SkyLine Tracker O&M Manual | Arctech Solar System

SKYLINETRACKING SYSTEM
SKYLINE TRACKING SYSTEM
OPERATION & MAINTENANCE (O&M) MANUAL
FOR SKYLINE TRACKING SYSTEM
Doc.
Rev.
Project
OPERATION & MAINTENANCE
S kyLine O&M Manual
1 .4
PROJECT NAME
MANUAL
-China · Japan · India · U.S. · Spain · Mexico · Australia · UAE · Chile · Argentina · Vietnam-
Log of the document
Rev.
Description
Date
Created
1.0
First release
2020/07/10
LYR & FSR
1.3
Some wording ana controller pic,
lubricant type update.
2020/08/11
Pascal & Yisong
1.4
Wording updating in wind protection 2020/09/08
setting
Checked Approved
Pascal
TABLE OF CONTENTS
1.
FOREWORD ...................................................................................................... 4
1.1. ABOUT THIS MANUAL .................................................................................................................................... 4
1.2. SAFETY RECOMMENDATIONS AND SYMBOLS USED .......................................................................... 5
2.
DATASHEET OF SKYLINE TRACKER ............................................................. 6
3.
GENERAL TRACKER DESCRIPTION .............................................................. 8
4.
LIST OF TOOLS REQUIRED .......................................................................... 11
2 | Page
Doc.
Rev.
Project
OPERATION & MAINTENANCE
S kyLine O&M Manual
1 .4
PROJECT NAME
MANUAL
5. LIST OF RELATED DOCUMENTS .................................................................. 12 6.
SOLAR TRACKER FUNCTIONALITY OVERVIEW ......................................... 12
6.1. HORIZONTAL SINGLE AXIS TRACKER (HSAT) ...................................................................................... 12
6.2. DAYTIME TRACKING .................................................................................................................................... 12
6.3. BACKTRACKING ............................................................................................................................................ 12
6.4. AI TECHNOLOGY(Optional) .......................................................................................................................... 13
7.
WIND PROTECTION SKYLINE ....................................................................... 14
7.1. Wind Stow Strategy with Weather Warning ................................................................................................. 14
7.2. Wind Stow Strategy Without Weather Warning .......................................................................................... 15
7.3. Summary ........................................................................................................................................................... 15
8.
POWER SUPPLY ............................................................................................ 16
9.
AI CONTROLLER AND COMMUNICATIONS ................................................. 18
10. CONTROLLER INTERFACE AND WORKING MODES .................................. 23
11. GENERAL TROUBLESHOOTING ................................................................... 24
12. PREVENTIVE MAINTENANCE ....................................................................... 27
1. FOREWORD
1.1. ABOUT THIS MANUAL
This O&M manual explains how to safely operate and maintain Artech’s SkyLine tracking system. Please
pay special attention to the key warnings presented in this manual. It describes the proper operation
and maintenance procedures and provides minimum standards required for product performance
and reliability, as well as for warranty purposes. Failure to follow the guidelines set forth can result in
property damage, bodily injury, or even death.
3 | Page
Doc.
Rev.
Project
OPERATION & MAINTENANCE
S kyLine O&M Manual
1 .4
PROJECT NAME
MANUAL
• Ensure that operation and maintenance is completed by a trained professional.
• Comply with all applicable local or national codes, including any that may supersede this manual.
• Use only SkyLine original parts or parts supplied or recommended by Arctech Solar.
Replacements with parts from other sources may void any applicable warranty.
• Comply with all applicable fire codes including, but not limited to, keeping walkways clear and
avoiding obstacles.
• Ensure provided information is accurate. Issues resulting from inaccurate information are the
installer’s responsibility.
• Ensure safe installation of all electrical parts. All electrical installation and procedures should be
conducted by a trained professional. All work must comply with national, state and local installation
procedures, product and safety standards.
COPYRIGHT STATEMENT: All the contents of this manual, including the graphics contained herein, are
intended for the use of the recipient to whom the document and all associated information are directed.
Arctech Solar Holding Co., Ltd. owns the copyright of this document, which is supplied in confidence. It
must not be used for any purpose other than that for which it is supplied and must not be reproduced, in
whole or in part stored in a retrieval system or transmitted in any form or by any means without prior
permission in writing from Arctech Solar Holding Co., Ltd. ARCTECH SOLAR® is a trademarked tracker
and module mounting structure of Arctech Solar Holding Co. A patent covering the ARCTECH SOLAR®
has been granted.
