE 3) ................................................................................... 17
4.3.4.1 LINKING WITH THE PROJECT PLAN ................................................................................ 18
4.3.5 CONFIGURATION AND TEST (PHASE 4…6).......................................................................... 21
4.3.5.1 CONFIGURATIO DEVICES ................................................................................................ 21
5. HARDWARE OVERVIEW ............................................................................................................... 27
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TracSmart
COMMISSIONING Rev.0
1.OBJECTIVE
Solem – México
The purpose of this manual is to serve as an introduction and guide to the control systems
installed in TracSmart monofila trackers models (RS485/Zigbee communication). Commisioning must not
be carried out without the prior official approval of Gonvarri, for which the corresponding Quality Check
List must be approved.
2.DEFINITIONS
 TCU: Control unit of the solar tracker or "single-line". This element is a slave unit, which
transmits data and receives commands. It is not an intelligent system, it depends on a
previous sequential programming or an intelligent network control unit (NCU).
 NCU: Intelligent network control unit, capable of selecting and transmitting orders to the
corresponding TCUs. The cabinet contains a Suntrack32 CPU, a Zigbee gateway and a
Ethernet switch.
 Zigbee System: Wireless communication system and low consumption that allows
transmitting through digital broadcasting. Its objective is the applications that require
secure communications with low data transmission rate and maximization of the useful
life of its batteries.
 RSU: Remote unit of atmospheric sensors, with anemometer as available option. This
element is a unit that transmits the data obtained from its corresponding sensors.
3.REQUIREMENTS
The following items must be taked into consideration before the beginning of
PreCommissioning/Commissioning works.
 Gonvarri Structural CheckList must be approved by Gonvarri
 Gonvarri must be informed within 6 weeks in order to start the Precommissioning works.
In the communication must be indicated the number and location of trackers ready for
precommissioning works.
 Precommisioing will be perform by CUSTOMER according to the planning
 PFV must be energized in order to have AC with suitable V/Hz values. Electrical
generators are not recommended due to the voltage pikes that can produce damages in
the devices. Gonvarri will not be responsible of the damage in the control in case to use
electrical generators even with the use of intermedium elements to try to reduce peaks.
4
TracSmart
COMMISSIONING Rev.0
 Features of the communication network:

