U.S. Solar Mounts AGM Racking Systems

Automatic Tracking & Controls

Installation Manual

Introduction

The U.S. Solar Mounts Tracking controller allows the AGM racking system to track the sun. AGM racking systems can be oriented in the following arrangements during installation:

1. A North-South row(s) for E-W tracking, typically used in the Southern half of the US. This type of installation allows the AGM system to track the sun’s movement across the sky from 45⁰ East to 45⁰ West.

1. East-West row(s) for Elevation Tracking. This arrangement allows the AGM system to track the

sun’s elevation changes continually throughout the year. In either arrangement, the AGM tracking control sensor is accurate to within .5⁰ of actual sun location. In addition to tracking functions, the controller has the following features:

A. Manual control capability B. Anemometer input – Optional – Provides wind speed data to the controller. C. Flat Park input – Optional, requires wind speed sensor package. D. Park command input – commands a slave unit to park when a master unit goes into park. E. Park command output – can command up to 8 additional trackers to go to their Park positions.

Input voltage range: 10-56VDC Output current: 10 Amps continuous Park command output: (Vin – 3.5V) @ 0.1A maximum On initial application of power or reset button push and release, the status leds will light for one second to indicate proper led function—all normal functions halted during led test.

STANDARD MAIN COMPONENTS

The AGM tracker package includes the follow main Items:

A. Tracker control Enclosure – Fiberglass w/Stainless hardware and mounting brackets. a. Control Board b. Power Supply – 120V, 208/230-240V input is standard

B. Sun Sensor a. Pre-installed onto a Stainless Steel mounting bracket b. With Control Cable Pre-Connected to the sensor

C. Mounting Hardware a. SS hardware for mounting the enclosure onto 4” SCH40 Steel Tube b. SS hardware for mount the sensor bracket onto the extruded rails.

Testing: All of our trackers go through 100% testing prior to leaving our facility. All automatic and manual functions are tested under load.

Installing the actuator

The actuator is shipped in the fully retracted position. Limit switches have been pre-set and tested prior to shipment. Installation of the actuator should be performed WITH THE ARRAY IN THE FLAT POSITION. The ¾” Actuator Mounting Bolt is shipped pre-installed in the drive cradle along with the associated spacers, washers and locking nut.

1. Remove the nut & washer from the bolt and set aside 2. Carefully withdraw the bolt and remove the inside washer and the first spacer 3. Insert/install the actuator eyelet onto the ¾” bolt 4. Re-install the spacer and inside washer while pushing the bolt back to its original

position 5. Re-install the outer washer and nut so that the actuator hangs from the bolt & drive

cradle 6. Tighten the nut secure, but not so much that the bolt cannot be rotated by hand.

The actuator should now be hanging from the drive cradle like the drawing below.

Installing the actuator-continued

7. Locate the actuator mounting plate. The plate was shipped with the nut, washers and bolt in place.

8. Remove the bolt and hardware and set aside. 9. Align the plate with the lower actuator mounting eye 10. Re-install the bolt and hardware. 11. Tighten the hardware securely, but make sure the plate can still pivot on the eyelet

The actuator and Mounting Plate should now be connected and look like this:

Installing the actuator-continued

12. Swing the actuator & mounting plate towards the pole until the plate is seated flat against the pole. 13. Install 2 galvanized U-Bolts through the mounting plate. 14. Ensure that the plate is seated flat against the pole – tighten the U-Bolts securely

The Actuator, Mounting Plate & U-Bolts installed & tightened.

Installing the Control Cabinet

The control cabinet mounts on the pole using 2 Stainless Steel Clamping U-Bolts. A Stainless Steel mounting plate has been pre-installed onto the box for this purpose. NOTE: The Stainless Mounting Plate is designed to mount onto standard 4” SCH40 steel tubing. If you are installing the AGM system onto 6” pipe or have other non-standard tube sizes, the plate will need to be mounted onto some other structure. Common methods include the use of Uni-Strut channel and U-Bolts to fit your pipe size. Special mounting hardware is not included with the tracker control cabinet. The control cabinet mounts 90⁰ to the actuator, either Left or Right.

Control Cabinet

4” SCH40 Tube

Mounting the Remote Sensor

The remote sensor needs to be attached to the upper (North) end of a rail so that the mounting surface of the sensor is parallel with the plane of the array—where on the array is not critical as long as the sensor receives unobstructed sun during the hours when the array is expected to track.