DISCLAIMER: Information and data contained in this manual is exclusively for the purpose of assisting in
the operation and maintenance of Arctech Solar Holding Co., Ltd.’s ARCTECH SOLAR®. No warranty is
given nor can liability be accepted for use of this information for any other purpose. Arctech Solar Holding
Co., Ltd. has a policy of continuous product development and reserves the right to amend specifications
and parameters without notice.
The parts and spare parts supplied by Arctech Solar have been specially designed by Arctech Solar for its
trackers, non-original parts and spare parts and / or not validated by Arctech Solar will be considered
invalid, however Arctech Solar may certify these elements and their safety.
1.2.SAFETY RECOMMENDATIONS AND SYMBOLS USED
1. Comply with all the applicable local or safety standards and laws, including those that may supersede
this manual.
2. Use only original parts or parts supplied or recommended by Arctech Solar. Replacements with parts
from other sources may avoid any applicable warranty.
3. Use only tools recommended by the manufacturer and which are certified, regulated and in good
condition. These tools must only be used for the purpose they are made for.
4. The personal who is to perform these activities must wear certified personal protective equipment (PPE)
associated for each task during installation, operation, service and maintenance of the tracking system
and follow local regulations always.
4 | Page
Doc.
Rev.
Project
OPERATION & MAINTENANCE
S kyLine O&M Manual
1 .4
PROJECT NAME
MANUAL
In all tasks, it is mandatory to wear high visibility clothing, safety boots, protection gloves,
googles, hearing protectors and a hard hat.
5. The working area and its environment must be clean and tidy with no elements that could obstruct
visibility or works.
6. For works that may have electric shock risk, make sure the protections are designed for this purpose.
7. Do not perform any works while under the effects of alcohol or drugs.
8. Do not perform any works if feeling tired or sleepy.
9. Make sure that you adopt an appropriate posture while performing the tasks which will not cause pain
or injuries.
10. Do not perform any works in case of doubt or if any of the above-mentioned instructions are not being
implemented.
1.3 AFTER SALES SERVICE
For any issue regarding after sales, please contact us by e-mail:
[email protected]
5 | Page
Doc.
Rev.
Project
OPERATION & MAINTENANCE
S kyLine O&M Manual
1 .4
PROJECT NAME
MANUAL
2. DATASHEET OF SKYLINE TRACKER
6 | Page
Doc.
Rev.
Project
OPERATION & MAINTENANCE
S kyLine O&M Manual
1 .4
PROJECT NAME
MANUAL
7 | Page
Doc.
Rev.
Project
OPERATION & MAINTENANCE
S kyLine O&M Manual
1 .4
PROJECT NAME
MANUAL
8 | Page
Doc.
Rev.
Project
OPERATION & MAINTENANCE
S kyLine O&M Manual
1 .4
PROJECT NAME
MANUAL
9 | Page
Doc.
Rev.
Project
OPERATION & MAINTENANCE
S kyLine O&M Manual
1 .4
PROJECT NAME
MANUAL
3. GENERAL TRACKER DESCRIPTION
Arctech’s Skyline is a string-powered tracking system which tracks the Sun’s position throughout the day
and returns to stow during night-time. Different stow routines are also used in diverse weather conditions,
such as high winds, heavy rainfall or snowfall. Once the trackers are installed and commissioned, the
trackers continue to track the sun's trajectory in auto-mode
Figure. Main functional groups of the Solar Tracker “SkyLine”
1 | Page
0
Doc.
Rev.
Project
OPERATION & MAINTENANCE
S kyLine O&M Manual
1 .4
PROJECT NAME
MANUAL
MAIN ASSEMBLIES OF THE
SKYLINE TRACKER
Item
1
Description
Qty. per
Assy.
Qty per tracker
1
DRIVE ASSEMBLY
1.1
Slew Drive Motor Assembly
1
1.2
Drive Seat Welding Assembly
2
1.4
Control Box
1
1.3
Bolts, nuts and Washers M20
-
1.4
Bolts, nuts and Washers M16
-
2
Normal post head ASSEMBLY
Refer to installation
manual
2.1
Pre-assembled bearing pedestal
1
2.2
Plastic Bearing
2
2.3
Bearing Baffles
2
2.4
Bolts and fasteners M16
-
3
Refer to installation
manual
TORQUE TUBE ASSEMBLY
3.1
Torque Tubes
8
3.2
Torque Tubes Connection
8
3.3
Bolts, nuts and Washers M20
-
4
Refer to installation
manual
PURLIN ASSEMBLY
4.1
Purlin
1
4.2
U-Bolt
1
4.3
Bolts, nuts and Washers M10
-
1 | Page
1
S kyLine O&M Manual
1 .4
PROJECT NAME
Doc.