Solem – México
o Ethernet (Max 100 Mbps) to interconnect all NCU´s in the same subnet. The
communication subnet between NCU´s must be done prior Commissioning works
start.
o If Optical fiber is used between CT’s (NCU’s will be located inside the CT’s) must
be installed a Switch (optical fiber to copper) in the connection to NCU’s
 The following data is required:
 3 reserved IPs by NCU
 Meanwhile the commissioning takes place it is required that no remote access to NCU’s
from SCADA of the project happens.
 Internet Access for NCU´s must be granted in order to have remote support as well as
recommended for operation(Clock synchronization with SNTP server)
 In case NCU cabinet is located inside a CT or closed enclosure, Zigbee antenna must be
placed outside the building to ensure correct communication between NCU and TCUs.
 Leave the antenna freely hanging down – do not fasten it to any structure. The antenna
should be at least 30 cm far from the closest post.
 TCUs, NCU and RSU must be powered according to technical specifications.
 Anemometers must be placed and connected to the RSU´s.
 NCU´s & RSU´s must be powered.
4.CONTROL PRODUCT
4.1 MAIN COMPONENTS
The different elements or main components for this control system are illustrated and defined
below:
5
TracSmart
COMMISSIONING Rev.0
Solem – México
Figure 1: TCU.
The control unit (TCU) is installed in each of the trackers and will be energized directly to the
power supply of the plant. This control unit is connected by Wireless to the nearest accessible network
created by one of the existing NCU's, if there were. A TCU can also be operative with the absence of any
network if a sequential programming is incorporated previously. The utility or function of a TCU is to
register and send different types of parameters to the NCU to which it is connected and receive and
execute the orders received by it or, if none of the latter exists, the TCU would execute the sequential
programming previously installed.
Figure 2: RSU.
As an option, remote control units (RSU) can be installed with the objective of measure
parameters by using of installed sensors that give the desired information in particular. Generally these
sensors record information related to weather conditions that may affect the integrity of any part of the
solar trackers. One of the most common sensors are those that measure the speed of the air. The RSU's
must be connected to the general power supply of the plant for its operation.
6
TracSmart
COMMISSIONING Rev.0
Solem – México
Figure 3: NCU
The "intelligent" component that receives the information from the previous elements and the
necessary subsequent test is the red control unit (NCU). The NCU creates a wireless network to which the
TCUs and RSUs that are within their reach are connected, as long as there is no network created by
another NCU to which they connect before. The NCU's must be connected to the general power supply of
the plant for its operation, for the moment not available from the independent power system.
4.2 BASIC OPERATION
Figure 4: Scheme interconnection of devices and operation control system.
7
TracSmart
COMMISSIONING Rev.0
In the previous diagram you can see an example of a complete control system from the level of
Solem – México
data collection "in situ" and mechanical action by using of the RSU's and / or TCU's devices, up to the level
of supervision by the corresponding competent person in the field (by ethernet) or at a distance (by web).
In this particular case, the TCU's will be installed to each one of the existing TracSmart trackers,
transmitting different parameters to the NCU to which it is connected through the Wireless Zigbee
system. The information received by the NCU is recorded and studied for a possible response order that
must be executed mechanically by the TCU involved with the activate of the rotation motor of the main
beams whose movement will vary the inclination of the photovoltaic panels to the position chosen by the
own NCU.
In addition to the TCUs, there are also other types of devices that register different parameters
and send them to the corresponding NCU, it is the RSU's, which record data as the speed of wind thanks
to the sensors to which they are connected. This device is totally passive, it only registers and sends data,
in no case is it capable of making decisions or has tools to execute any type of order.
It is interesting to know that a TCU can also perform the functions of an RSU using sensors whose
connectors are of the same type as those of the corresponding TCU.
In the diagram on the left you can see the
connections between the different devices of a control
system in a hypothetical and simple photovoltaic park.
The control units NCU1, NCU2, NCU3 and NCU4 each
manage their own sector generating a network to which
all the TCUs at their reach are connected. An NCU can
manage approximately a total of 200 TCUs thanks to the
mesh typology that it is using. However, it is necessary to
try to avoid metal barriers that hinder and limit
connectivity, forcing the installation of more control units.
The four control units are connected to each other thanks
to an ethernet cable creating a closed circuit and
connected to an industrial PC with a router in the field to
which it is possible to access by direct connection "in situ"
or by remote internet, enabling a correct monitoring.
Figure 5: Control system layout in photovoltaic park.
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4.3 COFIGURATION AND COMMISSIONING OF THE TCU

Solem – México
Figure 6: Commissioning process
Figure 7: Commissioning.
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4.3.1 PRE-COMMISSIONING REVIEW

Solem – México
The following requirements are essential prior to any commissioning process:

 If the NCU is installed inside a closed warehouse or building, the antenna of the Zigbee system
must be placed outside the building to ensure proper communication between the NCU and the
different TCUs.
 Channeling routes and wiring traverses between TCU and antenna should be designed with
special care.
 The antenna must not be tied with bridles and it will be placed hanging from its cable freely.
 TCUs, NCU and RSU must be connected to the power supply according to the technical
specifications of GONVARRI.
 The Zigbee communications network must be developed and implemented according to the
technical specifications of Solar Steel.
4.3.2 PROJECT PLANNING
With the uploading of the layout of the project, the locations of the TCU's should be planned
according to the SCADA identifiers for each node, with an optimal design of the network for maximum
coverage and according to the location of the different NCUs and the optimized subnets of the TCUs
Figure 8: Layout
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Figure 9: Location of the NCU and the TCU subnet for its design. Example with 4 NCU and subnet design.
Figure 10: Final location of the NCU.
Figure 11: Creation of the subnet address table for TCUs with theoretical coordinates
in addition to identifiers for each TCU in local SCADA.
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4.3.2.1 NCU QUICK CONFIGURATION GUIDE

