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Installation Guide:

First SolarSingle-Axis Tracker

COPY Installation Guide: First SolarSingle-Axis Tracker Global REV 1.0 www.firstsolar.com © Copyright 2014, First

Global

REV 1.0

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Table of Contents

1 General Document Overview

4

1.1 Purpose

4

1.2 Scope

4

1.3 Notice

5

1.4 Safety Symbols and Signal Words

6

1.5 Common Terms

7

1.6 Key Definitions

7

2 Tracker System Installation Overview

8

2.1 Tracker System Components Overview

8

2.2 Component Installation Sequence

10

2.3 Recommended Component On-Site Storage

10

3 Tracker Assembly Installation

11

3.1 Tracker Installation Drawings

11

3.2 Tracker Assembly Images

11

3.3 Tracker Assembly Installation Warning, Caution and Notice Statements

16

3.4 Tracker Assembly Installation Tips

17

3.5 Suggested Material Staging for Tracker Assembly

18

3.6 Suggested Workflow for Tracker Assembly

19

3.7 Specialized Tools for Tracker Assembly Installation

22

4 Tracker Controller Installation

24

4.1 Tracker Controller Physical Installation

24

4.2 Tracker Controller Electrical Installation

25

5 Controller to Actuator Cables (CTAC) Installation

27

5 Controller to Actuator Cables (CTAC) Installation 27 www.firstsolar.com © Copyright 2014, First Solar, Inc. |

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5.1 Wire Management Drawings

27

5.2 Controller to Actuator Cable Packaging

27

5.3 Controller to Actuator Cable Labeling

28

5.4 Controller to Actuator Cable Connections to Tracker Controller

29

6 Tracker Gateway Installation

30

6.1 Tracker Gateway Physical Installation

30

6.2 Tracker Gateway Electrical Installation

31

6.3 Tracker Gateway Communication Installation

31

7 Tracker Weather Station Installation

32

7.1 Tracker Weather Station Physical Location

32

7.2 Tracker Weather Station Electrical Installation

34

7.3 Tracker Weather Station Communication Installation

34

8 Tracker Backup Power System Installation (optional)

35

9 Commissioning

36

10 Warranty Terms & Conditions

37

11 Appendices

38

Terms & Conditions 37 11 Appendices 38 www.firstsolar.com © Copyright 2014, First Solar, Inc. |

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1 General Document Overview

1.1 Purpose

This Installation Guide: First Solar Single-Axis Tracker (PD-6-202) is intended to provide information concerning installation of First Solar’s single-axis tracker system in a photovoltaic power plant site. This document may be used to plan installation of tracker system components, including developing resource estimates for installation of the tracker system components.

Failure to install, commission, operate and maintain First Solar’s tracker system in the manner described below will void the applicable warranty (refer to the First Solar Single-Axis Tracker Warranty Terms And Conditions (PD-5-120)).

1.2 Scope

This document is not intended to:

1. Be a substitute for site specific drawings that details the installation.

2. Provide details of the tracker system that may be required for permitting purposes.

3. Suggest any unsafe installation practices.

4. Provide guidance for designing a photovoltaic power plant incorporating the First Solar’s tracker system. (See the Application Manual First Solar Single-Axis Tracker (PD-6-241) for design guidance.)

5. Provide guidance for commissioning the First Solar Tracker Product. (See the Commissioning Manual First Solar Single-Axis Tracker (PD-6-234) for commissioning guidance.)

6. Provide guidance for operating and maintaining the First Solar Single-Axis Tracker. (See the User Guide: First Solar Single-Axis Tracker (PD-5-220) for operation and maintenance guidance.)

7. Provide comprehensive installation and operation instructions for First Solar’s tracker backup power system (See the First Solar Tracker Backup Power System User Guide (PD-6-205).

Solar Tracker Backup Power System User Guide (PD-6-205). www.firstsolar.com © Copyright 2014, First Solar, Inc. |

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1.3

Notice

Changes to certain Tracker System Components are common as First Solar continuously strives for product improvements. All products within the same model classification remain functionally equivalent and compatible with one another, even though there may be slight differences. Modifications that do not impact product functionality may be made without notification.

First Solar reserves the right to make changes to design or specifications applicable to the First Solar Single-Axis Tracker at any time without notice. Accordingly, the Buyer is responsible for verifying that data sheets are current before placing orders or finalizing system permitting and/or design. Neither First Solar nor its affiliates assume any responsibility for use of information furnished by First Solar or its affiliates, nor for any infringements of patents or other rights of third parties that may result from the use of such information. No license is granted by implication or otherwise under any patent or patent rights of First Solar or its affiliates.