1. Carefully uncoil the shielded control cable that connects the Remote Sensor to the control cabinet.

2. Route the cable from the control cabinet upwards through the racking and out to the end of the nearest rail.

3. Using the supplied 5/16” carriage bolts, fasten the mounting bracket onto the side of the rail.

4. Tighten the mounting bolts securely.

The sensor bracket will only mount onto a rail end in one direction.

A completed Remote Sensor mounted onto a rail end.

Wiring Connections

- - + + L N GND

DC Power Supply 120/208/230/240 Input 24VDC Output

Sensor is pre-wired

Optional Connections

Connect A.C. Power Here

Wire Detail

The actuator motor has a pre-wired cable that connects it to the controller. Individual wire designations are listed in the chart below. Wire Size Wire Color Function #14 RED Power Wire (+ for extend) #14 BLACK Power Wire (+ for retract) #18 BLUE Limit Switch – Retract – Park Sensing SW #18 PINK Limit Switch – Retract – Park Sensing SW #18 GREEN Limit Switch – Extend #18 VIOLET Limit Switch – Extend

Red Wire Positive (+) Actuator Extends

STATUS INDICATORS

PWR DC power is on. ALARM Wind alarm control asserted—move array to flat park position. With delay on, this led remains lit during the

60 minute wind alarm recovery delay. Reset button clears wind alarm.

ALARM (FLASHING)

Output overload—protection circuit shuts off outputs and waits an hour before trying again. Overload can be cleared by cycling mode switch manual-auto or press-release reset button.

PRK Low light park asserted—move array to east limit or flat park (dip switch selectable). PAUSE Dim light due to absence of clear sun, stop movement until light recovers or darkness falls. PAUSE (FLASHING)

With delay on, a one minute delay is forced after a move is completed. During this delay, the pause led flashes.

TRACK Light level high enough to track

Abnormal conditions

Typically, motor failure or mechanical system jam (from ice build up) or heavy wind load: Tracker will attempt to move the array for 1 second. If motor overcurrent condition is sensed, tracker will terminate output drive and flash the ALARM LED (at a half second rate) for 1 hour before attempting another move.

Notes on initial installation, power up and adjustments.

When power is applied, if the ambient light level is above the track threshold and if the mode rocker switch is in AUTO, it will then commence tracking immediately unless S1-1 is in the DLY position, in which case there may be a one minute delay.

Trim Pots and Adjustment

Designation Function RT3 For halting movement of the array under conditions of obscured sun where pause is not invoked.

This control is trimming out internal control and light sensor offsets. Clockwise rotation shifts bias to the west, counterclockwise to the east

RT4 Sets the wind speed at which the wind alarm acts. Counterclockwise limit corresponds to 20-mph, clockwise limit corresponds to 40mph.

RT5 Adjusts the light level at which the tracker control changes from track to pause. Adjust clockwise for greater sensitivity (tracks at lower light levels).

Note that the trimpots have a maximum rotation range of approximately 270 degrees. Use a light touch and small screwdriver when adjustment is necessary. Damage to trimpots due to over-torqueing is not covered under warranty.

Dip-Switch Settings & Functions

S1-1 on the PCB controls the delay function. During the initial installation, this is in the OFF (SETUP) position. In this state, everything happens “instantaneously”—a useful condition when tweaking the track trimpots and setting the Light Sensitivity. When S1-1 switch is in the ON (DLY) position (for normal, unattended operation), the following delays are added to the system operation:

1. When an autotrack move is completed, a one minute delay must be counted down before the next move is enabled. This is to reject transient events such as something flying over the sensor and, in cases where the sensor is shaded by moving vegetation during part of the tracking day, to hold off and/or reduce movement during back and forth shading events which aren’t representative of true sun position. If this delay is active, the PAUSE led will flash twice per second.

2. A 30 minute delay is added to the PARK movement. This is for conditions of

changing cloud cover (where the sun occasionally pokes through) to keep the tracker from sending the array back and forth between PARK and TRACK positions. Light conditions must remain below PARK threshold for 30 minutes before the controller will allow movement. (There is only a 10 second delay when changing from PARK to TRACK.) When the park delay is active, PARK led flashes twice per second.

3. A 60 minute delay is added to the recovery from wind alarm park.

S1-2 Selects the “low light” park position—OFF selects the east limit, ON selects flat park.

Notes on the “flat park” function:

When power is first applied or the reset button is pushed, the control starts by assuming that it’s “west (or North) of flat”, as this is the normal state it would find if tracking to the afternoon. After power on or reset, as the array passes through the flat park position, the control will remember which side of the switch that it’s on and return to it when a flat park move is required. Wind alarm always gives flat park. The flat park sensing switch is normally open (N.O.) and closes only when the array is in the desired flat position. Park command output: Is used to tell a “slave” unit(s) to go to park. The idea here is that the master unit can carry the anemometer and send the slaves flat as required.