Solem – México
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4.3.2.2 RSU QUICK CONFIGURATION GUIDE

Solem – México
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4.3.2.3 TCU QUICK CONFIGURATION GUIDE

Solem – México
Note: Any step or information regarding the PV panel of the TCU must be omitted since for the
Aguascalientes project the model used will be energized with the power supply of the plant.
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4.3.2.3.1 DATA ACQUISITION

Solem – México
Figure 12: Hand scanner and "Suntrack Scan" application
Use the Android APP Suntrack Scan to obtain the MAC address, as well as the coordinates of all
the TCUs of the work, scanning them from the label that appears on the front of the TCU. This requires a
precision of at least 5 m in the GPS.
The scans will be recorded by displaying a counter on the screen to make sure we have scanned
all the TCUs. In this counter only the different scans will be reflected, always being preferable when in
doubt to scan a TCU twice to leave it without scanning.
Figure 13: TCU's identification program.
Once the scan is finished, the data is uploaded to the cloud, with the session closed.
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4.3.3 CONFIGURATION AND VERIFICATION (PHASE 3…6)

Solem – México
Scope: Configure the network and devices, verify the operation and start tracking.
Prerequisites for phase execution (mark with an X and make comments if necessary):
All devices have been installed and configured
according to the "Quick Configuration Guide".
All the devices were scanned and the data was
uploaded to the server.
Internet connection available in the place. (at least one computer in place with internet access
and TeamViewer installed)
Procedure:
 Perform the map combination operation using Suntrack Server.
 Carry out the network configuration and parameterization of the device with the "Suntrack
Inject" tool.
 Perform the site acceptance test using the "Suntrack SAT" tool.
 Complete this form and send a copy by email to your contact GONVARRI.
Result of phase execution (mark with an X and make comments if necessary):
The network has been configured.
All devices were parameterized.
The acceptance test of the site has been
validated.
Master calendar and updated FRACES files (Commissioned termination, notification of defective
devices, etc.)
The site is fully operational.
4.3.4 COMBINATION OF MAPS (PHASE 3)
Scope: Link object instance names to unique identifiers

Procedure:
1. Start a web browser (preferably Chrome), open "tools.suntrack.es" and log in with your
credentials.
2. Choose the site.
3. Manually fill in the MAC addresses to:
a. NCU’s
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b. GW’s (these must be provided by GONVARRI - obtained from the factory traceability file,
Solem – México
in accordance with the S / N of the NCUs)
c. RSU’s
4. Visually verify that the address plan and the capture data are coherent ("overlay" button).
5. Start the map linking process ("Merge with scan data"): this may take a few minutes.
4.3.4.1 LINKING WITH THE PROJECT PLAN
Figure 14: SunTrack Server
This APP will help us to configure the connection of the scanner to the internet (Internet
connection is required). It allows the advanced configuration of each work with graphic tools and data
tables as well as working in automatic connection with the desktop application Suntrack Desktop.
Login to the remote server Suntrack Web Server with the corresponding credentials.
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Choose the project.

Solem – México
Selection of the work to be done by loading the data previously captured with the scanner and stored in
the server.
Execution of the process
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Process executed. Linking the plane with the loaded data.

Solem – México
Run the address scheduler.
Manually check the errors with the graphical tool and confirm the configuration.
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4.3.5 CONFIGURATION AND TEST (PHASE 4…6)

Solem – México
Scope: Implement parameters related to the network configuration of the site.