For information regarding First Solar and its products, please visit www.firstsolar.com. For technical support, please contact technicalsupport@firstsolar.com.

support, please contact technicalsupport@firstsolar.com. www.firstsolar.com © Copyright 2014, First Solar, Inc. |

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1.4 Safety Symbols and Signal Words

Indicates a safety hazard or unsafe practice.REDACTED COPY 1.4 Safety Symbols and Signal Words Indicates an electrical shock hazard. DANGER Indicates a

Indicates an electrical shock hazard.Signal Words Indicates a safety hazard or unsafe practice. DANGER Indicates a hazardous situation that, if

DANGER

Indicates a hazardous situation that, if not avoided, will result in death or serious injury.

WARNING

Indicates a hazardous situation that, if not avoided, could result in death or serious injury.

CAUTION

Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.

NOTICE

Indicates information considered important, but not hazard-related (e.g., messages relating to property damage).

hazard-related (e.g., messages relating to property damage). www.firstsolar.com © Copyright 2014, First Solar, Inc. |

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1.5 Common Terms

Terms Found In Site Drawings (colloquial)

Equivalent Meaning (proper name)

actuator control cable

controller to actuator cable

anemometer

weather station

anemometer control panel

weather station enclosure

battery backup power

backup power system

cable

wire, wiring

gateway controller

gateway enclosure

gateway control panel

gateway enclosure

gateway tracker control panel

gateway enclosure

longitudinal retention plates

longitudinal retainers

MIB

module interface bracket

post

pile

TIB

table interface bracket

tracker anemometer

tracker weather station

tracker control unit

tracker controller

tracker main beam

torque tube

Table 1.List of items that may be found in site design drawings and their corresponding correct definitions or equivalents.

1.6 Key Definitions

“Agreement” means the Tracker System Components Supply Agreement to which this Installation Guide is an Appendix.

“Application Manual” has the meaning ascribed to such term in the Agreement and refers to First Solar Single-Axis Tracker Application Manual (PD-6-241).

“Commissioning Manual” has the meaning ascribed to such term in the Agreement refers to First Solar Single-Axis Tracker Commissioning Manual (PD-6-234).

“Tracker System” means an assembly of Tracker System Components that have been installed and commissioned in accordance with the requirements of the Agreement, this Installation Guide, the Application Manual and the Commissioning Manual.

“Tracker System Components” has the meaning set forth in the Agreement.

Components” has the meaning set forth in the Agreement. www.firstsolar.com © Copyright 2014, First Solar, Inc.

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2 Tracker System Installation Overview

2.1 Tracker System Components Overview

A high level overview of the Tracker System Components can be found in Figure 1. A description of the Tracker System Components’ functions and typical quantities can be found in Table 2.

functions and typical quantities can be found in Table 2. Figure 1. Diagram of Tracker System

Figure 1. Diagram of Tracker System Components.

Table 2. Figure 1. Diagram of Tracker System Components. www.firstsolar.com © Copyright 2014, First Solar, Inc.

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Component

Function

Typical Quantity

Tracker

Structure and mechanism that hold and point modules in the direction of the sun (includes the actuator, table, bearings and torque tube). Each tracker assembly holds 60 First Solar modules.

270 to 360tracker assemblies per array. Example: 326 tracker assemblies in a 1.956 MWdc array (assuming 100 W First Solar module)

assembly

tracker

The system “brain”. The tracker controller positions trackers at the appropriate angle based on local conditions (time, date, wind, and user input), and provides status of trackers to the gateway.

24 to 39tracker controllers per array.

controller

Tracker

The main communication hub to tracker controllers, weather stations, backup power system, and SCADA system. The tracker gateway aggregates data for tracker controllers of each array and converts this data into information that is comprehensible to the SCADA system. The tracker gateway will receive and process information from the tracker weather stations and the backup power systems.

1

gateway

to 3tracker gateways per array.

Tracker

Collects weather information from the anemometer sensors and broadcasts weather information over the network to the tracker gateways.

to 8 tracker weather stations per project site.

2

weather

station

 

(optional)

The backup power system passes grid supplied power through to trackers until a power outage occurs, at which time it switches to battery backup. Included in the system are the necessary inverters/charger and batteries. This system is optional.

to 1 backup power system per array.

0

backup

power

 

system

(BPS)

Table 2. Overview of Tracker System Component function and typical quantity. See Application Manual First Solar Single- Axis Tracker (PD-6-241)for more information about quantities.