NOTES: • In order for the master-slave control to assert, the (-)DC inputs must be tied

together. • The park command output will drive 8 slaves • Slave boards must have their own flat park switches and light sensors. • WIND ALARM PARK has priority over TRACK, PAUSE, and low light PARK.

CAUTION:

Do not connect any of the RTN or RETURN terminals between master and slave boards together!

Sensor induced pause: When the light intensity on the remote sensor drops below that required to generate a detectable error signal, the tracker may pause without the PAUSE led being illuminated--if the TRACK led is on, assume sensor induced pause during obscured sun conditions. Separate return terminals are supplied for all limit switches. In installations where wiring permits it, all of the limit switch returns may be tied together and taken to a single limit switch return terminal. The limit switch returns connect electrically to (-) DC input and must not be used to conduct high current, as this will damage the PCB and cause failure. This means that there must be no “external” connection between limit switch returns and (-) DC input. The limit switches can be magnetically actuated reed switches or mechanically actuated type. They are “normally open” and close when drive system nears limit of non-destructive travel. If your actuators have built-in limit switches, the limit switch inputs to the control can be “not connected” and the tracker control will function properly.

Rocker switches

MANUAL/AUTO/PARK:

1. In manual position, enables the EAST/OFF/WEST rocker switch control. Manual operation overrides wind alarm park. Park switch position forces (low light) park condition. Auto (switch flat) is for unattended automatic tracking.

EAST/OFF/WEST: Manual movement control when manual mode selected. NOTE: Depending on the AGM tracker model, “East-West” may refer to “North-South” if elevation tracking is used. DO NOT use the light sensor cable strain relief nut to mount the light sensor, as this can compromise the mechanical and hermetic integrity of the unit and cause failure. The RESET button resets the control chip, clearing all alarm and fault flags. This is a “reboot”, similar to removing and reapplying input power.

Warranty Information

U.S. Solar Mounts is so confident in our products that we warranty each Mounting Structure to be free from defects in materials and workmanship for fifteen (15) years from the date of first purchase when installed properly and used for the purpose for which it is designed. The warranty covers the replacement cost of parts to repair the product to proper working condition. Transportation, labor and incidental costs associated with warranty items are not reimbursable. This limited warranty shall transfer from the original buyer/end user to subsequent buyers/end users for the remainder of the warranty term provided the solar system is not moved or relocated from its originally installed location.

Exclusions

If, in U.S. Solar Mounts' sole judgment, a mounting structure has been subject to misuse, neglect or accident, or has been damaged through abuse or failure to follow U.S. Solar Mounts operation or maintenance instructions, this warranty is void. This warranty does not cover Galvanizing, Anodizing, Paint or other finishes applied by third-party vendors. Furthermore, it does not cover units that have been altered, modified or repaired without written authorization from the manufacturer, or units used in a manner or for a purpose other than that specified by the manufacturer. This warranty will also not cover damage due to acts of God, lightning, fire, flood, severe weather, hailstorms, insect and pest infestation, and other events reasonably beyond U.S. Solar Mounts' control. This warranty does not inc lude electr ica l or electronic components , which carry a 1-year warra nty from the manufacturer. Warranty coverage does not include any transportation costs for return of components or for reshipment of any repaired or replaced components.

U.S. Solar Mounts' entire liability and your exclusive remedy, whether in contract, tort or otherwise, for any claim related to or arising out of breach of the warranty covering the Mounting Structures shall be correction of defects by repair, replacement, or credit, at U.S. Solar Mounts' sole discretion. Refurbished Mounting Structures or Components thereof may be used to repair or replace the Mounting Structures.

Proof of original purchase is required to file a warranty claim.

Pictures of the original installation must be sent in to us within 30 days of installation for your warranty to be enacted.

Procedure

Claims under this warranty will be considered if submitted by registered or certified mail to U.S. Solar Mounts Corp. 3498 Acorn Ave. Sparta, WI 54656 within 15 days following the discovery of any defect covered by this warranty, with specific details in writing, and provided U.S. Solar Mounts or its agents are permitted a commercially reasonable opportunity to examine and analyze the workmanship claimed to be defective. An authorized representative of U.S. Solar Mounts must approve any claim in writing. THIS WARRANTY, WHICH IS LIMITED AS INDICATED ABOVE, PROVIDES SPECIFIC LEGAL RIGHTS. YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.