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SUNTRACK NETWORK CONTROL UNIT

Installation and Operation Manual

2 (31) Date - you Give you

P4Q Electronics/ Installation and Operation Manual 2018-06

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Nº Document - Document No.

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D003-PS18025

P4Q has all rigths reserved. Suntrack provides this document without warranty in any form either expressed or implied. P4Q could revise this document at any time without notice.

This

document

contains

proprietary

and

confidential

information.

Reporduction and/or disclosure through any means, is prohibited unless expressed,

F.423.03. Rev.A

written consent of authorized representative of P4Q electronics S.L.

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SUNTRACK

SUMMARY Suntrack Network Control Unit Installation and maintenance.

APPLICATION The Local control unit provides local automatized management of the trackers. On the one hand, it reads and centralizes all the necessary data from the trackers: the positions of the axes, the target position, and the alarms. These data is enough to determine if the tracker is working properly. In case it is necessary to read more data from any tracker, an individual access can be permorfed, since the control unit also provides the possibility to access any tracker remotely. On the other hand, it also reads the wind speed from the anemometer, and it is able to take the decision of sending a safe position request to the trackers if the wind speed is higher than the established threshold value. This local supervision of the wind speed is necessary to avoid dangerous situations of the trackers.

F.423.03. Rev.A

SUMMARY REVIEW REV

YYYY-MM

A

2018-06

AUTOR

A. Martinez

COMMENTARY

Adaptation

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ÍNDICE GLOSSARY, TECHNICAL TERMS AND ABBREVIATIONS ..................................... 6 1.- SAFETY INSTRUCTIONS ...................................................................................... 7 2.- CONDITIONS FOR PACKAGING AND STORAGE .............................................. 9 2.1.- Reception Conditions .................................................................................................................................9 2.2.- Storage Conditions .....................................................................................................................................9

3.- DESCRIPTION OF UNIT ...................................................................................... 10 3.1.- General Description .................................................................................................................................. 10 3.1.1.- Technical Characteristics ................................................................................................................ 10 3.1.2.- Mechanical Characteristics............................................................................................................. 11 3.1.3.- Mechanical Diagram ......................................................................................................................... 12 3.1.4.- Electric Diagram ................................................................................................................................ 13 3.1.5.- Phase, Neutral and Ground............................................................................................................. 14 3.1.6.- UPS Signals ........................................................................................................................................ 14 3.1.7.- Anemometer ....................................................................................................................................... 14 4.1.- Earth .............................................................................................................................................................. 16 4.2.- Electrical cabinet Location...................................................................................................................... 17 4.2.1.- Mechanical Aspects .......................................................................................................................... 17 4.2.2.- Thermal Aspects ................................................................................................................................ 17 4.2.3.- Safety .................................................................................................................................................... 18 4.3.- Fixing the Cabinet ..................................................................................................................................... 20 4.4.- Cable Routes .............................................................................................................................................. 21 4.5.- Electric Connection .................................................................................................................................. 21 4.5.1.- Connection of Unit ............................................................................................................................ 21 4.6.- Startup .......................................................................................................................................................... 22 4.6.1.- Wind Alarm .......................................................................................................................................... 22 4.6.2.- Cleaning position .............................................................................................................................. 22 4.7.- Uninstalling the Electrical Cabinet........................................................................................................ 23

F.423.03. Rev.A

4.8.- Uninstalling CPU-Control Suntrack 32H .............................................................................................. 23 4.9.- Verification and Problems ....................................................................................................................... 24 4.9.1.- CPU-Control Suntrack 32H Leds ................................................................................................... 24 4.9.2.- Pointing Problems ............................................................................................................................. 24 4.9.3.- Reset CPU-Control Suntrack 32H ................................................................................................. 25

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5.- MAINTENANCE ................................................................................................... 26 6.- TERMS AND CONDITIONS OF WARRANTY ..................................................... 27 6.1.- Duration of Warranty ................................................................................................................................ 27 6.2.- Conditions of the Warranty ..................................................................................................................... 27 6.3.- Exclusion of Liability ................................................................................................................................ 27 6.4.- Representations ......................................................................................................................................... 28