Tracker (PD-6-241)for more information about quantities. www.firstsolar.com © Copyright 2014, First Solar, Inc. |

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2.2 Component Installation Sequence

Installation of tracker assemblies involves following the general sequence of steps described in Section 3. Other system components (such as the tracker controllers, the tracker gateways, the backup power systems, and the tracker weather stations) may all be installed in parallel to the tracker assemblies. Once tracker assemblies are structurally complete, and the tracker controllers are installed, complete installation of the controller to actuator cables is possible.

of the controller to actuator cables is possible. CAUTION Trackers shall not be considered commissioned and

CAUTION Trackers shall not be considered commissioned and released for operation until they are able to communicate with an active tracker weather station. Until that time, trackers may generate power but must remain near or at a flat orientation (±7.5°).Without an active tracker weather station, the trackers may not be able to accommodate the design wind loads at extreme tilt angles.(See the Commissioning Manual: First Solar Single-Axis Tracker (PD-6-234).)

2.3 Recommended Component On-Site Storage

First Solar recommends storing the following items indoors (prior to installation):

node assembly

SD card

First Solar recommends storing the following items outdoors (prior to installation), but away from areas at risk of flooding or water submersion:

actuator

tracker controller

tracker weather station

tracker gateway

tracker backup power system

First Solar recommends storing the following items in a ventilated indoor area (prior to installation):

tracker backup power system batteries

First Solar recommends using plastic delivery boxes to store bearing assemblies that may be returned to vendor for reuse to prevent foreign material accumulation.

vendor for reuse to prevent foreign material accumulation. www.firstsolar.com © Copyright 2014, First Solar, Inc. |

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3 Tracker Assembly Installation

3.1 Tracker Installation Drawings

Any drawing set for tracker assembly provided by First Solar will specify torques ranges for fasteners, and tolerances for component locations, and will remain subject to updates. For the remainder of this document, such drawing set will be referred to as the “Tracker Installation Drawings”. It is the Buyer’s responsibility to obtain the most current drawing set for accurate information and ensure the most current version is used.

3.2 Tracker Assembly Images

Figure 2 through Figure 10show photo images of the major tracker assembly components.

(Image Redacted)

Figure 2. Bearing assembly with view of adjustment capability. The torque tube fits into the square slot.

capability. The torque tube fits into the square slot. www.firstsolar.com © Copyright 2014, First Solar, Inc.

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(picture redacted)

Figure 3. Torque tube highlighted in red; pile highlighted in green; bearing assembly circled in yellow.

highlighted in green; bearing assembly circled in yellow. Figure 4. Torque tube interface bracket. www.firstsolar.com

Figure 4. Torque tube interface bracket.

circled in yellow. Figure 4. Torque tube interface bracket. www.firstsolar.com © Copyright 2014, First Solar, Inc.

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(Image Redacted)

Figure 5. Actuator arm.

(Image Redacted)

Figure 6. Actuator highlighted in red, and lower actuator mount highlighted in green. The linear actuator is shown in full extension. The lower actuator mount attaches to the pile and connects to the linear actuator’s trunnions.

the pile and connects to the linear a ctuator’s trunnions. www.firstsolar.com © Copyright 2014, First Solar,

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REDACTED COPY Figure 7. Torque tube and table interface brackets (TIBs); TIBs highlighted in red. TIBs

Figure 7. Torque tube and table interface brackets (TIBs); TIBs highlighted in red. TIBs and tables (Configuration A) are an alternative to MIBs.

(Image Redacted)

Figure 8. Table highlighted in red. TIBs and Tables (Configuration A) are an alternative to MIBs.

and Tables (Configuration A) are an alternative to MIBs. www.firstsolar.com © Copyright 2014, First Solar, Inc.

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REDACTED COPY Figure 9. Module interface brackets (MIBs). MIBs (Configuration B) are an alternative to TIBs

Figure 9. Module interface brackets (MIBs). MIBs (Configuration B) are an alternative to TIBs and tables.

(Configuration B) are an alternative to TIBs and tables. Figure 10. Fast clip with panels mounted.

Figure 10. Fast clip with panels mounted.

TIBs and tables. Figure 10. Fast clip with panels mounted. www.firstsolar.com © Copyright 2014, First Solar,

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3.3 Tracker Assembly Installation Warning, Caution and Notice Statements

WARNING Wear electrically rated PPE when working on interconnected modules or other electrical system components.

WARNING Wear electrically rated PPE when working on interconnected modules or other electrical system components.

WARNING Wear appropriate safety helmets and safety glasses (ANSI Z87.1- 2003) during installation of tracker

WARNING Wear appropriate safety helmets and safety glasses (ANSI Z87.1- 2003) during installation of tracker assembly. Take appropriate precautions when reaching overhead during torque tube installation.