Rev.
Project
OPERATION & MAINTENANCE
5
MANUAL
Refer to installation
manual
SPRING ASSEMBLY
5.1
Spring
1
5.2
Spring Adjusting seat
1
5.3
Spring Upper Fixing plate
1
5.4
Bolts, nuts and Washers M12
-
6
DAMPER ASSEMBLY
Refer to the GA drawing.
6.1
Damper
1
6.2
Damper Adjusting seat
1
6.3
Damper Upper Fixing plate
1
6.4
Bolts, nuts and Washers M12
-
All fasteners should have been torqued according to the installation manual using the maximum allowable
value. In this manual, when torque checks are required, they should be done using the appropriate
required value.
TORQUE VALUE TABLE
Hex Bolt size
Join description
Torque,
Nm
Torque, ft-lb
M4
Antenna bracket to antenna
1.5
1.1
M6
Modules to purlin (If applied)
8~11
5.9~8.1
M8
Controller brackets to torque tube,
communication box bracket to wind sensor
post
14~17
10.3~12.5
M10
Purlin to torque tube, Wind sensor post
connection
35~40
25.8~25.9
1 | Page
2
Doc.
Rev.
Project
OPERATION & MAINTENANCE
S kyLine O&M Manual
1 .4
PROJECT NAME
MANUAL
M12
Bearing baffle, torque tube connector,
spring arm to torque tube, damper/spring
lower bracket to pile
70~85
51.6~62.7
M16
Motor post head to pile, normal post head
to pile, wind sensor post assemblies
180~210
132.8~154.9
M20
Slew drive to motor post head
380~440
280.3~324.5
4. LIST OF TOOLS REQUIRED
The following list shows the recommended tools for Operation & Maintenance. However, other tools may
be used according to the staff team experience:
1 | Page
3
Doc.
Rev.
Project
OPERATION & MAINTENANCE
S kyLine O&M Manual
1 .4
PROJECT NAME
MANUAL
1 | Page
4
OPERATION & MAINTENANCE
MANUAL
Doc.
Rev.
Project
S kyLine O&M Manual
1 .4
PROJECT NAME
5.LIST OF RELATED DOCUMENTS
•
•
•
•
SkyLine Installation Manual
Slew Drive O&M Manual
Tracker layout and GA drawings
Annex (included at the end of this document)
OPERATION
6. SOLAR TRACKER FUNCTIONALITY OVERVIEW
Automatic system which drives solar panels to receive solar irradiation.
6.1. HORIZONTAL SINGLE AXIS TRACKER (HSAT)
The rotation axis is horizontal with respect to the ground.
6.2. DAYTIME TRACKING
This tracking technology uses geographic latitude, longitude, and time as the main parameters, and
astronomical algorithms (a general formula for the sun's position and horizontal coordinates) to calculate the
sun's altitude α and azimuth γ.
The mechanical system is then driven by the intermittent drive motor of the control system. At the same time,
the rotation position of the real time photovoltaic power generation system is detected by the inclination sensor,
to achieve the purpose of closed-loop control further optimizing the tracker accuracy.
6.3. BACKTRACKING
During sunrise and sunset, shadow will be casted on consecutive PV arrays due to the low altitude of the Sun.
Increasing row spacing can effectively reduce power caused by shadow occlusion, but it will increase
investment costs such as land, cables, and construction.
15 | Page
OPERATION & MAINTENANCE
MANUAL
Doc.
Rev.
Project
S kyLine O&M Manual
1 .4
PROJECT NAME
Backtracking technology is a reverse-direction tracking routine. Its application in PV tracking systems can avoid
shadow occlusion between PV arrays ensuring the optimisation of power generation of PV systems, and
reducing the land area.
In simple terms, the backtracking routine uses the control system to calculate whether there is a shadow
between the PV arrays in the morning and afternoon according to the module pitch, the array size and the
azimuth and altitude of the sun. If there is shadow, the tracker will turn in the opposite direction to avoid it and
until the shadow is no longer there.