Procedure:
For each NCU of the site:
1. Turn on NCU.
2. If applicable, connect the Zigbee antenna or the NCU extension cable.
3. Connect the jumper cable to the battery - the NCU must have uninterruptible power supply from
now on.
Connect a PC to a point in the network.
Start the "Inject" program, log in with the client's credentials, select the site and start the process. This
may take a few minutes.
Start the program "S.A.T.", log in with the client's credentials, select the site and start the process. This
may take a few minutes.
4.3.5.1 CONFIGURATIO DEVICES
Figure 15: Suntrack Inject.
This application will access the online data in the Suntrack server required for the configuration.
This tool provides a visual summary of the work and allows offline operation within it as well as
configuration of the devices including automatic configuration capability and error log.
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The application will allow us to configure the IP addresses and ports of the NCU. For this, it must
be taken into account that each NCU needs 2 LAN IP addresses. One will give us access to the NCU itself,
and the other to the Gateway that will allow us to communicate directly with each TCU
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Example:
NCU 1 Control Unit: 192.168.0.35
NCU 1 Gateway Zigbee: 192.168.0.36
NCU 2 Control Unit: 192.168.0.55
NCU 2 Gateway Zigbee: 192.168.0.56
The default subnet masks are as follows:
- Control Unit: 255.255.0.0 (not configurable at the moment)
- Gateway Zigbee: 255.255.255.0 (configurable)
In the case of the configuration of the output or input ports of an NCU, the NCU requires that
these ports be open in the Router to access external servers:
 UDP 123: Port for synchronization of time and date.
 TCP 25: Port for sending emails (SMTP).
To have external access to the devices, different ports are used for their connection:
Control Unit: TCP 503 (configurable)
Gateway Zigbee: TCP 502 (configurable)
Both IP ports must be redirected so that we can connect with both elements.
TCP remote configuration port:
Extra configuration of the NCU: TCP 56666 (not configurable).
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On the other hand, for the configuration of the Gateway it is necessary to open the Internet
browser with the IP address of the Gateway itself.
Go to Applications -> Python. Load "MBTABLE.DAT”.
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The activation and automatic execution of the Modbus server must be configured in the
Solem – México
Gateway. This process is done through "Auto-start Settings”.
To restart the Gateway just go to Administration-> Reboot.
Another possible configuration that we are allowed to modify is the tracking parameterization
data corresponding to the solar trackers. In the NCU software window, for each TCU:% battery, state, sun
position (x, y) and alarms
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Each TCU has defined security positions for any circumstance, wind, cleaning etc. For example, for
Solem – México
wind position settings:
1. Set the safeguard position in the “safe param”tab.
The request for the safe position is changed through the NCU.
“0” means “No alarm”
“1” means “Go to safe position 1” etc
Seconds: time in each position for the “safe position request” to be changed again by NCU.
2. Set the wind limits in the RSU with anemometer.
Example:
Mild wind limit: Change the value in “No wind threshold”. Km/h =30. Time: 300 sec. Above this
time, the sistema will be send a “Safe position request” to all groups of TCU’s Stromg wind limit:
Change the value in “Wind alarm Threshold. Km/h =40 Time: 10 sec (to detect strong wind gusts).
The limits work as described:
3. Set the wind alarm for each of the two groups of TCUs (configurable) in the NCU software in the
"Wind Alarm" tab. The same process is applied to the cleaning position.
The NCU will change "Safe position request" in the parameters of each group of TCU's.
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Finally, using a parameter file predefined by the client, from any NCU all the parameters can be
downloaded automatically to each follower.
Typical parameters to download:
- Angular limitations
- Post-tracking parameters (separation between rows, thickness of the panels).
- Clock time updates.
- Frequency of movement (dead band) etc
5.HARDWARE OVERVIEW
For the project 50 NCUS (Solem 1) and 47 NCUs (Solem 2) and 24 RSUS (Solem 1) and 23 RSUs
(Solem 2) and 1 Anemometers per RSUs will be used.
General Aspects:
Consumption(W) Dimensions(mm) Weight(Kg) IP
NCU 20 500 400 200 10,5 66
RSU 10 347,6 276,4 176,6 3 67
Height(mm) Diameter(mm) Cable Lenght(m)