CAUTION Installation is to be performed only by qualified personnel.

CAUTION Installation is to be performed only by qualified personnel.

CAUTION First Solar ’s Single -Axis Tracker should be installed according to project site drawings.

CAUTION First Solar’s Single-Axis Tracker should be installed according to project site drawings.

CAUTION DO NOT disassemble any of the bearing assemblies; assemblies are pre-assembled and tightened to

CAUTIONDO NOT disassemble any of the bearing assemblies; assemblies are pre-assembled and tightened to factory-specified torque, and are to be fixed to vertical posts AS-IS. Lateral adjustments are acceptable where necessary.

CAUTION DO NOT use bolts that have been previously tightened or pre- stressed bolts that

CAUTIONDO NOT use bolts that have been previously tightened or pre- stressed bolts that are structurally compromised and will not retain their strength if recycled.

CAUTION Wear safety glasses (ANSI Z87.1-2003) and cut-resistant gloves when working on non-interconnected modules or

CAUTION Wear safety glasses (ANSI Z87.1-2003) and cut-resistant gloves when working on non-interconnected modules or systems.

NOTICE

Ensure that bolt and nut threads are clean and dry before installing.

NOTICE

The First Solar’s tracker bearings do not require lubrication or maintenance of any kind. DO NOT introduce oil, silicon or other solvents onto the bearing surfaces. DO NOT apply paint to the bearings.

the bearing surfaces. DO NOT apply paint to the bearings. www.firstsolar.com © Copyright 2014, First Solar,

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NOTICE

For maximum performance, the actuator will arrive pre-calibrated from the factory

and must be installed AS-IS to allow the First Solar’s Single-Axis Tracker to track the sun within its specified range of motion. Install top actuator bolt first and bottom mount last.

DO NOT remove the seal from the actuator shaft. DO NOT rotate the actuator shaft.

DO NOT modify the actuator in any way.

Failure to comply with the above will result in voiding of the applicable warranty, i.e., warranty provided pursuant to the First Solar Single-Axis Tracker Warranty Terms And Conditions.

3.4 Tracker Assembly Installation Tips

Alignment of posts and bearings is a priority (slots allow precise install).

Torque fasteners to proper specifications and orientation. (See relevant Tracker Installation Drawings).

Lubricated nuts (indicated by blue or green colored wax) and non-lubricated nuts have different torque specifications. (See relevant Tracker Installation Drawings).

The shorter of the two torque tubes must be paired with the actuator on any given tracker.

Each tracker has two torque tubes and four bearings. The two torque tubes must be situated in the

same orientation across the four bearings.

not operate correctly. See the Figure 11, section (a), for incorrect installation and Figure 11, section (b), for correct installation of torque tubes in bearings.

If the orientation is clocked incorrectly, the tracker will

If the orientation is clocked incorrectly, the tracker will Figure 11. (a) Incorrect orientation in bearings

Figure 11. (a) Incorrect orientation in bearings will result in incorrect tracker operation. (b) Correct orientation or torque tubes in bearings.

(b) Correct orientation or torque tubes in bearings. www.firstsolar.com © Copyright 2014, First Solar, Inc. |

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3.5 Suggested Material Staging for Tracker Assembly

Figure 12shows suggested staging of materials for tracker assembly installation. In Figure 12, Core” refers to the lower actuator mount, actuator, bearing assembly, and actuator arm, collectively. “Drive” refers to a path that may be taken by a skid steer or forklift in distributing components prior to installation. The diagram only shows a portion of an array. The remainder of the array could follow a similar staging pattern.

of the array could follow a similar staging pattern. Figure 12. Suggested layout for tracker installation

Figure 12. Suggested layout for tracker installation in aerial view. The arrows correspond to general paths for material staging by skid steer, forklift, or other vehicle, during material deployment.

forklift, or other vehicle, during material deployment. www.firstsolar.com © Copyright 2014, First Solar, Inc. |

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3.6 Suggested Workflow for Tracker Assembly

Figure 13, Figure 14, and Figure 15 provide a suggested workflow for assembly of the tracker. As shown in each figure, steps such as installation of the bearings with or without the lower mount can be done in parallel. Figure 14 and Figure 15 contain details for installation of configurations A and B.

(Image Redacted)

Figure 13. Suggested workflow for tracker assembly.

Figure 13. Suggested workflow for tracker assembly. www.firstsolar.com © Copyright 2014, First Solar, Inc. |

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(Image Redacted)

Figure 14. Suggested workflow for tracker assembly. Configuration A uses TIBs and tables. Configuration B uses MIBs.