The operation of the tracker throughout the day is: as the Sun's altitude increases after sunrise, the tracker
gradually rotates from the flat or starting position to the maximum angle until the time when there is no shading
between PV arrays. Then it goes into regular tracking, which is turning towards the sun. In the afternoon, there
will be shadow occlusion between PV arrays and the tracker will be in the backtracking mode again, from the
maximum tracking angle position gradually turning to flat position to ensure that there is no shadow occlusion
in the PV array throughout the day.
Figure. PV arrays in the morning or evening without backtracking
Figure PV arrays in the morning or evening with backtracking
6.4. AI TECHNOLOGY(Optional)
In addition, the AI tracking algorithm continually self-adapts to daily operating conditions including (but not
limited to) slope etc, and optimizes the algorithm accordingly for enhanced productivity in varying conditions of
operations.
By using its own meteorological database and real-time weather data our system is able to identify if cloud
shadows are being projected over the panels and make the trackers work individually in consequence.
16 | Page
OPERATION & MAINTENANCE
MANUAL
Doc.
Rev.
Project
S kyLine O&M Manual
1 .4
PROJECT NAME
7.WIND PROTECTION SKYLINE
7.1. Wind Stow Strategy with Weather Warning
If the weather forecast signal indicates that tomorrow there will be a thunderstorm or hurricane whose wind
speed ≥ 25m/s (3s gust, 10m), a gale warning information will be generated. By the warning information, the
gale protection strategy will be initiated for the next day, despite the anemometer measurements.
This gale mode can be categorized by wind directions. The most critical directions for the tracker are East and
West (+- 30 degrees).
Under gale mode and depending upon measured wind speed, the wind stow strategy can be categorized into
two routines: i) gale protection and ii) stow.
During i) gale routine, there are three possible positions:



East Stow Position: East wind condition, system stays on east stow position.
Flat position: System remains flat.
West Stow Position: West wind condition, system stays on west stow position.
The field wind speed is acquired by the anemometers. The anemometers take the wind speed data in the
frequency of one acquisition per second, and the anemometer outputs wind data in a frequency of every three
seconds (the output data is the average value of the closest 3 second). The tracker communication system
processes the received wind speed data every 30 seconds (calculate the average output value 30 seconds’).
Both East and West have two modes that depend on real-time wind speed measured by the field anemometer.
If we are in gale mode, the system acquires wind direction and one of the following three will occur:



Wind coming from the EAST: Normal Tracking to Flat Position – Stay in Flat position
Wind coming from the WEST: Move to Flat position – Normal Tacking to West Wind Position
Wind coming from the NORTH or SOUTH: Normal Tacking to the closest stow position at the time
anemometers detect wind above threshold.
If real-time wind speed is higher than 12 m/s (30s gust), the system will enter Stow Mode directly:



East Wind: East Stow Position – East Stow Position – East Stow Position
West Wind: West Stow Position – West Stow Position – West Stow Position
North/South Wind: Move to the closest East or West position, depending on time of the day anemometer
detects wind speeds above the stow threshold
Stow mode means the tracker is always nose down, which is the most stable position.
The different modes are shown in the following diagram:
17 | Page
OPERATION & MAINTENANCE
MANUAL
Doc.
Rev.
Project
S kyLine O&M Manual
1 .4
PROJECT NAME
7.2. Wind Stow Strategy Without Weather Warning
Regardless the warning routine, field anemometers keep acquiring real-time wind speed data at all times
during normal operation mode (no gale warning received). This protects the trackers from large instantaneous
wind gusts that had not been forecasted and are higher than 12m/s (30s average). If the instantaneous speed
is larger than 12m/s (30s average), the trackers will rotate into stow position
7.3. Summary
There are two routines operating simultaneously for added protection.
a)
b)
c)
d)
e)
Stow angle: 30 degree from horizontal. At this tilt tracker is very stable.
Wind stow mode gets triggered at 12 m/s (30s interval, detected at 4 m height).This is equivalent to
15 m/s, 3 sec gust measured at 10 m height.
Consider the speed of motor is about 5 second per degree, the rapid stowing time from 0deg to
30deg, or 60deg to 30deg will be less than 2.5min.
Tracking mode gets resumed once wind speed is lower than 8 m/s for a constant interval of 180
seconds.
Gale mode – warning in place from the day before – trackers flat and moving to nose down tilt if
wind speed is more than 12 m/s (30 sec)
18 | Page
OPERATION & MAINTENANCE
MANUAL
Doc.
