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Use and Maintenance Manual MONOLINE 3H Single‐Axis Tracker

DOCUMENT Nº.: Use and Maintenance Manual – MONOLINE 3H REV.:00 DATE: 20/04/2018 [ENGLISH VERSION]

Rev.

DATE

MODIFIED SECTION

DESCRIPTION

PREAPRED

REVIEWED

APPROVED

00

20/04/2018

All document

Creation document

Javier Cepeda

Germán Moreno

Ivan Arkipoff

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CONTENTS 1. Preliminaries ..................................................................................................................................................... 5 2. Warning 3. Security notice .................................................................................................................................................. 5 3.1. Safe functioning........................................................................................................................................... 5 3.2. Safety signs .................................................................................................................................................. 6 3.3. Specialized staff ........................................................................................................................................... 6 3.4. Operation .................................................................................................................................................... 6 3.5. Measures in case of abnormal functioning ................................................................................................. 8 3.6. Maintenance/repair .................................................................................................................................... 8 3.7. Cleaning ....................................................................................................................................................... 9 3.8. Waste disposal .......................................................................................................................................... 10 4. User instructions manual ................................................................................................................................ 11 4.1. Sectors of use ............................................................................................................................................ 11 4.2. Machine description .................................................................................................................................. 13 4.3. Maneuver description ............................................................................................................................... 22 4.4. General security rules ................................................................................................................................ 23 4.5. Indications on noise................................................................................................................................... 24 4.6. Danger areas ............................................................................................................................................. 25 4.7. Less obvious dangers ................................................................................................................................. 26 4.8. Measures, elements and security devices ................................................................................................. 26 4.9.

Description of danger, prohibition and obligation signals ................................................................... 30

4.10.

Pictographs disposition ........................................................................................................................ 31

5. Maintenance instructions manual .................................................................................................................. 33 5.1. Transportation and displacement ............................................................................................................. 33 5.2. Unpacking .................................................................................................................................................. 34 5.3. Installation and assembly .......................................................................................................................... 34 5.3.1. Electrical installation ......................................................................................................................... 35 5.4. Commissioning .......................................................................................................................................... 36 5.5. Maintenance ............................................................................................................................................. 37 5.5.1. Maintenance Report ......................................................................................................................... 39 5.6. Failures location ........................................................................................................................................ 40 5.7. Storage ...................................................................................................................................................... 43 5.8. Dismantling................................................................................................................................................ 43 6. Annex ................................................................................................................................................................ 44 6.1. TCU Operation Manual

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6.2. NCU Operation Manual 6.3. RSU Operation Manual 6.4. RSU Operation Manual

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1. PRELIMINARIES This manual is written as a practical guide for the safe and correct use of the machine, and also for its proper maintenance. THE MACHINE WILL ONLY BE STARTED UP IF ALL INDICATIONS MENTIONED IN THIS MANUAL HAVE BEEN OBSERVED. ATTENTION! NEVER USE THE MACHINE FOR USES OTHER THAN THE ONES AUTHORIZED BY THE MANUFACTURER. ATTENTION! BEFORE ANY MAINTENANCE OPERATION IT IS COMPULSORY TO STOP THE MACHINE, ISOLATE IT FROM THE ELECTRICAL SUPPLY AND BLOCK IT.

ATTENTION! ALL ADJUSTMENT, REPAIR AND MAINTENANCE TRANSACTIONS SHALL BE MADE BY SPECIALIZED, COMPETENT, AND AUTHORIZED TECHNICAL STAFF.

2. WARNING •

This manual is an essential part of the machine and, as it is stated in the Directive 2006/42/EC of the European Parliament and of the Council on machinery (R.D. 1644/2008 Annex I), it must be kept.

•

It must be read carefully as it contains important indications on safe use and maintenance.

•

This machine must be used only for the purpose for which it has been manufactured; any other use could be dangerous, for which reason the manufacturer will not be liable for damage caused.

•

Any intervention or modification which alters the structure or the working cycle must be made or authorized by the manufacturer.

•

The substitution of pieces, elements or equipment, will be made considering the original pieces.

•

If this is not so, the manufacturing company will not be liable for the possible consequences.

3. SECURITY NOTICE 3.1. SAFE FUNCTIONING Security notices contained in this section and through the manual are applicable to the works carried out in the machine. Besides, the text includes warning concerning security matters. It is very important to observe the indicated security notice. If this is not made, personal or material damage in the machine or in other equipment may occur. Taking all this into account, we provide here some basic recommendations concerning safety.

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•

Read and get familiar with the contents in this section before installing, starting up, maintaining or repairing the machine.

•

Read and observe the warnings concerning specific areas indicated in the text.

•

Keep this manual and show it to the staff operating the machine.

•

Wear the right personal clothes and the necessary protective equipment.

•

Study and take all security measures prescribed by the company, general accident prevention regulations and security legislation.

3.2. SAFETY SIGNS The following signs are used throughout the manual to indicate hazards or their potential causes. Read them carefully! Failure to observe a warning could cause personal injury and/or damage to the machine or other equipment.

Key words The following words are associated with the signs used in this manual as well as on labels placed on the machine to indicate the potential risk level of hazardous situations that could cause damage or personal injury. DANGER: Indicates an imminent risk which, unless avoided, will cause loss of life or serious injury. WARNING: Indicates an imminent risk which, unless avoided, will cause serious injury. CAUTION: Indicates a potential risk which, unless avoided, could cause minor or moderate injuries. This word is also used to alert against unsafe practices that could cause damage to property. (See section 7.10. DESCRIPTION OF DANGER, PROHIBITION AND OBLIGATION SIGNALS).

3.3. SPECIALIZED STAFF “Specialized staff” will be meant to be the staff who know the machine in depth, as much as its safe usage, ways of maintaining and repairing. Besides, specialized staff must be physically prepared to do the corresponding tasks, to know the rules and security regulations, and must have been trained to install, work, maintain and repair the machine appropriately. It is the responsibility of the company using the machine to ensure that staff fulfils these requirements.

3.4. OPERATION The machine must be operated by specialised staff in accordance with the instructions given in this manual. ATTENTION! NOT TO ATTEND SECURITY WARNINGS MAY CAUSE PERSONAL INJURIES, DEATH OR MATERIAL DAMAGE.

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Before using the machine carefully read the present operation and maintenance manual, especially those sections regarding safe working and safe use of the machine. The machine must only be used by properly trained staff who have been informed of the hazards associated with the operation of the machine and the precautions required to be taken. Never allow the machine to be operated by staff under the effect of substances that impair their reactions or who are unable to operate it for physical reasons. Before starting the machine ensure that there are no persons in its danger areas. The greatest care has been taken in the design and manufacture of the machine to ensure the safety of the operator. Therefore every one of the safety devices used are essential and may not be removed or eliminated under any circumstances; any tampering can cause a hazard to you and those around you. Before starting up the machine, ensure that all its protective guards and safety devices are in place and fully serviceable, that moving parts are not blocked, that there are no damaged items and that all the machine components are correctly installed and in proper operating condition. Otherwise do not operate the machine. Any safety devices removed for cleaning, maintenance or repair work must be reinstalled immediately upon completing the work. Prior to performing any maintenance, repair or cleaning work the machine must be locked out and tagged out. In other words, turn the main power switch to '0' (OFF), lock it out and signpost it appropriately. It is strictly forbidden to use the machine if any distortion or malfunction is detected. In such case the machine must be immediately locked out and tagged out (isolated from the power supply and signposted appropriately) and the technical support service called to correct the faults detected. Certain practices or minor alterations by the user can cause damage and/or accidents. Users are advised against carrying out any alterations without prior approval by the manufacturer or construction company. The use of non‐original replacement parts can compromise the proper operation of the machine. The manufacturer declines any liability for the use of such parts. Always keep the machine clean and in good operating condition. Adjustments and repairs should always be performed by specialized, qualified and authorized staff. Always check that the machine has not been tampered with by other persons. Check that none of the safety elements have been tampered with. Do not use the machine in unfavorable weather conditions (strong wind, storms, etc.). Keep your limbs and/or clothes clear from rotating or moving parts. Do not wear loose clothes when maintaining units with rotating or moving parts. Remove wristwatches, rings, necklaces or similar jewelers items and tie up or cover long hair prior to performing any work on or with the machine.

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NEVER USE THE MACHINE FOR PURPOSES OTHER THAN THOSE AUTHORISED BY THE MANUFACTURER. If in doubt contact the manufacturer. The fencing must remain closed throughout the operation of the machine. NEVER leave the perimeter fencing open while the machine is in operation. NEVER open the switchboard cabinet unless the power supply has been disconnected. In case of fire disconnect the machine from the power supply and use extinguishers with foam resistant to alcohol, dust, water spray or CO2, depending on the nature of the fire.

3.5. MEASURES IN CASE OF ABNORMAL FUNCTIONING If a failure takes place when working the machine, proceed as follows: •

Stop the machine.

•

Turn the power supply off by setting the main power switch to zero (OFF), lock it out and signpost it appropriately.

•

Verify the absence of voltage.

•

Have the unity repaired only by authorized, specialized, competent staff. WARNING: DO NOT START UP THE MACHINE UNTIL THE DETECTED FUNCTIONING FAILURE HAS BEEN REPAIRED.

3.6. MAINTENANCE/REPAIR For the execution of maintenance or repair procedures rely only on specialized, competent, authorized staff. When carrying out these tasks, please wear adequate clothes and protection equipment.