7.- TRADEMARKS .................................................................................................... 29 ANEXO I.- REPAIR INCIDENT SHEET..................................................................... 30

F.423.03. Rev.A

ANEXO II.- INCIDENT IN TRANSPORT SHEET ...................................................... 31

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FIGURES FIGURE 1.- SUNTRACK CABINET ........................................................................................ 9 FIGURE 2.- CABINET SUPPORT ......................................................................................... 11 FIGURE 3.- CABINET DIMENSIONS ................................................................................... 11 FIGURE 4.- ZIGBEE MECHANICAL DIAGRAM.................................................................... 12 FIGURE 5.- ZIGBEE ELECTRIC DIAGRAM ......................................................................... 13 FIGURE 6.- POWER TERMINAL BLOCK ............................................................................. 14 FIGURE 7.- POWER TERMINAL BLOCK ............................................................................. 14 FIGURE 8.- ANEMOMETER TERMINAL BLOCKS AND WIRING ........................................ 15 FIGURE 9.- FITTING THE ANEMOMETER .......................................................................... 15 FIGURE 10.- FITTING THE CABINET .................................................................................. 20 FIGURE 11.- CONCRETE ANCHORS AND NYLON WALL PLUGS..................................... 20 FIGURE 12.- CONNECTION ................................................................................................ 21 FIGURE 13.- SUNTRACK NCU DISCONNECT TERMINAL BLOCK .................................... 22 FIGURE 14.- SUNTRACK CPU-CONTROL SCREWS AND SPACERS ............................... 23 FIGURE 15.- CPU-CONTROL SUNTRACK 32H LEDS ........................................................ 24 FIGURE 16.- CPU-CONTROL SUNTRACK 32H POWER CONNECTOR ............................ 25 FIGURE 17.- BATTERY ........................................................................................................ 25

TABLES TABLE 1.- GLOSSARY ........................................................................................................... 6 TABLE 2.- TECHNICAL CHARACTERISTICS ...................................................................... 10

GLOSSARY, TECHNICAL TERMS AND ABBREVIATIONS

F.423.03. Rev.A

TERM

DESCRIPTION

Sw

Software

Hw

Hardware

NCU

Network Control Unit

TCU

Tracker Control Unit

RSU

Remote Sensor Unit

SNTP

Simple Network Time Protocol

UDP

User Datagram Protocol Table 1.- Glossary

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1.- SAFETY INSTRUCTIONS It is very important to read this safety section thoroughly as the SUNTRACK UNIT works with high voltage which is dangerous for personnel as well as for equipment.

It is recommended that the manual should be read before using the Suntrack unit. P4Q Electronics is not responsible for damage caused by undue use, negligence, modifications or the use of different materials to those authorized by the manufacturer.

Warning: It is of the utmost importance that the installation instructions included in this document should be strictly followed.

If a mechanical or electrical component is found to be defective do not use the product and contact your supplier right away.

If the installation instructions are not followed serious problems may arise, such as: damage to the unit, physical harm or even death from electric shock.

Should the unit not be installed immediately, it is advisable to keep it in its original packaging, and it should be kept in a dry and ventilated area.

The Suntrack unit should only be installed by a qualified electrician

F.423.03. Rev.A

and authorized by the supplier.

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The work tools used to realize the installation of Suntrack should have prior approval for the job taking into account the voltage present in the system.

Conductors used should be adequate for the appropriate section, resistant coatings and composed of material capable of enduring long periods of exposure to the sun.

Wiring should be protected from rodents, as they can deteriorate the electric insulation.

During installation, the conductor ends should be protected to avoid accidental contact with high voltage.

Once the installation startup has been carried out, the installed units as well as the cables should not be moved. Carry out the assembly so that this cannot happen accidentally.

Install the unit in a vertical position and do not put objects on top of the equipment.

Follow the instructions carefully as described in this document.

F.423.03. Rev.A

Otherwise “The warranties will be void and claims invalidated”.

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2.- CONDITIONS FOR PACKAGING AND STORAGE

2.1.- Reception Conditions Once the product has been received and before opening the same, packaging of the product should be checked and verified that it remains in perfect condition.