A uses TIBs and tables. Configuration B uses MIBs. www.firstsolar.com © Copyright 2014, First Solar, Inc.

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REDACTED COPY Figure 15. Suggested workflow for tracker assembly. Configuration A uses TIBs and Tables. Configuration

Figure 15. Suggested workflow for tracker assembly. Configuration A uses TIBs and Tables. Configuration B uses MIBs.

A uses TIBs and Tables. Configuration B uses MIBs. www.firstsolar.com © Copyright 2014, First Solar, Inc.

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3.7 Specialized Tools for Tracker Assembly Installation

Several tools are useful and recommended to render tracker assembly installation more efficient and/or safe. These tools are summarized in Table 3. Figure 16 through Figure 20provide some images of these tools.

Tool

Purpose

lower mount spacer

Locates lower actuator mount relative to the bearing.

joystick

Control of the actuator without a tracker controller.

MIB installation jig

Spacing tool that enables proper positioning of MIBs on torque tube.

actuator arm installation tool

Proper centering of actuator arm around the bearing assembly.

actuator replacement kit

Enables safe replacement of an actuator.

Table 3. Summary of tools useful for tracker assembly

Table 3. Summary of tools useful for tracker assembly Figure 16. Lower mount spacer dimensions dictated

Figure 16. Lower mount spacer dimensions dictated by Tracker Assembly Prints. This tool is not provided by First Solar but can be fabricated by construction team.

by First Solar but can be fabricated by construction team. Figure 17. Joystick. www.firstsolar.com © Copyright

Figure 17. Joystick.

be fabricated by construction team. Figure 17. Joystick. www.firstsolar.com © Copyright 2014, First Solar, Inc. |

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REDACTED COPY Figure 18. MIB installation jig (if configuration B is implemented). Figure 19. Actuator arm

Figure 18. MIB installation jig (if configuration B is implemented).

MIB installation jig (if configuration B is implemented). Figure 19. Actuator arm installation tool (if configuration

Figure 19. Actuator arm installation tool (if configuration B is implemented).

arm installation tool (if configuration B is implemented). Figure 20. Actuator replacement kit. www.firstsolar.com

Figure 20. Actuator replacement kit.

B is implemented). Figure 20. Actuator replacement kit. www.firstsolar.com © Copyright 2014, First Solar, Inc. |

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4 Tracker Controller Installation

4.1 Tracker Controller Physical Installation

NOTICE

If distance between top of tracker controller enclosure and the top of the pile the tracker enclosure is mounted on is less than 8 inches, it may interfere with the tracker and movement and damage the tracker assembly.

NOTICE

If tracker controller enclosure is mounted below the 100-year flood level, then the controller could become partially submerged during storm conditions and be damaged.

The First Solar tracker controller is intended to be mounted on an I-Beam at a minimum of 1 ft above grade (or 1 ft above 100-year flood level, whichever is higher). The top of the First Solar tracker controller must be a minimum of 8 inches from the top of the pile to clear the tracker assembly. Follow NEC 110.26 guidelines for working space around the tracker. In general this is 30 inches wide, 78 inches high and 36 inches to 48 inches deep (76 cm x 198 cm x 91 to 122 cm).

See Appendix A and Appendix B for the two possible mounting configurations of the tracker controller.

Figure 21 shows a fully installed tracker controller.

Figure 21 shows a fully installed tracker controller. Figure 21. Tracker controller with wiring going to

Figure 21. Tracker controller with wiring going to actuators on the right.

controller with wiring going to actuators on the right. www.firstsolar.com © Copyright 2014, First Solar, Inc.

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4.2 Tracker Controller Electrical Installation

REDACTED COPY 4.2 Tracker Controller Electrical Installation DANGER Tracker controller enclosure must be properly

DANGER Tracker controller enclosure must be properly grounded to avoid death or serious injury due to electric shock.

At the end of physical installation, the tracker controller shall be provided by Buyer with an approved conduit and shall be permanently connected to a protected branch main supply that is properly grounded.

The wiring to provide power to the tracker controller shall comply with the national regulations of the countries in which the appliance is to be sold.

The electrical supply provided by Buyer shall be equipped with a disconnect device to disconnect all ungrounded AC lines. Buyer should follow standard lockout/tagout procedures for all servicing.

The tracker controller may be shipped without a cutout for AC mains input. It is the electrician’s responsibility to cut the appropriate sized hole for the conduit in use and to plug unused cutouts with a NEMA 4 approved hole plug.