Rev.
Project
S kyLine O&M Manual
1 .4
PROJECT NAME
8.POWER SUPPLY
8.1. POWER SUPPLY 300-1500 V
During the day and under normal circumstances, the controller is powered from the strings with negligible
impact on the power generation. To ensure the system works at any time, the lithium battery remains fully
charged during the day and supplies power at night. Even then, the battery is in a shallow charge-discharge
state which protects and extends the battery life.
To protect the system, there is an inline fuse (DC 1500 V) outside the box.
8.2. FROM STRINGS
Power comes to the AI controller directly from the PV strings, from a parallel circuit. This way we can see the
cost in power supply cables reduced and have a more efficient method which does not rely on any external
devices.
The power loss generated by this system is insignificant:
In a day, the tracker will go through 2 round trips
(+30° -> +60° -> 0° -> -60° -> 0° -> +30°) and it takes 10 seconds for the
motor to rotate the tracker by 2 degrees.
 Daily power consumption of the motor -> 10s * (240/2 times) * 24W = 8 Wh.
 Daily power consumption of the internal circuit of the controller -> 0.5W * 24h = 12 Wh
 Daily power consumption of the control system -> 8 Wh + 12 Wh = 20Wh
There are normally 30 Skyline trackers for a 1MW project.
19 | Page
OPERATION & MAINTENANCE
MANUAL
Doc.
Rev.
Project
S kyLine O&M Manual
1 .4
PROJECT NAME
 Daily power consumption of a 1MW control system -> 0.6kWh / day,
Comparing it to the average daily power generation of most PV plants, which is 3000 ~ 5500kWh / MW / day, it
only takes up to 0.01 ~ 0.02%, and most existing PV power plants have AC and DC over-provisioning.
Battery back-up
At night and under special circumstances, the system is powered by the lithium battery. These circumstances
may be heavy wind or snow, which cause heavy load.
Also, if the PV power supply fails for any reasons, the system will automatically switch to battery supply so there
is no loss which could affect power generation.
For low temperature environments, the controller has a pre-installed heating module which assures the right
functioning of the battery.
If the supply falls, the battery mode will be activated to ensure power generation for approximately 3 days.
20 | Page
OPERATION & MAINTENANCE
MANUAL
Doc.
Rev.
Project
S kyLine O&M Manual
1 .4
PROJECT NAME
9.AI CONTROLLER AND COMMUNICATIONS
The Artificial Intelligence controller is located next to the slew drive attached to the torque tube completely
integrated in the system and with the safety button facing South. There is no need to open the box, as it can
be operated remotely. If any internal components must be replaced,
please refer to the “Troubleshooting” section of this manual for more
information.
9.1. GENERAL SPECIFICATIONS:
ELECTRICAL SPECIFICATIONS
Input power
15 - 30 W
Input voltage
300 - 1500 V
Input current
0 - 0,02A DC
Output current
24 Vdc
Max. Output power
150 W
Rated output power
80 W
Max. Output current
6A
Rated output current
3A
Battery type
Battery capacity
Daily energy consumption
Static power
Li - ion battery
77,7 Wh
< 0,02 kWh/day
< 0,5 W
SELF LEARNING AND WORKING MODE
Cloudy mode
Optional
Terrain correction
Optional
Bifacial module mode
Optional
Backtracking mode
Yes
21 | Page
OPERATION & MAINTENANCE
MANUAL
Doc.
Rev.
Project
Wind protection mode
S kyLine O&M Manual
1 .4
PROJECT NAME
Yes
GENERAL DATA
Certification
TUV, UL, CE
Operation temperature
-20ºC to 60ºC (-30ºC to 60ºC Optional)
Communication method
Lora/RS485
Protection level
Weight
Dimensions
IP65
2,5 Kg
400*128*132 mm (L*W*H)
AI Controller installation
The AI controller is mounted under the torque tube with the emergency button facing south.
22 | Page
OPERATION & MAINTENANCE
MANUAL
Doc.
Rev.
Project
S kyLine O&M Manual
1 .4
PROJECT NAME
9.2. POWER-CONTROL COMPONENTS:
1
Emergency stop switch - External rotation release
2
DC rotatory switch
3
Communication cable port
4
Reserved
5
Reserved
6
PV connection to positive terminal of module string
7
PV connection to negative terminal of module string
8
Motor cable port
Connecting the AI controller to check parameters or activating manual working mode:
23 | Page
OPERATION & MAINTENANCE
MANUAL
Doc.