In case of damage, contact the transport company or supplier, and notify them about the damage caused to the packaging.

Important: Damage should be notified in written form within a maximum of three days [See Annex III. Transport Incident Template]

Figure 1.- Suntrack Cabinet

2.2.- Storage Conditions If the unit is not installed right away, it is advisable to keep it in its original

F.423.03. Rev.A

packaging and situated in a dry and ventilated environment.

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3.- DESCRIPTION OF UNIT The Suntrack Network Control Unit, implements a gateway between the tracker network and the SCADA system that can monitor and control the field of trackers. The NCU provides the capability of detecting a high wind condition with the support of the Suntrack trackers with anemometer. The NCU will determine if the winds reach a preset threshold, and it will send all the trackers to safe position.

3.1.- General Description 3.1.1.- Technical Characteristics

Marked CE-026/09-01-EE-I1. Polyester Casing for installing externally with a degree of protection of IP66. Working temperature range: -25 a 65ºC. Protection against voltage through a 320V varistor incorporated inside. Configurable by software.

PARAMETERS

UNIT

Nominal Input Voltage

100 - 240

VAC

Input Voltage Range

90 - 264

VAC

Nominal Input Frequency

50 - 60

Hz

< 0.80A @ 115Vac, < 0.60A @ 230Vac

A

Input Current F.423.03. Rev.A

Table 2.- Technical Characteristics

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3.1.2.- Mechanical Characteristics There are four holes at the back of the cabinet for support the unit.

Figure 2.- Cabinet Support

The Suntrack polyester cabinet has IP66 protection grade and 500 x 400 x 200 mm dimensions.

F.423.03. Rev.A

Figure 3.- Cabinet Dimensions

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3.1.3.- Mechanical Diagram The following picture shows a mechanical diagram from the different parts of the control cabinet.

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Figure 4.- ZigBee Mechanical Diagram

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3.1.4.- Electric Diagram The following picture shows a connection diagram from the different parts of

F.423.03. Rev.A

the control cabinet.

Figure 5.- ZigBee Electric Diagram

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3.1.5.- Phase, Neutral and Ground NCU must be connected to the ground connection to allow that the overvoltage protection works properly and guarantee the people’s safety.

Figure 6.- Power terminal block

3.1.6.- UPS Signals UPS Potential free contacts must be connected to the UPS Terminal Blocks.

Figure 7.- Power terminal block

3.1.7.- Anemometer Anemometer power signals must be connected to the Anemometer Terminal Blocks. . The anemometer has 10 metres cable and three holes at the back to

F.423.03. Rev.A

facilitate fixing it to the structure.

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Figure 8.- Anemometer terminal blocks and wiring

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Figure 9.- Fitting the anemometer

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4.- INSTALLATION OF EQUIPMENT

Installation of the Suntrack should be only be executed by trained and qualified personnel. Special tools which are the standard tools of specialized technicians are necessary.

Before initiating cabinet installation, planning is crucial so as to provide an organised work method. To realize the installation the following steps should be followed:

4.1.- Earth The earthing system should be regulated by the corresponding norms of each country.

Earthing of the installation should be at a unique point. Place all the Earth conductors at one point, so as to reduce the risk of damage due to power surges

F.423.03. Rev.A

derived from lightning.

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4.2.- Electrical cabinet Location The priority selection criteria for situating the cabinet depend on the condition of its surroundings and the facility for connecting the connectors.

The equipment is prepared for working outdoors and can bear adverse atmospheric conditions such as snow and hailstone.

Below there are certain points to be considered when positioning the control cabinet. 4.2.1.- Mechanical Aspects

Mount on a stable and resistant surface, one should take into account the mechanical aspects of the equipment as well as its weight: approximately 10.5 Kg.

Install the equipment in a vertical position. Do not leave objects on top of the unit. 4.2.2.- Thermal Aspects

The surface where the assembly is realized should not made of inflammable material. If it is necessary to assemble on these types of materials (e.g. Wood), it is necessary to add a heat resistant and non-inflammable coating.

Should the equipment be installed in the interior of an enclosed building, one should ensure that there is sufficient ventilation. Air temperature directly influences the performance

F.423.03. Rev.A

and durability of the unit.