Conduit fittings provided by Buyer shall be installed in the end-use application per local electrical codes. Buyer will install such conduit fittings in such a manner as to not compromise the NEMA 4 ingress protection rating of the system.

The AC input terminal block contains two each of Black, White, and Green terminal blocks. Black is for the live voltage, white is neutral and green is earth ground. The pairs of terminal blocks are jumpered together to facilitate continuing AC wiring to the next device on the circuit.

continuing AC wiring to the next device on the circuit. www.firstsolar.com © Copyright 2014, First Solar,

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5 Controller to Actuator Cables (CTAC) Installation

5.1 Wire Management Drawings

Any drawing set for the tracker assembly wire management provided by First Solar will include specific wire management component location detail on the tracker assembly and will remain subject to updates. For the remainder of this document, such drawing set will be referred to as the “Tracker Wire Management Drawings”. It is the Buyer’s responsibility to obtain the most current drawing set for accurate information and ensure the most current version is used.

5.2 Controller to Actuator Cable Packaging

The CTACs will be delivered to Buyer in kits containing up to 12 cables.

tracker controllers to the actuators. One tracker controller may control up to 12 actuators. Each tracker assembly will have one actuator. Some tracker controllers will control fewer than 12 actuators. For such cases, extra cables not used in the kits can be set aside as spares. In some instances, it may be possible to use a longer cable to replace a shorter one. For example, a 90 foot long cable can be used as a spare for a 60 foot long cable if the extra slack can be appropriately looped and attached properly.

The CTACs will connect the

Figure 22 shows the typical numbering scheme for actuators found in the site design drawings. The specific numbering scheme is found in the site design drawings.

numbering scheme is found in the site design drawings. Figure 22. Typical actuator numbering convention.

Figure 22. Typical actuator numbering convention.

drawings. Figure 22. Typical actuator numbering convention. www.firstsolar.com © Copyright 2014, First Solar, Inc. |

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5.3 Controller to Actuator Cable Labeling

The CTACs will be labeled on each end with part number and suffix. The suffix which is the last two numbers on the label will provide information about the cable length. Multiplying the number by 15 will provide the length of the cable (see Table 4). For example: the cable labeled 20-00528-07 will be 105 feet long (7 × 15 = 105).

Cable part number label

length (ft.)

20-00528 -01

15

20-00528 -02

30

20-00528 -03

45

20-00528 -04

60

20-00528 -05

75

20-00528 -06

90

20-00528 -07

105

20-00528 -08

120

20-00528 -09

135

20-00528 -10

150

20-00528 -11

165

20-00528 -12

180

20-00528 -13

195

20-00528 -14

210

20-00528 -15

225

20-00528 -16

240

20-00528 -17

255

20-00528 -18

270

20-00528 -19

285

20-00528 -20

300

20-00528 -21

315

20-00528 -22

330

20-00528 -23

345

20-00528 -24

360

Table 4.

Cable part number label, and corresponding length.

Table 4. Cable part number label, and corresponding length. www.firstsolar.com © Copyright 2014, First Solar, Inc.

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5.4 Controller to Actuator Cable Connections to Tracker Controller

The CTACs are connected to the tracker controller on the outside of the tracker controller (see Figure 21). Figure 23provides a closer view of where the controller to actuator cables connect to the tracker controller. On the inside of the tracker controller enclosure, the surge suppressor board (the blurred out portion of the image) has the actuator channels numbered from A0 to A11, with the first actuator starting at A0 or “Actuator 1” as shown in Figure 23. The site specific prints may have actuators numbered according to Figure 22and therefore should be connected according to Figure 23.

22and therefore should be connected according to Figure 23. Figure 23. Image of the interior and

Figure 23.Image of the interior and exterior of the tracker controller enclosure. Appropriate numbering on tracker controller enclosure for controller to actuator cables connection is illustrated. The controller’s PCBA surge suppressor board on the interior side is labeled as A0, A1, A2 through A11, and corresponds to Figure 18’s labels “Actuator1”, “Actuator 2”, “Actuator 3”,through Actuator 12”.

2” , “Actuator 3” ,through ” Actuator 12” . www.firstsolar.com © Copyright 2014, First Solar, Inc.

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6 Tracker Gateway Installation

6.1 Tracker Gateway Physical Installation

NOTICE

If tracker gateway is mounted below the 100-year flood level, then the tracker gateway could become partially submerged during storm conditions and be damaged.

The tracker gateway is intended to be mounted on an I-Beam at a minimum of 1 ft above grade (or 1 ft above 100-year flood level, whichever is higher) using provided mounting kit.