Anemometer 0 138,5 123,62 20 0,154 65
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INPUT-TYPE OF CABLE
Solem – México POWER COMM
NCU CABLE CHARACTERISTICS DEPENDS ON DISTANCES BETWEEN ELEMENTS TCP CAT5(LOCAL)/TCP CAT6(NETWORK)
POWER COMM
RSU CABLE CHARACTERISTICS DEPENDS ON DISTANCES BETWEEN ELEMENTS N/A
POWER COMM
Anemometer Cable Supplied with Anemometer Cable Supplied with Anemometer
AC Input Voltage Range(VAC) Tolerance AC Input Voltage Range(VAC)

NCU 100-240 90-264
RSU 100-240 90-264

Nominal Input Frequency Range(Hz) Tolerance Input Frequency Range(Hz)
NCU 50-60 47-63
RSU 50-60 47-63

For the Installation and operation as well as technical details of the units the following
documentation can be followed:
 NCU_Installation_and_Operation_Manual
 RSU_Installation_and_Operation_Manual
28
GSS Arizona 11040
N. Solar Canyon Way
Surprise, AZ 85379 USA
Tel.: +1 623 476 2248
Fax.: +1 623 476 5849
Çepas Gonvarri Group

175. Sokak No: 2 - 2/A (Istanbul yolu 25.KM.)
Saray Mahallesi KAZAN/ANKARA/TÜRKiYE
Tel.: +90 312 815 47 23
Fax: +90 312 815 47 27
www.cepas.com.tr
Gonvarri Colombia
Calle 86 Nº 45-90, Itagüi, Antioquia - Colombia
Tel.: 574 444 50 11 Ext 171
Fax.: 574 444 50 11 Ext 9
www.industriasceno.com
Hiasa
Polígono industrial de Cancienes
33470 Corvera, Asturias - España
Tel.: 34 98 512 82 00
Fax: 34 98 550 53 60
www.hiasa.es
SOLAR STEEL hEAdquARTERS

San Vicente, 8 48001
Bilbao - Spain
Phone: +34 944 23 31 37
info@gsolarsteel.com
www.gonvarristeelservices.com
www.gsolarsteel.com

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TracSmart

Generic Installation Manual Rev.3

GENERIC INSTALLATION MANUAL

Document GSS-MI- 2018-01

DOCUMENT UPDATES RECORD

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1. SUMMARY OF CONSTRUCTION TASKS AND KEY WARNINGS

CONSTRUCTION STEP KEY WARNING

Surveyor to mark the exact

Pile’s installation According to the foundation designed

Slew drive’s installation To check the orientation

Torque tubes’s installation Refer to project site plan

Secondary beam’s installation

Modules’s installation According to manufacturer’s manual

Align and Secure modules

To check the metric and estándar in order to

To install controller Self powered or external power

To perform the steps to install the

To fill the check list 100% of the structure

2. GENERAL INFORMATION RESPONSABILITIES, SAFETY AND

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SOLAR STEEL is only responsible for the items it supplies.

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Real tracker could be different from 3D image

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Fig.2 Front view

Fig.3 Top view

Fig.4 Lateral view

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4. STORAGE OF THE STRUCTURE

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7. ASSEMBLY STEPS AND WARNINGS

2. Do not apply a tightening torque above the recommended maximum. An excess of

3. Use a lubricant or antifriction coating on the threads. In critical applications or that

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a lot and this reduces the risk of seizure.

2. PILLARS STAKEOUT AND INSTALLATION.

The installation of pillars will be made according to specifications of Engineering department.

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MOTOR PILE EXTREME PILES

MOTOR/EXTREME PILES HEIGHT PILES

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The tracker is supported by a series of pillars following north-south direction.

Fig 6. Pillars layout

Pillars height leveling

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Fig 7. Pillars Leveling

Central pillar – warning

Clean the area of rust or dirt to

Apply the zinc rich paint in the

Galvanization Finishing Touches

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In some cases, burr-free areas

Release of the Zinc coating is

in the repaired zone is 100 microns.

3. ASSEMBLY AND LEVELLING OF SUPPORTING ELEMENTS.

Fig 8.Motor supports and regulation/shaft support

and extreme piles.

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