-

TAKE THE FOLLOWING STEPS BEFORE TRYING TO MAINTAIN OR REPAIR THE MACHINE. Parar la máquina.

•

Stop the machine.

•

Turn the power supply off by setting the main power switch to zero (OFF), lock it out and signpost it appropriately.

•

Verify the absence of voltage.

•

If the machine energizes itself, repeat the previous steps: unplug, mark and cover. Try to energize the machine again.

•

If the machine does not energize itself, begin the maintenance /repair tasks. ATTENTION! ALL ADJUSTMENT, REPAIR AND MAINTENANCE TASKS SHALL BE CARRIED OUT ONLY BY SPECIALIZED, COMPETENT, AUTHORIZED TECHNICAL STAFF.

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For maintenance or repair tasks, the following individual protection equipments will be needed:

DUTY: It is compulsory to use safety shoes insulation and reinforced toe. Not to use it may cause personal injuries.

DUTY: It is compulsory to use security gloves against mechanical stresses. Not to use them may derive in personal injuries.

DUTY: It is compulsory to wear a security helmet when there is risk of impact with low machine parts and/or ejections, or of falling objects, tools or parts of the machine. Use security gloves against mechanical stresses. Not to use them may derive in personal injuries or death.

(See section 8.5 MAINTENANCE in this manual)

3.7. CLEANING As a consequence of the natural movement of the whole equipment it is not necessary to clean the solar panels as often as if they were stable solar panels. However, not to damage the equipment right performance, it is advisable to clean the plaques, at least twice a year (depending on the weather conditions in every area), with pressurized water, mixed with degreasing cleaner and polish, using a rubber brush not to scratch the modules crystal. For cleaning tasks of the machine and working area, the procedure is as follows: •

Set the NCU switch ON/OFF in position "CLEANING".

•

Activate the emergency stop button in TCU.



Turn the power supply off by setting the main power switch to zero (OFF), lock it out and signpost it appropriately.



Proceed with the cleaning of all its elements.



Lubricate the machine with the recommended greases and oils, or those with similar characteristics.



Check and revise the right state of the electrical and mechanical elements.



Once the machine is clean, check the right collocation and operation of the installation security devices.

For that purpose, it will be necessary to use the following individual protection equipments:

DUTY: It is compulsory to use safety shoes insulation and reinforced toe. Not to use it may cause personal injuries. 20180420 MONOLINE 2.0 Use and Maintenance Manual Rev. 00

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DUTY: It is compulsory to use security gloves against mechanical stresses. Not to use them may derive in personal injuries.

DUTY: It is compulsory to wear a security helmet when there is risk of impact with low machine parts and/or ejections, or of falling objects, tools or parts of the machine. Use security gloves against mechanical stresses. Not to use them may derive in personal injuries or death.

WARNING: avoid the accumulation of liquids, powder and solids suspended on the machine as they could affect the performance and correct operation of the machine. CAUTION: Eliminate any oils or grease on floors which could appear after maintenance or performance works. Not to do so might cause personal injuries. IMPORTANT: Before using any machine cleansing product, always check its safety instructions or the information sheet provided by the manufacturer. CAUTION: In case of accidentally dropping any product please check the security details provided by the manufacturer.

3.8. WASTE DISPOSAL Disposal of equipments and materials must be carried out according to the regulation in force. In order to avoid pollution, pay special attention to the waste disposal method. •

•

Always collect the oil drained from your machine in suitable containers and deliver it to a specialised collection and management company. Never drain directly on the ground, nor dump it on drains, rivers, lakes or the sea. Respect laws and regulations concerning dangerous objects or products disposal such as oils, fuel, cooling gel, solvent, filters or batteries

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4. USER INSTRUCTIONS MANUAL 4.1. SECTORS OF USE The machine will be used only for POSITIONING THE SOLAR PANELS SO THAT THEY STAY CLOSE AND AT RIGHT ANGLES TO THE SOLAR RAYS, FOLLOWING THE SUN PATH FROM SUNRISE IN THE EAST TO SUNSET IN THE WEST, in the conditions indicated by the manufacturer. ATTENTION! NEVER USE THE MACHINE FOR USES OR CONDITIONS OTHER THAN THE AUTHORIZED BY THE MANUFACTURER

ATTENTION! Never use the machine with an inappropriate type or greater number of photovoltaic panels than recommended by the manufacturer.

ATTENTION! Do not use the machine in adverse weather conditions (strong wind, storms, etc.). 

This machine will be used for the only purpose for which it was specifically designed. Any other use will be considered as inadequate and as such, non reasonable.



The manufacturer or provider will not be liable for the possible damage caused by inappropriate , wrong and/or non reasonable use.



Safe and right use of the machine implies following the User Manual indications and particularly: - The machine must be operated only by staff who has been previously informed on its right use (if necessary, the manufacturer or distributor will be asked), and also of the dangers it implies, of the security measures to be taken during the working process including readjustment and tools replacement, of the sequence of actions minimizing these risks and of the actions specifically prohibited. -

Work must always be carried out using the protection systems provided with the machine (these must not be retired nor cancelled), which must be revised and kept with the periodicity indicated in the user manual.

-

Methods of safe working established will be of application.

-

Maintenance of the machine will be carried out following the indicated guidelines, by staff having the basic knowledge on the machine operation, the mechanical and electrical aspects which make them able to correctly exert his/her task.

-

During maintenance transactions the security measures provided with the machine will be of application or, as the case might be, other indicated complementary measures. DANGER: The use of this machine in a way other than the described in this document may derive in personal injuries, death or material damage.

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The following actions of the machine owner or worker are some of the many possible cases of inappropriate use of the machine. These usages will allow the manufacturer to declare himself non liable in case of personal injuries or material damages which may occur: •

To use the machine with materials different from the ones authorized by the manufacturer.

•

To modify or make changes in the unit without previous approval. -

Modifications in the machine performance speed, by altering the pre‐regulated and stated tared by the manufacturer, or by modifying transmissions.

-

Any mechanical and/or electrical modification in the machine, its parts or its installations

•

Only use original replacement parts supplied by the manufacturer.

•

To carry out a wrong assembly or installation.

•

Wrong use, wrong storage or wrong maintenance.

•

To ignore security notices.

•

To cancel or ignore the use of security devices.

•

To ignore instructions related to the installation, assembly, maintenance or repair, or to carry out these tasks by non specialized staff.

•

To use inappropriate auxiliary equipment or unsuited materials.

•

To break the security rules at work or the regulations issued by authorities or security councils.

•

Damage of the machine as a result of natural catastrophe such as strong winds, ice, storms or other catastrophes.

•

Installation in the equipment of more photovoltaic panels than recommended, or of panels different from the ones recommended.

•

To make an inconvenient packaging of the sent back shipment.

•

Damage of the machine as a result of chemical influences.

•

Avoid use in extreme temperature and climate conditions.

use,

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storage,

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4.2. MACHINE DESCRIPTION It is a machine whose function is POSITIONING THE SOLAR PANELS SO THAT THEY STAY CLOSE AND AT RIGHT ANGLES TO THE SOLAR RAYS, FOLLOWING THE SUN PATH FROM SUNRISE IN THE EAST TO SUNSET IN THE WEST.

This machine is made up by a number of metal frames arranged along a North‐West axis, onto which the photovoltaic modules are mounted. The rails or supports of said photovoltaic modules are joined by a metal section attached to a rotating driver, located in the centre of the assembly, which provides the East‐ West movement (zenithal axis) to enable solar tracking. The maximum reachable angle is +/‐ 55º, resulting in a significant improvement in production compared with a fixed‐structure system.

Solar tracker at maximum tilt position (55º to the horizontal) and in stow position (0º)

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El seguidor solar se compone principalmente de los siguientes elementos o componentes: A.‐ SUPPORT POSTS. B.‐ MOTOR. C.‐ ROTATION BEAM. D.‐ SOLAR PANEL RAILS. E.‐ SOLAR PANELS. F.‐ SAFETY ELEMENTS AND DEVICES2.

C

B

A

D

E

2

See section 7.9. MEASURES, ELEMENTS AND SECURITY DEVICES.

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The installation support structure (support posts, torque tube and solar panel rails) has been made and designed with the necessary resistance and dimensions so that the set has the necessary stability to be used without the risk of turning over, falling down or being displaced untimely. The support posts lies on a foundation or concrete shoe with wire mesh, which remains attached to the shoe through nuts and locknuts on anchorage steel bolts (see plans of installation and assembly for each site).

Attached to the posts heads are the torque tubes on which the solar panels are mounted by means of their support brackets (rails), allowing the direct anchoring and fixing of several different panel types (monocrystalline, polycrystalline or thin film photovoltaic solar panels). The entire assembly’s support structure is made of steel with several coatings, assuring adequate corrosion resistance. And it is designed and manufactured to withstand the maximum capacity of solar panels indicated on TECHNICAL CHARACTERISTICS OF THE MACHINE, according to model. The zenithal movement of the solar panels is carried out by means of a rotating driver located on the central pillar of the structure. The rotating driver mainly consists of slew drive connected to a motor that apply the necessary torque to move the torque tube.

Rotation Beam

Slew Drive

Motor

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Thus, the rotating driver orients the solar panel following the sun’s course from sunrise to sunset, keeping close to the perpendicular of the sun’s rays. Its movement and position is controlled by an automated device with PLC (TCU, RSU and NCU), an inclinometer (include in TCU) that detects the panel inclination angle, and two end stops preventing it from rotating beyond the permissible limits (+/‐ 55º on the zenithal axis).