See Appendix C for mounting configuration.

Figure 24 shows a fully installed tracker gateway.

Figure 24 shows a fully installed tracker gateway. Figure 24. Tracker gateway enclosure. www.firstsolar.com

Figure 24. Tracker gateway enclosure.

tracker gateway. Figure 24. Tracker gateway enclosure. www.firstsolar.com © Copyright 2014, First Solar, Inc. |

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6.2 Tracker Gateway Electrical Installation

REDACTED COPY 6.2 Tracker Gateway Electrical Installation DANGER Tracker gateway enclosure must be properly grounded to

DANGER Tracker gateway enclosure must be properly grounded to avoid death or serious injury due to electric shock.

At the end of physical installation, the tracker gateway shall be provided by Buyer with an appropriately- sized conduit and shall be permanently connected to a protected branch main supply that is properly grounded.

The electrical supply wiring to the tracker gateway shall comply with the national regulations of the countries in which the appliance is to be sold.

The electrical supply provided by Buyer shall be equipped with a disconnect device to disconnect all ungrounded AC lines. Buyer should follow standard lockout/tagout procedures for all servicing.

The tracker gateway may be shipped without a cutout for AC mains input. It is the electrician’s responsibility to cut the appropriate sized hole for the conduit in use and to plug unused cutouts with a NEMA 4 compliant hole plug.

Conduit fittings provided by Buyer shall be installed in the end-use application per local electrical codes. Buyer will install such conduit fittings in such a manner as to not compromise the NEMA 4 ingress protection rating of the system.

The AC input terminal block contains two each of black, white, and green terminal blocks. Black is for the live voltage, white is neutral and green is earth ground. The pairs of terminal blocks are jumpered together to facilitate continuing AC wiring to the next device on the circuit (if any).

6.3 Tracker Gateway Communication Installation

The tracker gateway requires a CAT 5/6 Ethernet cable to connect it to the plant network. If the required length of Ethernet cable to reach the tracker gateway is greater than the allowable distance for the Ethernet cable, routing a fiber optic cable to the tracker gateway is recommended. The tracker gateway does not have a fiber to Ethernet media converter so appropriate equipment would need to be specified by the Buyer. First Solar does not provide the Ethernet cable, fiber optic cable, fiber to Ethernet media converter, or fiber patch panel as part of the Tracker System.

or fiber patch panel as part of the Tracker System. www.firstsolar.com © Copyright 2014, First Solar,

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7 Tracker Weather Station Installation

7.1 Tracker Weather Station Physical Location

NOTICE

If tracker weather station enclosure is mounted below the 100-year flood level, then the tracker weather station could become partially submerged during storm conditions and be damaged.

The overall assembly with tracker weather station enclosure, mounting components, pipe, sensor and pile will be referred to as the tracker weather station tower. The First Solar Tracker Weather Station is intended to be mounted on an I-Beam at a minimum of 1 ft above ground (or 1 ft above 100-year flood level, whichever is higher).

First Solar provides a lightning rod (identified as an air terminal in Appendix A). It is the Buyer’s discretion to mount it to the tracker weather station tower to aid in protecting the electronics from lightning strikes.

Buyer must ensure that the arrow on top of the Anemometer points to the north for accurate reporting of wind direction. Buyer is to drill a small hole in the bottom edge of the mounting collar that corresponds with the north quadrant of the anemometer for viewing from the ground while installed.

See Appendix D for tracker weather station tower mounting configuration.

Figure 25shows a fully installed tracker weather station.

Figure 25shows a fully installed tracker weather station. www.firstsolar.com © Copyright 2014, First Solar, Inc. |

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REDACTED COPY Figure 25. Tracker weather station with anemometer on top of pile, and weather station

Figure 25. Tracker weather station with anemometer on top of pile, and weather station enclosure near the bottom.

top of pile, and weather station enclosure near the bottom. www.firstsolar.com © Copyright 2014, First Solar,

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7.2 Tracker Weather Station Electrical Installation

COPY 7.2 Tracker Weather Station Electrical Installation DANGER Tracker weather station enclosure must be properly

DANGER Tracker weather station enclosure must be properly grounded to avoid death or serious injury due to electric shock.

At the end of physical installation, the tracker weather station shall be provided by Buyer with an appropriately-sized conduit and shall be permanently connected to a protected branch main supply that is properly grounded.

The electrical supply wiring to the tracker weather station shall comply with the national regulations of the countries in which the appliance is to be sold.

The electrical supply provided by Buyer shall be equipped with a disconnect device to disconnect all ungrounded AC lines. Buyer should follow standard lockout/tagout procedures for all servicing.