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Do not install the unit in the interior of a cabinet or enclosure.

Although the electrical cabinet can be installed outdoors, it should not be installed on a location which is exposed to the Sun. It is advised that the unit should be situated and orientated northwards. To prevent the electrics being exposed to the sun.

The recommended altitude for the installation of the unit should be less than 2.000 meters. 4.2.3.- Safety

The cabinet has IP66 protection, that is, it is protected from dust, involuntary immersion, water jet and high temperature, nevertheless one should be aware of the following safety aspects.

Do not store next to inflammable liquids and materials of the unit, the temperature of the unit can facilitate the possibility of fire.

Wiring should be protected against rodents that can deteriorate the electric insulation, endangering personnel as well as the risk of fire. Cover the connectors not in use to ensure water tightness and avoid entrance of unwanted animals.

To avoid direct and indirect contacts it is important to F.423.03. Rev.A

verify that the cabinet is closed securely.

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The unit has internal screening for protection against direct contact. For protection against indirect contact, all the metallic parts of the units are earthed.

For the installation and maintenance of the unit it is important to use adequate work tools that comply with the

F.423.03. Rev.A

protection of direct and indirect contacts.

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4.3.- Fixing the Cabinet The tracker should be fixed vertically on a flat surface so that it is capable of bearing the weight of the unit. Position the unit vertically with the connectors in the lower part, in the establish position for fixing the same.

Fix to the structure using the concrete anchors and nylon wall plugs 8mm hole diameter and 40mm length included in the supply box.

Figure 10.- Fitting the Cabinet

Figure 11.- Concrete anchors and nylon wall plugs

Pay special attention to fixing the unit, as its weight is approximately 10.5Kg. Under no circumstances use the electrical cabinet assembly

F.423.03. Rev.A

holes to earth the unit.

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4.4.- Cable Routes Preparation for the routes where the conductors pass, this will facilitate the installation process. The conductors should have a route that provides mechanical protection and appropriately fitted so as to have a long and useful life.

4.5.- Electric Connection

Warning: Beforehand, one should check that all metallic elements are earthed. 4.5.1.- Connection of Unit

Position the unit vertically with the double-membrane seals in the lower part, in the position that it is assigned for fitting it. There are 2xM25, 5xM20, 5xM16 cable glands and 6.5mm diameter hole for ZigBee antenna.

Figure 12.- Connection

DO NOT connect the general power supply of the Suntrack-NCU

F.423.03. Rev.A

until the installation has been completed.

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4.6.- Startup 4.6.1.- Wind Alarm

The Suntrack NCU provides the capability of detecting a high wind condition, with the support of the Suntrack with anemometer. The NCU will determine if the winds reach a preset threshold, and it will sent all the trackers to safe position.

To deactivate the wind alarm, the wind speed read by the anemometers must remain below the wind limit. 4.6.2.- Cleaning position

The cleaning position is the position that the different trackers group adopts if the disconnect terminal block of the each group is turned on. The solar plant is divided in groups and by default the cleaning position is 30 degrees. Group 1 …… …… Group 8 Group NOT Cleaning Position

Group Cleaning Position

F.423.03. Rev.A

Figure 13.- Suntrack NCU disconnect terminal block

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4.7.- Uninstalling the Electrical Cabinet Disconnect the power connection.

Disconnect the rest of the connections. Extract the fixing screws and take away the equipment.

4.8.- Uninstalling CPU-Control Suntrack 32H

Turn off RCCB and Circuit Breaker

Disconnect the power connector.

Disconnect the rest of the connector.

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Extract the fixing screws and take away the equipment.

Figure 14.- Suntrack CPU-Control screws and spacers

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4.9.- Verification and Problems Guidelines are provided in case of an alarm in the system. 4.9.1.- CPU-Control Suntrack 32H Leds

The following picture shows the different leds of the control cabinet:

Figure 15.- CPU-Control Suntrack 32H Leds

Sw On is a status indicator that shows the correct working order of the system.

Establish communication between the Suntrack NCU and the monitoring programmer switch on “Comm” Led.