Rotation Beam

TCU

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The solar tracker incorporates an electric control box (TCU) including the variable SSR that energize the motor. The installation assembly complete with several solar trackers (up to 200) controlled by the main control box (NCU), which includes the PLC and the, allowing the necessary start‐up mode (manual or automatic) settings to be entered and displaying information on any error occurring during operation. The weather station (RSU) is connected directly with the NCU, in order to send all the climatic data. TCU

NCU

RSU

SYSTEM COMUNICATION

The single‐axis solar tracking is carried out by means of the astronomical programming implemented on the PLC in NCU, which drives the trackers to position the solar panels at the optimal inclination relative to the sun throughout the day. In addition, a backtracking algorithm is implemented to prevent self‐shading of the solar trackers at certain times of day (early in the morning and late in the evening), leading to an enhancement in production, since when it detects that one row is casting a shadow on the one immediately behind it, the system corrects its inclination angle to avoid such shading.

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Without backtracking

With backtracking

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The machine is also equipped with a wind vane and anemometer to measure the wind speed, so that in case of strong winds the panels are placed in the horizontal idle position, offering the least possible resistance to the wind. Additionally the machine has a number of safety measures, elements and devices, as described in section 7.9. The (approximate) dimensions of the machine in mm: See PLANS OF GENERALS DIMENSIONS of the machine. These dimensions are approximate, and they may vary without affecting security of the machine.

4.3. MANEUVER DESCRIPTION The manufacturer's technical staff will be responsible for setting the parameters required for commissioning of the machine; It is the normal operation of the automatic machine completely. So, the user will only intervene in tasks start‐up/stop, process control and SURVEILLANCE of SAFETY conditions. Thus, the maneuver description consists of the starting up, process controlling and stopping of the machine. Prior to starting up the machine, check the effectiveness and full functionality of the safety devices and verify that no moving parts are blocked, that there are no damaged elements, and that all the machine components are correctly placed and fully operational. Never start up the machine if any of its safety devices have been removed or disabled. Prior to starting up the machine check for the absence of people in the machine’s danger areas.

For the START UP of the machine the procedure is as follows: 1

Turn on the mains power supply by means of the main power switch.

2

Unlock the emergency stop.

3

Connect with NCU and select in AUTO/MANUAL and select AUTO in all the Group.

Both in plants with few units and in those with a large number of solar trackers there is the possibility of adding a real‐time tracker status and movement monitoring system (SCADA). This type of software monitors and records essential equipment information and allows detailed observation of each individual tracker, as well as changing their operating status, resetting the PLC or instructing it to move to a certain position. Normal STOPPING of the solar trackers can be performed either individually or for the entire installation, by pressing the red button “STOP” corresponding.

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In case of EMERGENCY or malfunction: -

Depress the red EMERGENCY STOP BUTTON on the TCU to stop the individual solar tracker involved in a safe manner.

-

Alternatively, connect with NCU and select in AUTO/MANUAL and select MANUAL in a group that you will like to stop.

The EMERGENCY STOP BUTTONS are easily accessed and provide a swift and easy means of stopping the machine in a safe manner in the event of a hazardous situation. Once such a situation disappears, the machine must be reset by manually clearing.

4.4. GENERAL SECURITY RULES WARNING: NOT TO ATTEND SECURITY WARNINGS MAY CAUSE PERSONAL INJURIES, DEATH OR MATERIAL DAMAGE. Before using the machine carefully read the present operation and maintenance manual, especially those sections regarding safe working and safe use of the machine. The machine must only be used by properly trained staff who have been informed of the hazards associated with the operation of the machine and the precautions required to be taken. Never allow the machine to be operated by staff under the effect of substances that impair their reactions or who are unable to operate it for physical reasons. Before starting the machine ensure that there are no persons in its danger areas. The greatest care has been taken in the design and manufacture of the machine to ensure the safety of the operator. Therefore every one of the safety devices used are essential and may not be removed or eliminated under any circumstances; any tampering can cause a hazard to you and those around you. Before starting up the machine, ensure that all its protective guards and safety devices are in place and fully serviceable, that moving parts are not blocked, that there are no damaged items and that all the machine components are correctly installed and in proper operating condition. Otherwise do not operate the machine. Any safety devices removed for cleaning, maintenance or repair work must be reinstalled immediately upon completing the work. Prior to performing any maintenance, repair or cleaning work the machine must be locked out and tagged out. In other words, turn the main power switch to OFF, lock it out and signpost it appropriately. It is absolutely essential that the machine undergo thorough regular inspections to ensure the functionality of all its components. Follow the recommendations given in the maintenance section in this manual. It is strictly forbidden to use the machine if any distortion or malfunction is detected. In such case the machine must be immediately locked out and tagged out (isolated from the power supply and signposted appropriately) and the technical support service called to correct the faults detected.

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Certain practices or minor alterations by the user can cause damage and/or accidents. Users are advised against carrying out any alterations without prior approval by the manufacturer or construction company. The use of non‐original replacement parts can compromise the proper operation of the machine. The manufacturer declines any liability for the use of such parts. The manufacturer or distributor will not accept liability for any damage arising from any work or alteration performed on the machine without the manufacturer’s or distributor’s prior consent.

The machine must be kept clean and in proper operating condition, especially as regards its moving parts, controls, indicators, etc. Do not perform any cleaning, adjustment or maintenance work while the machine is in operation. Adjustments and repairs should always be performed by specialized, qualified and authorized staff. Always check that the machine has not been tampered with by other persons. o

Check that none of the safety elements have been tampered with. Do not use the machine in adverse weather conditions (strong wind, storms, etc.). Keep your limbs and/or clothes clear from rotating or moving parts. Do not wear loose clothes when maintaining units with rotating or moving parts. Remove wristwatches, rings, necklaces or similar jewellery items and tie up or cover long hair prior to performing any work on or with the machine. NEVER USE THE MACHINE FOR PURPOSES OTHER THAN THOSE AUTHORISED BY THE MANUFACTURER. If in doubt contact the manufacturer. ANY INTERVENTION ON THE ELECTRICAL INSTALLATION, EVEN A SLIGHT ONE, REQUIRES THE INTERVENTION OF AUTHORIZED, SPECIALIZED, COMPETENT STAFF. Any work on the machine must be carried out with clean, suitable tools in good condition. Avoid using non‐approved tools. ¡DANGER! DO NOT OPEN THE ELECTRICAL DASHBOARD DISCONNECTING THE MACHINE ELECTRICAL SUPPLY.

WITHOUT

PREVIOUSLY

Any transport, assembly or dismantling must be made by staff specifically trained for such work. Never allow unauthorised staff to operate or repair the machine. In case of fire disconnect the machine from the power supply and use extinguishers with foam resistant to alcohol, dust, water spray or CO2, depending on the nature of the fire. The fencing must remain closed throughout the operation of the machine. NEVER leave the perimeter fencing open while the machine is in operation.

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Do not install on the unit a number of photovoltaic panels exceeding the manufacturer’s recommendation or an unsuitable type of photovoltaic panels.

4.5. INDICATIONS ON NOISE Operation of the machine generates, under normal conditions of use, a noise which surpasses the reasonable limits stated by the European rule, LEVEL OF CONTINUOUS EQUIVALENT PONDERED ACOUSTIC PRESSURE 0,1 °).

F.423.03. Rev.A

The system has been designed to guarantee Long duration and reliability.

D003-PS14006_NexTracker_SnowLine_revA_RSU_Installation and Operation Manual_EN.doc

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

3 (58) Date - you Give you

P4Q/ Installation and Operation Manual

2014-06-05

Rev

Nº Document - Document No.

A D003-PS14006

SUNTRACK

SUMMARY SUNTRACK Installation and maintenance.

APPLICATION PS14006

SUMMARY REVIEW

REV

F.423.03. Rev.A

A

YYYY-MM-DD

2014-06-05

AUTOR

A.Martinez

COMMENTARY

First review

D003-PS14006_NexTracker_SnowLine_revA_RSU_Installation and Operation Manual_EN.doc

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

4 (58) Date - you Give you

P4Q/ Installation and Operation Manual

2014-06-05

Rev

Nº Document - Document No.