The tracker weather station may be shipped without a cutout for AC mains input. It is the electrician’s responsibility to cut the appropriately-sized hole for the conduit in use and to plug unused cutouts with a NEMA 4 compliant hole plug.

Conduit fittings provided by Buyer shall be installed in the end-use application per local electrical codes. Buyer will install such conduit fittings in such a manner as to not compromise the NEMA 4 ingress protection rating of the system.

The AC input terminal block contains two each of black, white, and green terminal blocks. Black is for the live voltage, white is neutral and green is earth ground. The pairs of terminal blocks are jumpered together to facilitate continuing AC wiring to the next device on the circuit (if any).

7.3 Tracker Weather Station Communication Installation

The tracker weather station requires a 6-strand single mode fiber optic cable to connect it to the plant network. First Solar does not provide the fiber optic cable or fiber patch panel as part of the Tracker System.

cable or fiber patch panel as part of the Tracker System. www.firstsolar.com © Copyright 2014, First

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8 Tracker Backup Power System Installation (op- tional)

Details for installation of the Tracker Backup Power Systems can be found in the installation sections of the User Guide: First Solar Single-Axis Tracker Backup Power System (PD-6-205).

Figure 26 shows a typical installation of the BPS. This system is optional.

a typical installation of the BPS. This system is optional. Figure 26. Typical BPS installation. www.firstsolar.com

Figure 26. Typical BPS installation.

system is optional. Figure 26. Typical BPS installation. www.firstsolar.com © Copyright 2014, First Solar, Inc. |

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9

Commissioning

Detailed guidance for commissioning the tracker system is found in Commissioning Manual: First Solar Single-Axis Tracker (PD-6-234). Commissioning activities with the Tracker System may begin prior to module installation or delivery of grid power to the project site.

installation or delivery of grid power to the project site. www.firstsolar.com © Copyright 2014, First Solar,

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10 Warranty Terms & Conditions

Please refer to, First Solar Single-Axis Tracker Warranty Terms and Conditions (PD-5-120) for warranty terms, limitations, and product return policies.

warranty terms, limitations, and product return policies. www.firstsolar.com © Copyright 2014, First Solar, Inc. |

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11

Appendices

Appendix A. Interface, Tracker Controller with Channel to Pile Flange

38

Appendix B.

Interface, Tracker Controller with Channel to Pile

39

Appendix C.

Kit, Interface, Gateway to Pile

40

Appendix D.

Kit, Tower, Weather Station

41

40 Appendix D. Kit, Tower, Weather Station 41 www.firstsolar.com © Copyright 2014, First Solar, Inc. |
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Appendix A. Interface, Tracker Controller with Channel to Pile Flange

A. Interface, Tracker Controller with Channel to Pile Flange www.firstsolar.com © Copyright 2014, First Solar, Inc.

www.firstsolar.com

© Copyright 2014, First Solar, Inc. | PD-6-202 | REV 1.0 | Installation Guide: First Solar Single-Axis Tracker |Page 38 of 42

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Appendix B. Interface, Tracker Controller with Channel to Pile

B. Interface, Tracker Controller with Channel to Pile www.firstsolar.com © Copyright 2014, First Solar, Inc. |

www.firstsolar.com

© Copyright 2014, First Solar, Inc. | PD-6-202 | REV 1.0 | Installation Guide: First Solar Single-Axis Tracker |Page 39 of 42

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Appendix C. Kit, Interface, Gateway to Pile.

REDACTED COPY Appendix C. Kit, Interface, Gateway to Pile. www.firstsolar.com © Copyright 2014, First Solar, Inc.

www.firstsolar.com

© Copyright 2014, First Solar, Inc. | PD-6-202 | REV 1.0 | Installation Guide: First Solar Single-Axis Tracker |Page 40 of 42

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Appendix D. Kit, Tower, Weather Station

REDACTED COPY Appendix D. Kit, Tower, Weather Station www.firstsolar.com © Copyright 2014, First Solar, Inc. |

www.firstsolar.com

© Copyright 2014, First Solar, Inc. | PD-6-202 | REV 1.0 | Installation Guide: First Solar Single-Axis Tracker |Page 41 of 42

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Appendix D. Kit, Tower, Weather Station (continued)

COPY Appendix D. Kit, Tower, Weather Station (continued) www.firstsolar.com © Copyright 2014, First Solar, Inc. |

www.firstsolar.com

© Copyright 2014, First Solar, Inc. | PD-6-202 | REV 1.0 | Installation Guide: First Solar Single-Axis Tracker |Page 42 of 42