Third led indicates if there is an alarm in the system.

The “Prog” Led will show if a new software version is updating. 4.9.2.- Pointing Problems

F.423.03. Rev.A

Check AC power terminals.

Check Circuit Breakers status. D003-PS18025_RevA_NCU_Installation and Maintenance Manual_EN.DOC

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Check led status in Power Supply.

Check CPU-Control Suntrack 32H Power connector.

Figure 16.- CPU-Control Suntrack 32H Power Connector

4.9.3.- Reset CPU-Control Suntrack 32H

Disconnect Positive Terminal in Battery.

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Figure 17.- Battery

Turn off Residual-Current Circuit Breaker. D003-PS18025_RevA_NCU_Installation and Maintenance Manual_EN.DOC

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5.- MAINTENANCE Equipment maintenance should only be carried out by trained and qualified personnel. Special tools are needed which the technician has as standard.

Preventive equipment maintenance has to be carried out after one year from its installation, and subsequently every three years. The following points for the correct maintenance should be observed:

Check that all the mechanical connections of the unit are adequately adjusted, if not so, they should be tightened with the appropriate tools.

Check the good working order of the box and that it has no sign of corrosion or deterioration.

One should simulate abnormal behavior, such as wind, axis blockage, etc, so that all the alarms are generated correctly and that the system responds as expected.

Every year, the condition of the battery should be checked. To do this it should be cut off the power, wait 10 minutes and plug again. Check with the monitoring Sw PC that time is

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updated.

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6.- TERMS AND CONDITIONS OF WARRANTY 6.1.- Duration of Warranty The period of warranty is that which is specified on the supply contract and begins on the delivery of the unit. Should one decide to increase the warranty period it will be specified in the supply contract on request.

6.2.- Conditions of the Warranty During the warranty period, the equipment will be repaired at no cost in material or labour costs at the factory. Assembly costs at location are not included.

In case of equipment failure the warranty claim should be sent by mail to P4Q then one should wait to obtain authorization for delivery of the same. Please indicate the name of the company, the use that the unit is given, delivery address for the repaired unit and the person to contact as well as the telephone number. Authorization is realized after sending the completed error protocol filled in indicating the failure. (Annex II). P4Q cannot accept equipment received without prior notification in writing or without being informed of the failure.

6.3.- Exclusion of Liability P4Q is not in any way responsible in the following cases: Damage cause by undue use of equipment. Constant use of charges above those defined in the equipment specifications in the mounting and installation manual. Use in inadequate environmental conditions (see location section). Equipment damaged, dismounted o manipulated by unauthorised technical service. F.423.03. Rev.A

Lightning, accidents, water, fire and other circumstances beyond the control of the manufacturer.

D003-PS18025_RevA_NCU_Installation and Maintenance Manual_EN.DOC

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6.4.- Representations P4Q makes no representations or warranties with respect to the accuracy or completeness of the contents of this document and reserves the right to make changes to specifications and product descriptions at any time without notice. P4Q does not make any commitment to update the information contained

F.423.03. Rev.A

herein. Unless specifically provided otherwise.

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Ctra. Bilbao – Balmaseda Km 9 “Alonsotegi Elkartegia” Mod 27-29-51 Tel:(94)4982028 Fax:(94) 498 20 36 48810 ALONSOTEGI 2018 P4Q Electronics S.L CONFIDENTIAL

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7.- TRADEMARKS Suntrack © 2007. Reserves all rights..

F.423.03. Rev.A

All the products indicated in this manual are copyrighted and are distributed under license by P4Q Electronics S.L.

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F.423.03. Rev.A

ANEXO I.- REPAIR INCIDENT SHEET

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F.423.03. Rev.A

ANEXO II.- INCIDENT IN TRANSPORT SHEET

D003-PS18025_RevA_NCU_Installation and Maintenance Manual_EN.DOC

Ctra. Bilbao – Balmaseda Km 9 “Alonsotegi Elkartegia” Mod 27-29-51 Tel:(94)4982028 Fax:(94) 498 20 36 48810 ALONSOTEGI 2018 P4Q Electronics S.L CONFIDENTIAL