A D003-PS14006

ÍNDICE INTRODUCTION .................................................................................................................. 2 GLOSSARY, TECHNICAL TERMS AND ABBREVIATIONS ............................................... 9 1.- SAFETY INSTRUCTIONS ............................................................................................. 10 2.- CONDITIONS FOR PACKAGING AND STORAGE ..................................................... 12 2.1.- Reception Conditions .......................................................................................................................................... 12 2.2.- Contents of Packaging ........................................................................................................................................ 12 2.3.- Storage Conditions .............................................................................................................................................. 13

3.- DESCRIPTION OF UNIT ............................................................................................... 14 3.1.- General Description ............................................................................................................................................. 14 3.1.1.- Technical Characteristics ........................................................................................................................... 14 3.1.2.- Mechanical Characteristics........................................................................................................................ 15 3.1.3.- Block Diagram ............................................................................................................................................... 17 3.2.- Anemometer........................................................................................................................................................... 19 3.3.- Snow Sensor .......................................................................................................................................................... 20

4.- MONITORING THE SYSTEM........................................................................................ 22 4.1.- RSU Connection ................................................................................................................................................... 22 4.2.- Monitoring Sw Setup ........................................................................................................................................... 23

F.423.03. Rev.A

4.3.- Suntrack Modbus Master.................................................................................................................................... 27 4.3.1.- Save Data ........................................................................................................................................................ 27 4.3.2.- Communication ............................................................................................................................................. 27 4.4.- Menu ........................................................................................................................................................................ 30 4.4.1.- Suntrack .......................................................................................................................................................... 30 4.4.2.- Status............................................................................................................................................................... 31 4.4.2.1.- Wind Speed ............................................................................................................................................ 31 4.4.2.2.- Snow Level ............................................................................................................................................. 31 4.4.3.- Sw/Com ........................................................................................................................................................... 32 4.4.3.1.- Remote Com Parameters ................................................................................................................... 33 4.4.3.2.- Update ..................................................................................................................................................... 33 4.4.4.- Zigbee .............................................................................................................................................................. 34 4.4.4.1.- ZB Module Info ...................................................................................................................................... 34 4.4.4.2.- ZB Specified PAN ................................................................................................................................. 34 4.4.4.3.- ZB com Parameters ............................................................................................................................. 35 D003-PS14006_NexTracker_SnowLine_revA_RSU_Installation and Operation Manual_EN.doc

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4.4.4.4.- Short address ........................................................................................................................................ 35 4.4.4.5.- Association Indication ........................................................................................................................ 35 4.4.4.6.- Stack Profile........................................................................................................................................... 35 4.4.5.- Wind Sensor .................................................................................................................................................. 36 4.4.5.1.- No Wind Alarm Threshold .................................................................................................................. 36 4.4.5.2.- Wind Alarm Threshold ........................................................................................................................ 36 4.4.5.3 No Alarm Wind Time .............................................................................................................................. 37 4.4.5.4.- Alarm Wind Timer ................................................................................................................................. 37 4.4.6.- Snow Sensor.................................................................................................................................................. 38 4.4.6.1.- Snow Sensor Height ............................................................................................................................ 38 4.4.6.2.- Snow Sensor Calibration .................................................................................................................... 38 4.4.7.- P4Q Sensors ................................................................................................................................................. 39 4.4.7.1.- Wind Constants .................................................................................................................................... 39 4.4.7.2.- Snow Constants.................................................................................................................................... 39

5.- INSTALLATION OF EQUIPMENT ................................................................................ 41 5.1.- Earth ......................................................................................................................................................................... 41 5.2.- Electrical Cabinet Location ................................................................................................................................ 42 5.2.1.- Mechanical Aspects ..................................................................................................................................... 42 5.2.2.- Thermal Aspects ........................................................................................................................................... 42 5.2.3.- Safety ............................................................................................................................................................... 44 5.3.- Fixing the Cabinet ................................................................................................................................................ 45 5.4.- Cable Routes ......................................................................................................................................................... 46 5.5.- Fixing the Anemometer ....................................................................................................................................... 46 5.6.- Fixing the snow sensor ....................................................................................................................................... 47 5.7.- Electric Connection ............................................................................................................................................. 48 5.8.- Startup ..................................................................................................................................................................... 51 5.8.1.- Electrical Cabinet ......................................................................................................................................... 51 5.8.2.- Establish Communication .......................................................................................................................... 51 5.8.3.- Snow Sensor Parameters ........................................................................................................................... 51 5.8.4.- Anemometer Parameters ............................................................................................................................ 51

6.- MAINTENANCE ............................................................................................................ 53 7.- COMPLIANCE OF NORMS .......................................................................................... 54 8.- TERMS AND CONDITIONS OF WARRANTY .............................................................. 55

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8.1.- Duration of Warranty ........................................................................................................................................... 55 8.2.- Conditions of the Warranty ................................................................................................................................ 55 8.3.- Exclusion of Liability ........................................................................................................................................... 55 D003-PS14006_NexTracker_SnowLine_revA_RSU_Installation and Operation Manual_EN.doc

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9.- TRADEMARKS ............................................................................................................. 56 ANEXO I.- REPAIR INCIDENT SHEET.............................................................................. 57

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ANEXO II.- INCIDENT IN TRANSPORT SHEET ............................................................... 58

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FIGURES

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FIGURE 1.- SUNTRACK RSU CABINET ....................................................................................... 12 FIGURE 2.- CABINET SUPPORT .................................................................................................. 15 FIGURE 3.- CABINET DIMENSIONS ............................................................................................ 16 FIGURE 4.- BLOCK DIAGRAM...................................................................................................... 17 FIGURE 5.- POWER CONNECTOR .............................................................................................. 18 FIGURE 6.- IED ELECTRONICS ANEMO 4403 ............................................................................ 19 FIGURE 7.- NOVALINX 260-700 ULTRASONIC SNOW DEPTH SENSOR ................................... 20 FIGURE 8.- INSTALLATION DIAGRAM ........................................................................................ 21 FIGURE 9.- RSU SERIAL CONNECTION ..................................................................................... 22 FIGURE 10.- MODBUS TCP.......................................................................................................... 23 FIGURE 11.- INSTALLABLE .......................................................................................................... 23 FIGURE 12.- LANGUAGE SELECTION ........................................................................................ 23 FIGURE 13.- INSTALLATION WIZARD ......................................................................................... 24 FIGURE 14.- INSTALLATION DIRECTORY .................................................................................. 24 FIGURE 15.- DIRECT ACCESS .................................................................................................... 24 FIGURE 16.- ADDITIONAL TASKS ............................................................................................... 25 FIGURE 17.- INSTALLATION SUMMARY ..................................................................................... 25 FIGURE 18.- INSTALLING ............................................................................................................ 25 FIGURE 19.- INSTALLATION COMPLETED ................................................................................. 26 FIGURE 20.- SUNTRACK MODBUS MASTER.............................................................................. 26 FIGURE 21.- SAVE DATA ............................................................................................................. 27 FIGURE 22.- COMMUNICATION .................................................................................................. 27 FIGURE 23.- ENABLE COMMUNICATION.................................................................................... 28 FIGURE 24.- SUNTRACK.............................................................................................................. 30 FIGURE 25.- STATUS ................................................................................................................... 31 FIGURE 26.- SW/COM .................................................................................................................. 32 FIGURE 27.- SERIAL CONFIGURATION CHANGE ...................................................................... 33 FIGURA 28.- ZIGBEE .................................................................................................................... 34 FIGURE 29.- WIND SENSOR ........................................................................................................ 36 FIGURE 30.- SNOW SENSOR ...................................................................................................... 38 FIGURE 31.- P4Q SENSORS ........................................................................................................ 39 FIGURE 32.- FIXING SCREW ....................................................................................................... 45 FIGURE 33.- FITTING THE CABINET ........................................................................................... 45 FIGURE 34.- FITTING THE ANEMOMETER ................................................................................. 46 FIGURE 35.- FITTING THE SNOW SENSOR ............................................................................... 47 FIGURE 36.- CONNECTORS ........................................................................................................ 48 FIGURE 37.- CONNECTOR CONNECTION.................................................................................. 49 FIGURE 38.- AFEISA CONVERTER ............................................................................................. 50

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TABLES

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TABLE 1.- GLOSSARY .................................................................................................................... 9 TABLE 2.- TECHNICAL CHARACTERISTICS ............................................................................... 15

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GLOSSARY, TECHNICAL TERMS AND ABBREVIATIONS

TERM

DESCRIPTION

Sw

Software

RSU

Remote Sensor Unit

F.423.03. Rev.A

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. During installation which is dangerous for personnel as well as for equipment.

It is recommended that the manual should be read before using the SuntrackL RSU 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. Warranties or claims will be deemed void if the above instructions not tensiofully complied with.

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 and

F.423.03. Rev.A

authorized by the supplier.

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The work tools used to realise the installation of Suntrack RSU 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 start up 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. The Suntrack must be protected from overcurrent and overvoltage. Installer is the responsible for protecting communication inputs and voltage input.

Breakage of safety seals voids the warranty as stipulated in the signed supply contract.

F.423.03. Rev.A

Follow the instructions carefully as described in this document. 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]

Once unpacked, check that everything is included as indicated in the section 2.2 Contents of Packaging.

2.2.- Contents of Packaging The package contains a Suntrack RSU with a power cable, anemometer, snow sensor and antenna.

F.423.03. Rev.A

Figure 1.- Suntrack RSU Cabinet

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

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packaging and situated in a dry and ventilated environment.

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3.- DESCRIPTION OF UNIT The RSU is a sensor unit for wind speed and snow level remote measurement.

3.1.- General Description 3.1.1.- Technical Characteristics

Marked CE-026/09-01-EE-I1. IP67 cabinet designed for outside installation. External traceability label prepare to be out in the open. Warranty seals. Nylon IP67 circular connectors for quick connection. Working temperature range: -25 a 65ºC. Configurable by software. A PC application is provided to interact with the

F.423.03. Rev.A

unit (See fourth point of the manual).

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PARAMETERS

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AC Input Voltage Range

100 - 240

VAC

Input Frequency Range

47 - 63

Hz

Max. Input Current

300

mA

Out Maximum Voltage

24

VDC

Table 2.- Technical Characteristics

3.1.2.- Mechanical Characteristics

There are four screws at the back of the cabinet in order to support the unit.

Figure 2.- Cabinet Support

F.423.03. Rev.A

The Suntrack RSU cabinet has IP67 degree protection and 347,6 x 276,4 x 176,6 mm dimensions.

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Figure 3.- Cabinet Dimensions

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3.1.3.- Block Diagram

The following picture shows a block diagram from the different parts of the control cabinet.

Suntrack

Connection panel

Power

Rs485 Connection

Figure 4.- Block Diagram

Warning: The block diagram shows the Suntrack part that functions F.423.03. Rev.A

with high voltage and which extra care should be taken when using the cabinet.

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3.1.4.- Earth The SUNTRACK RSU must be connected to the ground connection to allow the over-voltage protections work properly and guarantee the people’s safety. Connect the installation ground to pin 3 from the CC-03PMMS power connector reference.

F.423.03. Rev.A

Figure 5.- Power Connector

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3.2.- Anemometer The anemometer employed for wind speed measurement is ANEMO 4403 from ied electronics.

Figure 6.- ied electronics ANEMO 4403

Supports wind speeds up to 200 km/h. The output is a voltage-free contact with a series resistance which opens and closes at a frequency that is directly proportional to the wind speed. The RSU establishes the relation between the wind speed given by the

F.423.03. Rev.A

anemometer (pulses per second) to wind speed measurement in km/h or Mph.

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3.3.- Snow Sensor The snow sensor employed for snow level measurement is 260-700 Ultasonic Snow Depth Sensor from Novalinx.

Figure 7.- Novalinx 260-700 Ultrasonic Snow Depth Sensor

The sensor works by measuring the time required for an ultrasonic pulse to travel to and from a target surface. This means that its output value represents the distance from the sensor to nearest surface. In order to calculate the snow level, the total distance from

F.423.03. Rev.A

the sensor to ground must be known.

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3.4.- Installation Diagram

F.423.03. Rev.A

Figure 8.- Installation Diagram

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4.- MONITORING THE SYSTEM The RSU is configurable externally via the Suntrack Modbus Master PC, which communicated by the MODBUS protocol over a RS-485 or over ZIGBEE. It is an Intuitive menu interface that allows monitoring the state of the units.

A series of variables can be visualized to discern the working condition of the system and the value of other variables can be modified to adjust said function.

4.1.- RSU Connection There are different possibilities to communicate a PC with RSU. One way is using the serial interface, connecting a RS-232 RS-485 converter or a USB RS-485. The RSU communication port should be connected to the convertor and the same to the PC and RSU to the power source. It is necessary to install the Afeisa’s Driver.

Figure 9.- RSU Serial Connection

It is also possible to connect with the RSU via the MODBUS TPC, using the

F.423.03. Rev.A

MB3180 Gateway.

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Figure 10.- Modbus TCP

Finally, Zigbee interface can also be used to connect to the RSU. For this purpose, it is necessary to use a Zigbee gateway, such as Digi’s Connectpor X2. The PC program is divided into 7 menus and in each one different variable configuration indicators appear.

Apart from the menus, the working modes of the system are always accessible, a button for saving the input data and another for communication.

4.2.- Monitoring Sw Setup

F.423.03. Rev.A

Figure 11.- Installable

Figure 12.- Language Selection D003-PS14006_NexTracker_SnowLine_revA_RSU_Installation and Operation Manual_EN.doc

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Figure 13.- Installation Wizard

F.423.03. Rev.A

Figure 14.- Installation Directory

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Figure 16.- Additional Tasks

F.423.03. Rev.A

Figure 17.- Installation Summary

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Figure 19.- Installation Completed

F.423.03. Rev.A

Figure 20.- Suntrack Modbus Master

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4.3.- Suntrack Modbus Master 4.3.1.- Save Data

Once wind and snow alarm configuration is finished, the data should be saved in the internal memory of the device so that it can be recovered after a power cut.

Figure 21.- Save Data 4.3.2.- Communication

Figure 22.- Communication

From here one can have access to the communication screen, at the same time it

F.423.03. Rev.A

provides information with reference to the same as well as to the communication device.

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Figure 23.- Enable Communication

Once the communication button is clicked, a window opens as shown, that allows inputting the communication port (Comm Device). So as to know to which it corresponds, go to My PC, right click properties, Hardware, Device Administrator and check COM ports to see where the USB serial port is installed.

To avoid possible error COMM port should be configured in the low communication ports, they should always be less than 7. Should they be configured by default in the high communication ports, the port assigned during the installation should be changed. To do this access “AFEISA USB Serial Port”

“Port

Configuration” port properties and click the button “Advance options” and in the drop down window “Port number” select the desired port.

For further information on the converter one can find references in the manual in the following link: http://www.afeisa.es/wafei/ficheros/manuales/comunicaciones/CMPE_CUSB485_v2.pdf

F.423.03. Rev.A

Each Suntrack system has Modbus device address by default, in this case is 186 for the serial connection.

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In case of communication through the MB3180 Gateway, the Comm Device will correspond to the IP address assigned internally by the company, leaving the remaining parameters by default.

Com Deafult parameters: Address: 186 Configuration: 19200 EVEN

Finally, in case Zigbee interface is used, the Comm Device will correspond to the IP address of the Connectport X2. In this case, Modbus addressing is configured at the Connecport, so the slave address that has to be entered in the PC software depends on

F.423.03. Rev.A

the configuration of the Connectport.

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4.4.- Menu The Suntrack Modbus Master screens are explained in this section. 4.4.1.- Suntrack

Figure 24.- Suntrack

F.423.03. Rev.A

The Suntrack presentation screen.

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4.4.2.- Status

Figure 25.- Status 4.4.2.1.- Wind Speed

Wind speed value measured in the RSU. 4.4.2.2.- Snow Level

Snow Level measured in the RSU. 4.4.2.3.- Wind Alarm

This alarm indicates that the measured wind speed value has been higher than the F.423.03. Rev.A

configured threshold value during a period of time. This configuration is described in 4.4.5 Wind Sensor.

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4.4.3.- Sw/Com

In this screen the user can visualize the configuration of the serial interface.

Figure 26.- Sw/COM

The controller works following the rules of the Modbus standard control, so it is essential to read how works this Standard: http://www.modbus.org/docs/Modbus_over_serial_line_V1_02.pdf .

To sum up the Modbus standard considers an 11bit serial character; Start bit – 8 bit data – parity bit – stop bit. So the no parity option requires the use of 2 stop bits.

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Remark: the use of no parity requires 2 stop bits.

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4.4.3.1.- Remote Com Parameters

The baud rate and the parity are the parameters for the serial interface. Modbus address is the slave address, by default is 186. To modify any of these parameters, new values must be written, and then click on “Save data” to be saved in EEPROM and after few seconds, click on the Restart button. Afterward, communication must be deactived, to key the new address and communication has to be reestablished with this new address.

Figure 27.- Serial configuration change

4.4.3.2.- Update

Software update button is available for updating the Sw, in the case that there is a new version available for install. The flag that indicates that a new software version is available will be deactivated once the update has been carried out correctly. That works with Remote Loading of the Sw. To do this it is necessary a Remote Loader, that it is not

F.423.03. Rev.A

included with the Sw and it is necessary to ask for it.

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4.4.4.- Zigbee

This tab shows the configuration of the Zigbee communication parameters. Take into account that the data only appears if the communication is established with the Zigbee module.

Figura 28.- Zigbee

4.4.4.1.- ZB Module Info

The module information is only an information tab; they are not configurable parameters. 4.4.4.2.- ZB Specified PAN

The PAN Id can be modified in order to force the module connection to a certain

F.423.03. Rev.A

coordinator.

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4.4.4.3.- ZB com Parameters

The Zigbee communication parameters can also be modified. When the new parameters are set, it is necessary to push the “Restart” button, in order that the Suntrack RSU starts working with them. 4.4.4.4.- Short address

This is an information parameter. The short address is used as a unique identifier for a node in the network. It is dynamically assigned when deploying a network with new nodes joining to it. Normally the coordinator starts the network and uses the short address 0x0000. Then it assigns other addresses to the joining devices that associate with it. 4.4.4.5.- Association Indication

This information parameter indicates if the new node has successfully joined to the network or not. Once obtained, the coordinator establishes a “Short address”, and then the “Association Indication” will put on zero, indicating that the device has joined zigbee network properly (0 = Success). 4.4.4.6.- Stack Profile

Functionality and interoperability of the protocol stack are governed by a set of rules called stack profile. A stack profile specifies, for instance, which addressing

F.423.03. Rev.A

mechanism is used and which level of security the application shall implement.

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4.4.5.- Wind Sensor

Figure 29.- Wind Sensor

The wind alarm activation and deactivation are configured in this tab. 4.4.5.1.- No Wind Alarm Threshold

Wind alarm deactivation threshold value. When the wind speed is lower than this value for a period of time (see 4.4.5.3) the wind alarm is deactivated. 4.4.5.2.- Wind Alarm Threshold

Wind alarm activation threshold value. When the wind speed is higher than this

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value for a period of time (see 4.4.5.4) the wind alarm is activated.

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4.4.5.3 No Alarm Wind Time

Period of time for wind alarm deactivation. Wind speed has to remain below the “No Wind Alarm Threshold” for this period of time in order to deactivate the wind alarm. 4.4.5.4.- Alarm Wind Timer

Period of time for wind alarm activation. When wind speed is higher than “Wind

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Alarm Threshold” for this period of time the wind alarm is activated.

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4.4.6.- Snow Sensor

Figure 30.- Snow Sensor 4.4.6.1.- Snow Sensor Height

This parameter indicates the height at which the snow sensor is installed. 4.4.6.2.- Snow Sensor Calibration

When this button is pressed the snow level calculation constants are calibrated.

F.423.03. Rev.A

This operation must be performed if the snow sensor height changes.

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4.4.7.- P4Q Sensors

Figure 31.- P4Q Sensors 4.4.7.1.- Wind Constants

These contants are used to calculate the wind speed in mps (meters per second), and they depend on the anemometer used for wind speed measurement. They are configured during P4Q manufacturing process and they shouldn’t be modified unless a different anemometer has to be employed for some reason. Wind Speed = Anemometer data (pulses per second) x K1 + K0

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4.4.7.2.- Snow Constants

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“Snow Sensor Calibration” button is pressed as shown in 4.4.6.2 Snow Sensor Calibration, assuming the snow sensor Novalinx 260-700 is employed. If a different snow sensor is employed they must be configured manually.

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Snow Level = Snow Sensor Data x K1 + K0

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5.- 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.

The installation and the commissioning is not responsibility of P4Q, but always can helps taking decisions or helping resolving problems. In this point there are basic steps to consider in the installation. If there are any doubts, do not hesitate to contact with Suntrack department. Take into account that can be some error in this document, so it is important to be in contact with the suntrack deparment. Nevertheless, in order to help, P4Q gives another document that can be usefull for the installation: DT-13003_RevA_Suntrack_Modbus_over_RS485.pdf

Suntrack recommends putting protections in the lines in order to protect the Suntrack of overvoltage due to storms, etc. It is also not recommendable to use generators, since the signal that gives is not stable and can cause problems.

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:

5.1.- 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 derived F.423.03. Rev.A

from lightning.

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5.2.- Electrical Cabinet Location The priority selection criteria for situating the cabinet depend on the condition of its surroundings and the facility for connecting the aerial 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. The Suntrack must be protected from overcurrent and overvoltage. It is necessary that communication and general power supply are properly protected because the warranty is not responsible for damages caused by external reasons. For more information, it is necessary to call the person responsible in P4Q. 5.2.1.- 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 3 Kg.

Install the equipment in a vertical position. Do not leave objects on top of the unit. 5.2.2.- Thermal Aspects

The surface where the assembly is realised 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

F.423.03. Rev.A

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

Although the 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.

The recommended altitude for the installation of the unit should

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be less than 2.000 metres.

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5.2.3.- Safety

The electrical cabinet has IP67 protection, that is, it is protected from dust, 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 verify that the cabinet is closed securely.

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 protection of direct and indirect contacts. The Suntrack must be protected from overcurrent and

F.423.03. Rev.A

overvoltage.

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5.3.- Fixing the Cabinet The cabinet 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.

Fix the cabinet to the structure, using the bracket screws at the back of the cabinet (distance between screws is 177,5mm and 195,3mm). The hole has M6X10. So, four hexagonal head screw M6X16 are included.

Figure 32.- Fixing screw

Figure 33.- Fitting the Cabinet

Pay special attention to fixing the unit, as its weight is approximately 3Kg.

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Under no circumstances use the electrical cabinet assembly holes to earth the unit.

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5.4.- Cable Routes Preparation for the routes where the conductors pass 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. Anemometer cable length: 20 meters Snow Sensor cable length: 7.6 meters

5.5.- Fixing the Anemometer The anemometer has three holes at the back to facilitate fixing it to the structure.

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Figure 34.- Fitting the Anemometer

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5.6.- Fixing the snow sensor

When mounting the sensor, attention must be payed to the cone of the ultrasonic beam. The beam width is 22 degrees which means the diameter of the beam will be 39% of the distance to the target, as shown in figure 35. This means that after travling 10 meters, the beam diameter will be 3.9 meters. In this example, the sensor would need to be mounted at least half the distance of the beam diameter, or 1.95 meters, away from the mast. Obstructed beam paths must be avoided. Use this formula to determine the minimum distance the sensor must be mounted away from the mast:

F.423.03. Rev.A

Crossarm Length = 0.194 x Height

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5.7.- Electric Connection

Warning: Beforehand, one should check that all metallic elements are earthed.

Position the unit vertically with the connectors in the lower part, in the position that it is assigned for fitting the same.

Snow Sensor

Anemometer

Seal

Communications

Power

Figure 36.- Connectors

DO NOT connect the general power supply of the Suntrack RSU until

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the installation has been completed.

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Connect the connectors to the Snow Sensor and the Anemometer and turn the main element of the connector completely. One should check that the connector is fixed to the Suntrack RSU.

Figure 37.- Connector Connection

POWER: Aerial reference LTWCC-03BFFM-LL7000. Panel reference LTWCC03PMMS-LC7001. -

Pin1

Neutral

-

Pin2

Phase

-

Pin3

Ground

SNOW SENSOR: Aerial reference LTWBD-07BFFM-LL7001. Panel reference

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LTWBD-07PMMS-LC7001. -

Pin1

Snow Sensor Vcc+

-

Pin2

(NC)

-

Pin3

Shield

-

Pin4

(NC)

-

Pin5

GND

-

Pin6

(NC)

-

Pin7

Signal

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ANEMOMETER: Aerial reference LTWBD-04BFFM-LL7001 / Conxal 62804PG-318. Panel reference LTWBD-04PMMS-LC7001. -

Pin1

(NC)

-

Pin2

GND

-

Pin3

Signal

-

Pin4

(NC)

COMUNICATIONS: Aerial reference LTWBD-06BFMA-LL7001/ Conxal 62806PG-318. Panel reference LTWBD-06PMFS-LC7001. -

Pin 1/3

Com Positive

-

Pin 2/4

Com Negative

-

Pin 5/6

Cable Shield

For the Power and Communication connectors first it is important to realise the wiring and later connect the Suntrack RSU unit. Connect the local communication connector and then the power supply to the SUNTRACK.

Figure 38.- Afeisa Converter

Proceed to power the equipment by activating the feed line.

F.423.03. Rev.A

The wrong supply polarity will result in a system fail.

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5.8.- Startup Once the Suntrack RSU control unit is installed, with the necessary wiring and sensors mentioned in position, the following points should be observed. 5.8.1.- Electrical Cabinet

Once the cabinet has been connected, the following sequence should be carried out before initiating start-up. -

Power the unit (See section 5.6).

-

Connect the communication connector joined to the USB/RS-485 converter (See section 4.1).

5.8.2.- Establish Communication

Establish communication between the Suntrack RSU and the monitoring programme. (See section 4). First of all it is necessary to install afiesa’s Driver. 5.8.3.- Snow Sensor Parameters

Check the Snow Sensor constant. Configure the height at which the snow sensor is installed and press the snow sensor calibration button to the snow level calculation constants are been calibrated. 5.8.4.- Anemometer Parameters

Check the Anemometer Sensor constant.

F.423.03. Rev.A

Enter the value period of time for wind alarm activation/deactivation.

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5.9.- Unistalling the Electrical Cabinet

Disconnect the power connector.

Disconnect the rest of the connectors.

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Extract the fixing screws and take away the equipment.

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6.- 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 behaviour, such as wind, etc, so that all the alarms are generated correctly and that the system

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responds as expected.

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7.- COMPLIANCE OF NORMS Suntrack RSU complies with the essential requirements of Electromagnetic Compatibility in accordance to the 2004/108/CE Guidelines.

The harmonized standards are: - EN 61000-6-2 (2005) - EN 61000-6-4 (2001) - EN 55011 (1998) + A1 (1999) + A2 (2002) - EN 61000-4-2 (1995) + A1 (1998) + A2 (2001) - EN 61000-4-3 (2006) - EN 61000-4-4 (2004) - EN 61000-4-5 (1995) + A1 (2001) - EN 61000-4-6 (1996) + A1 (2001) - EN 61000-4-8 (1993) + A1 (2001)

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- EN 61000-4-11 (2004)

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8.- TERMS AND CONDITIONS OF WARRANTY 8.1.- 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.

8.2.- Conditions of the Warranty During the warranty period, the equipment will be repaired at no cost in material or labor 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 authorisation 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 III). P4Q cannot accept equipment received without prior notification in writing or without being informed of the failure.

8.3.- 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.

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

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

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

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ANEXO I.- REPAIR INCIDENT SHEET

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ANEXO II.- INCIDENT IN TRANSPORT SHEET

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6.4 GEAR BOX OPERATION MANUAL

20180420 MONOLINE 3H Use and Maintenance Manual Rev.

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Transport, Handling & Storage Transport only in horizontal position, impacts should be avoided. Wear work gloves and be careful when handling the slewing drives. Use the holes of the rings in the slewing drives to fix bolts for safe hoisting, handling and placement. Store only in a horizontal position and in closed rooms, keep it away from getting wet, the surface corrosion protection of exposed mating surfaces lasts approximately 5 months in closed packaging. Longer period storage requires special protective measures.

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Installation Preparation Check the slewing drive for physical damage. Clean the slewing drive and the mounting structure, see Cleaning. Remove extraneous materials from supporting surfaces.

Cleaning Clean corrosion protection coating from supporting surfaces of the slewing drive, follow the instructions below: Clean the exterior of the mounting surfaces using cold solvent (e.g. diesel oil) that will not damage the rubber seals. Applicable provisions for cleaning media are observed (e.g. manufacturer provisions, protection of workers, environment protection).

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Permissible Flatness Deviation Table 1: permissible flatness including perpendicularity deviations for Slewing drives Size of Slew Drive

Permissible perpendicularity deviation in length

Permissible perpendicularity deviation in angle dimension

[in]

[mm]

degree

3”

0.009

0.237

0.32

5”

0.031

0.335

0.32

7”

0.016

0.405

0.32

9”

0.022

0.569

0.32

12”

0.032

0.807

0.32

14”

0.036

0.907

0.32

17”

0.045

1.133

0.32

21”

0.057

1.489

0.32

25”

0.069

1.753

0.32

28”

0.08

2.039

0.32

Figure 2.1 The form must resemble a sine curve that gradually rises and falls.

Mounting Bolts As the gearbox manufacturer, we do not supply, warrant or recommend the mounting fasteners used. Please take great care in specifying this item which will attach our product to yours. Prescribed sizes, number and quality grades shall be used. 8|S o l a r S l e w D r i v e M a n u a l

Grip ratio (grip length to diameter of bolt) shall be observed, from minimum ≥2 to maximum ≤10. Bolts with a fully threaded shaft should be not permissible. Slewing drive function, lifespan, and durability of the bolt connection are affected in case of non-compliance. Use flat washers of appropriate size and strength choice of tightening torques so that the permissible interfacial pressure is not exceeded. Mounting bolts are in normal cases adequately secured by correct preloading. Notice: Use of split rings, split washers, etc. not permissible. Tightening Torque

Mounting Bolt Dimension M6

M8

M10

M12

M16

M20

(1/4-20UNC)

(5/16-18UNC)

(3/8-16UNC)

(7/16-14UNC)

(5/8-11UNC)

(3/4-10UNC)

Class 8.8

11.5 N.M

28 N.M

55 N.M

97 N.M

240 N.M

470 N.M

Class 10.9

14 N.M

33 N.M

72 N.M

120 N.M

305 N.M

600 N.M

Class 12.9

17 N.M

42 N.M

83 N.M

145 N.M

360 N.M

705 N.M

Class

Table 2: Tightening Torque and initial preloads for mounting bolts. KMI does not warrant information of this table. Information is for guidance only.

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Install the Slewing Drive Clean the mounting structure, e.g. from welding, galvanizing, residues, dirt, etc. Lift the slewing drive with eye bolts. The slewing drive shall be mounted in unloaded condition. Remove the shipping bolts after setting on the final mounting structure. The following procedure shall be followed in order to avoid deviations between bolt tightening forces. Apply thread lock liquid to threads.

Brand: Type: TS242Threadlocking adhesive Note: General purpose, chemotropic, viscosity. For locking and sealing M6-M20 threads Parts can be separated using hand tools, controlled lubricity, can attain accurate clamp loads. Color: Blue Usage: Shake thoroughly before use Clean and dry parts with TS755 cleanser Lay thread lock liquid on thread gap requesting fitting parts fully. Preload the bolts crosswise. See the general pattern in sketch below of how bolts get torque in crosswise sequence. Start with either inner or outer ring. Do the crosswise torqueing of all bolts to 30% of tightening torque. Then repeat crosswise torque to 80% of tightening torque. Finally crosswise torque to 100% of the tightening torque.

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Figure 2.2 First completely torque inner or outer ring, then do the other ring. Once the screw is tightened, please permanently mark the position of the screw head to that of the stationary structure. This will be used later during inspection to be sure the screw head has not unwound.

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Determine Tilting Clearance The tilting clearance increases with raceway wear. To determine the increase in tilting clearance, it is necessary to take basic periodic measurements. Permanently designate the measuring point in the main load direction. Record all measured values into Table 3. Procedure Determine and mark the measuring spot at the point of load, both on the housing as well as on the worm wheel or on the slewing ring. Fix the dial gauge. The use of magnetic dial would be ideal in this case. Apply a 20kg load in “A” direction. Set the dial gauge on zero. Apply a 20kg load in “B” direction. The measured difference between “A” and “B” corresponds to the tilting clearance and serves as the basis for comparison for later inspections. Figure 2.3 Item

Load

Direction “A”

Direction “B”

Remark

1 2 3 4 5 6

Table 3: User Written Tilting Measurements General All subsequent measurements are performed at the same measuring point, with the same loads, at the same position of the housing relative to the worm wheel or gear ring and in the same sequence. All the measured values are recorded.

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Maintenance & Safety Checks Mounting Bolts To compensate for possible settling, it is necessary to retighten the bolts to the prescribed torque .This shall be done after no more than 100 hours of operation and without external load applied to the bolt connection. This inspection shall be repeated annually. The inspection frequency may be reduced under special operating conditions. In case of loose bolts, replace all bolts and washers with new ones. KMI does not supply or warranty any fasteners for attaching the slew drive to the customer’s equipment. The few large diameter cap screws shipped in the new slewing drives are for shipping purposes only. These are very low grade fasteners and should never be reused in the final installation of the slew drive.

Tilting Clearance

Measuring tilting clearance on new product without rated load Figure 4.1 • • • •

Fix the dial gauge. The use of magnetic dial would be ideal in this case. Apply a 20kg load in “A” direction. Set the dial gauge on zero. Apply a 20kg load in “B” direction. 15 | S o l a r S l e w D r i v e M a n u a l

•

The measured difference between “A” and “B” corresponds to the tilting clearance and serves as the basis for comparison for later inspections.

“A-B”≤Table 1 Value Table 1: Tilting clearance on new slew drives Size of Slew Drive

Permissible perpendicularity deviation in length

Permissible perpendicularity deviation in angle dimension

[in]

[mm]

degree

3”

0.002

0.06

0.09

5”

0.0035

0.09

0.09

7”

0.004

0.11

0.09

9”

0.006

0.16

0.09

12”

0.009

0.23

0.09

14”

0.010

0.26

0.09

17”

0.013

0.32

0.09

21”

0.017

0.42

0.09

25”

0.019

0.49

0.09

Measuring tilting clearance on new product under rated load • • • • •

Install slew drive into customer specific equipment using customer’s standard load, as long as the load falls within maximum guideline ratings of the KMI slewing drive. Take a measurement using the same instruction of 4.2.1 Record this value as the equipment’s starting raceway tilting clearance value. Raceway wear leads to increased tilting clearance. Check the increase in tilting clearance δk directly on a slewing drive. The value (m1) determined after installation of the slewing drive is considered as the basic value and is deducted from the latest inspection value (mx). The difference between mx and m1 may not exceed 0.8 mm (0.0315in) during the life of the drive. If this value is exceeded then the drive is worn out. δk = mx-m1 ≤δT perm δT perm= 0.8mm (0.0315in) 16 | S o l a r S l e w D r i v e M a n u a l

• • • • •

Checking the increase in tilting clearance δT not directly on slewing drive. Increase in tilting clearance is to be converted proportionally for each measurement (after the installation measurement) and compared with δk permissible. Reduce the inspection interval to 200 operating hours if the measured increase in tilting clearance amounts to approx. 75% of the maximum permissible increase in tilting clearance. Reduce the inspection interval once again after further increase in tilting clearance (to 50-100 operating hours). Replace the slewing drive if the maximum permissible increase in tilting clearance is reached.

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Torsional Clearance Gear wear leads to increased rotational backlash. Procedure: • •

Clip a dial gage between the stationary and rotating structure. Determine the rotational play by gently turning the upper structure against the stationary structure, reading the total difference in measurement from a clockwise to a counterclockwise turn.

Figure 4.2

• • •

Do not force the turning or the measurement will be inaccurate. The purpose of the measurement is to find the gap clearance. All measured values are to be recorded. At a rotational clearance of greater than the (Slew Size*25.4/400) mm the slewing drive should be considered for replacement.

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Lubrication Instruction Provisions about handling the respective lubricants must be observed. While rotating the slewing drive, inject grease into all the cleaned grease nipples consecutively until a continuous collar of fresh grease forms at least on one sealing lip.

Ball bearings lubricate point

Roller bearing lubricate point

Worm gear lubricate point

Roller bearing lubricate point

Ball bearings lubricate point

Figure 4.3 lubricate point

• • • • •

The roller bearings and worm gear are open to the same cavity, but it’s suggested to fill them using the separate grease points to be sure each is hit directly. The ball bearing is enclosed separately. While rotating the slewing drive, inject grease into all the cleaned grease nipples consecutively as follows: Roller Bearings - 40 cc of grease Worm Gear - 80 cc of grease Ball Bearings -100 cc of grease

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Weather Protection Paint spec Epoxy Epicon Zinc HB-2 KMI drives are coated with a special two part epoxy coating in KMI’s automated painting line to give the drive excellent heat and weather protection.

Epoxy Brand: EPICON ZINC HB-2 EPICON ZINC HB-2 is a high-build type epoxy zinc rich paint based on a combination of epoxy resin and polyamide resin pigmented with metallic zinc power. It has the following advantages: • • •

Long term rust-preventing property; Excellent physical properties such as toughness, impact and abrasion resistance; Extreme resistance to seawater, rain, heat, oil, oxidation and sunlight

Recommended Use: • • • • • •

As a primer for protection of blast-cleaned steel plates (ISO 8501-1 1988 Sa 2.5) Volume Solid: 52±2% Dry Film Thickness: 2.0-3.0 mils; 80-100 µm; Method of Application: Airless spray Thinner: EPOXY THINNER A Temperature Rating: 110C

Coating Brand: PRIME Type: 2K Straight Colors Color: Any from RAL color chart. KMI automated paint process can match any of 264+ RAL colors.

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Fastener and/or Coating Stainless Steel is used for every fastener to ensure no rust and long life. If the customer requires a non-stainless fastener, then it is coated with Zinc-Co-Nl to reduce the bolts rust. Features: 1. Excellent resistance to corrosion resistance, salt spray test 8-10 times for the traditional function of zinc, zinc and iron or zinc-nickel alloy plating for 2 to 4 times, 5um can be achieved when more than 1000 hours (red rust), 8µm when 2,000 hours or more (red rust), 24um, when up to 6000 hours or more (red rust). 2. Coating with low internal stress, high plating thickness, is not brittle. 20um thickness of the above, do not have a zinc bending tests peeling off problem. 3. Low current excellent gloss and covering power, such as for hanging plating, especially for computers, electrical box of the plating l8µm, the mist test (DIN50018) up to 6 cycles or more for the traditional galvanized two-fold. 4. Zinc deposit brightness is very good, high and low current of uniform thickness (1.5:1), traditional galvanized 4:1. 5. With a special anti-rust coating, such as nano-coatings, Magni Coating System rust-proof up to 6000 ~ 10000 hours (ASTM B117), acid-resistant up to 15 ~ 50cycles above (Kesternich test DIN50018) 6. The capacity of superior weather resistance 7. No hydrogen brittle of the problem

Grease Spec There are four places which are lubricated, they are (1)slewing ring ball bearings, (2)worm gear, (3)taper roller bearings and (4)planetary gears. Slewing drives are supplied fully lubricated. Table 5: Eco Friendly Grease Specifications 21 | S o l a r S l e w D r i v e M a n u a l

Taper Bearing Parts needed to be lubricated

Ring raceway Worm Gear Thread

Condition of Lubricate

Pre-lubricated by manufacturer

Recommended Grease Product name

Mobilux EP 2

Applicable temp. range in ºC

-40 to +130C

Color

Brown

Four-ball test

250 kg ASTM D 2596

Viscosity (-40 °C, 10 s-1) Pas

160

Dropping Point °C

190

Penetration, Worked 0.1 mm

280

Mobilux EP 2 is lithium hydroxystearate based grease. It’s formulated to provide extra protection against wear, rust and water. It is applied in heavy-duty application where high unit pressures are present. It provides excellent protection against rust and corrosion. Mobilux is suitable for the lubrication of enclosed gears and bearings, and for applications where conventional oil cannot be retained, or should not be used for environmental reasons. The grease helps to provide reduced wear under heavy load and vibration, protection against rust in the presence of water, extended bearing life in wet environments. It meets or exceeds the DIN 51825 (2004-06)

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Rubber Spec Composite rubber of NBR and PVC specification NBR has good oil resistance and wearing resistance, but lacks of age resistance and ozone proof of climate. To overcome this shortage, by research and test, adding PVC greatly improves NBR’s age resistance, ozone protection, oil resistance, wearing resistance and heat resistance. Measured Standards

Temperature Rating -20C to 120C Item

Test Conditions

Requirement

Unit

Standard

Room temp.

70±5

Shore A

GB/T 531

Tensile strength

10min

MPa

GB/T 528

Elongation at break

250min

%

GB/T 528

Usual status test Hardness

Air oven aging test

GB 3512

Hardness change

100℃

±15

/

Tensile strength change

70h

±30

%

-50max

%

Elongation at break change Oil resistance test

GB/T 1690

Hardness change

ASTM NO.1 Oil

±10

/

Tensile strength change

100℃

-30max

%

Elongation at break change

70h

-30max

%

-10 to +15

%

Volume change Oil resistance test

GB/T 1690

Tensile strength change

ASTM NO.3 Oil

-60max

%

Elongation at break change

100℃

-50max

%

Volume change

70h

+100max

%

Akron abrasion wear

Room temp.

0.4max

cm3/1.61km

GB 1689

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Comparison Test Report Client:

Date: 2009-7-31

Item Name: Rubber Seal

Material: NBR/PVC

Inspection Items

Inspection Condition

Normal test:

Room temp

NBR sample data

NBR+PVC sample data

Unit

Hardness

72

69

Shore A

The tensile-strength

13.2

13.7

MPa

The elongation at break

344

472

%

5

5

/

Heat resistance Hardness change Tensile strength change

100℃

14

4

%

Elongation change

70H

-29

-28

%

Oil-Resistance Test :

7014-1 Oil

The change rate of volume

100℃,70h

-10.51

-4.29

%

Oil-Resistance Test :

ASTM NO.3 Oil

The rate of volume change

100℃,70h

-8.33

-0.3

%

Compression permanent set

100℃,22h

57.7

52.7

%

Abrasion

cm3/1.61Km

0.29

0.26

%

Cheek

Audit

Authorize

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Liquid Sealant Product Description

LOCTITE® 510™ provides the following product characteristics: Technology

Acrylic

Chemical Type

Dimethacrylate ester

Appearance (uncured)

Opaque pink paste LMS

Components

One component - requires no mixing

Viscosity

High

Cure

Anaerobic

Application

Gaskets and Sealing

Strength

Medium

LOCTITE® 510™ cures when confined in the absence of air between close fitting metal surfaces. This product is a general gasket product suitable for hand dispensing or screen printing. TYPICAL PROPERTIES OF UNCURED MATERIAL • • • • • • • •

Specific Gravity @ 25 °C 1.1 Flash Point - See MSDS Viscosity, Brookfield - HBT, 25 °C, mPa·s (cP): Spindle TC, speed 2.5 rpm, Helipath 200,000 to 750,000LMS Spindle TC, speed 20 rpm, Helipath 40,000 to 140,000LMS Instant Sealing Capability Anaerobic sealants have the ability to resist low on-line test pressures while uncured. This test was performed with uncured product immediately after assembly of an annular polycarbonate sealing surface with an internal diameter of 50mm and an external diameter of 70 mm. Pressure Resistance, MPa: Induced Gap 0 mm 0.02 Induced Gap 0.125 mm 0.01 Induced Gap 0.25 mm 0.01

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TYPICAL CURING PERFORMANCE Cure Speed vs. Substrate The rate of cure will depend on the substrate used. The graph below shows the shear strength developed with time on grit blasted steel lap shears compared to different materials and tested according to ISO4587.

Cure Speed vs. Bond Gap The rate of cure will depend on the bond line gap. The graph below shows the shear strength developed with time on grit blasted steel lap shears compared to different controlled gaps and tested according to ISO 4587.

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Cure Speed vs. Temperature The rate of cure will depend on the temperature. The graph below shows the shear strength developed with time at different temperatures on grit blasted steel lap shears and tested according to ISO 4587.

Cure Speed vs. Activator Where cure speed is unacceptably long, or large gaps are present, applying activator to the surface will improve cure speed. The graph below shows the shear strength developed with time on grit blasted steel lap shears using Activator 7471™ and 7649™ and tested according to ISO4587.

TYPICAL PROPERTIES OF CURED MATERIAL Physical Properties: • • • •

Coefficient of Thermal Expansion, ISO 11359-2, K-1 80×10-6 Coefficient of Thermal Conductivity, ISO 8302, 0.1 W/(m·K) Specific Heat, kJ/(kg·K) 0.3 27 | S o l a r S l e w D r i v e M a n u a l

TYPICAL PERFORMANCE OF CURED MATERIAL Adhesive Properties: Cured for 1 hour @ 22 °C Compressive Shear Strength, ISO 10123: Steel pins and collars (grit blasted) N/mm² ≥1LMS(psi) (≥145) Cured for 24 hours @ 22 °C Compressive Shear Strength, ISO 10123: Steel pins and collars (grit blasted) N/mm² ≥7.5LMS(psi) (≥1,085) Lap Shear Strength, ISO 4587: Steel (grit blasted)

N/mm² 5 (psi) (725)

Tensile Strength, ISO 6922: Steel (grit blasted)

N/mm² 7.5(psi) (1,085)

Sealing Capability: An annular shaped gasket with an inner diameter of 50 mm and an external diameter of 70 mm was tested up to 1.3 MPa for leakage. Sealed to Maximum Induced Gap, mm: Mild steel ≤0.125 Aluminum 2011T3 ≤0.125

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TYPICAL ENVIRONMENTAL RESISTANCE The following tests refer to the effect of environment on strength. This is not a measure of sealing performance. Cured for 1 week @ 22 °C Lap Shear Strength, ISO 4587:Steel (grit blasted)

Hot Strength Tested at temperature

Heat Aging Aged at temperature indicated and tested @ 22 °C

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Chemical/Solvent Resistance

Aged under conditions indicated and tested @ 22°C. % of initial strength Environment

°C

100 h

500 h

1000 h

Motor oil (MIL-L-46152)

125

100

100

100

Unleaded Petrol

22

95

60

60

Water/glycol 50/50

87

160

110

110

General Information This product is not recommended for use in pure oxygen and/or oxygen rich systems and should not be selected as a sealant for chlorine or other strong oxidizing materials. For safe handling information on this product, consult the Material Safety Data Sheet (MSDS). Where aqueous washing systems are used to clean the surfaces before bonding, it is important to check for compatibility of the washing solution with the adhesive. In some cases these aqueous washes can affect the cure and performance of the adhesive. This product is not normally recommended for use on plastics (particularly thermoplastic materials where stress cracking of the plastic could result). Users are recommended to confirm compatibility of the product with such substrates. Directions for use 1. For best performance bond surfaces should be clean and free from grease. 2. The product is designed for close fitting flanged parts with gaps up to 0.25 mm. 3. Apply manually as a continuous bead or by screen printing to one surface of the flanges. 4. Low pressures (