Rev.
Project
S kyLine O&M Manual
1 .4
PROJECT NAME
a) Using USB – wireless module and Lora Wireless setting software, set the same frequency, Net ID and
air rate in the module and the controller.
b) Open Tracker Software.
c) Check parameters are ok. / Activate desired working mode by clicking on them.
For preventive maintenance check the proper section of this manual.
9.3. COMMUNICATIONS
One Communication Box for up to 96 controllers connected by Lora following this diagram:
24 | Page
OPERATION & MAINTENANCE
MANUAL
Doc.
Rev.
Project
S kyLine O&M Manual
1 .4
PROJECT NAME
Each Communication Box has two wind sensors, one for direction and one for speed, to provide real-time
weather data, and a GPS unit which updates GPS information of the controllers.
Check Protocol Explanation for more information.
25 | Page
OPERATION & MAINTENANCE
MANUAL
Doc.
Rev.
Project
S kyLine O&M Manual
1 .4
PROJECT NAME
10. CONTROLLER INTERFACE AND WORKING MODES
10.1. WORKING MODES:
1. AUTO MODE
In this mode the tracker rotates automatically according to the set parameters and AI algorithms yielding
best performance.
If the tracker is in auto mode and some occurrence happens, such as strong winds, snow, etc, the system
will start operating in a specific mode according to the occurrence.
2. MANUAL
If the tracker needs to be moved to a specific direction, this can be done with the keys “East” and “West”.
Select the key to rotate the tracker in the needed direction and click again to make it stop.
3. MANUAL (TARGET)
If the tracker needs to be moved to a particular tilt, this can be set in this mode.
4. WIND
When the systems are working in auto mode, if there are strong winds, this mode will be automatically
triggered, and the trackers will be sent to stow position (30 degrees from horizontal).
This mode can also be activated manually by clicking the key “wind” in the Arctech’s software or from the
SCADA interface.
5. RAIN
If it starts raining heavily, this mode can be manually triggered, and the trackers will start rotating from East
to West continuously. To protect the motors, this rotation will pause for 2 minutes every 10º.
26 | Page
OPERATION & MAINTENANCE
MANUAL
Doc.
Rev.
Project
S kyLine O&M Manual
1 .4
PROJECT NAME
6. SNOW
If there are heavy loads of snow, this mode can be manually triggered and the trackers can be moved to the
maximum tilt by selecting snow mode in the Arctech’s software or from the SCADA interface.
7. MAINTAIN
If this mode is selected, the trackers will move to the flat position (0 degrees, facing the sky).
8. CLEAN
In this mode the trackers will move to the inclination set during commissioning to ease the cleaning
process of the modules.
11. GENERAL TROUBLESHOOTING
Please, use the procedures in this section if:
1. A SYSTEM IS NOT WORKING
2. A SYSTEM IS NOT WORKING PROPERLY OR AS EXPECTED
3. THERE IS AN ALARM IN SCADA AND/OR IN THE ARCTECH SOFTWARE
The abnormal situations on the project site can be divided into two categories: tracking abnormality and
communication abnormality. Tracking abnormalities are classified into tracking stopping and tracking angle
anomalies; communication abnormalities are classified into control box anomalies and communication box
anomalies. Because the AI control box system is a highly integrated and modular system, the on-site
troubleshooting needs to be connected to the upper computer of the control box.
Abnormal communication
Troubleshooting steps for abnormal communication found from the communication box side or background
monitoring
1. Check the wireless module transmission of the communication box.
The antenna connection and placement of the communication box are correct, and the
parameter settings of the communication box are normal. For details, refer to the
troubleshooting section of the communication box in "About Common Problems and Solutions
on Site".
2. Check the control box side:
a) Check whether the antenna connection and placement are normal
b) Use the wireless debugging module (the parameter configuration is consistent with the wireless
module configuration on the communication box side) to try communicating with the control box
c) Turn off the emergency stop switch and DC breaker, wait for 5S and then turn it on again.
d) If the above steps cannot solve the communication problem, replace the control box.
27 | Page
OPERATION & MAINTENANCE
MANUAL
Doc.
Rev.
Project
S kyLine O&M Manual
1 .4
PROJECT NAME
Abnormal tracking
Connect the host computer and the control box to communication through the wireless debugging module,
check the alarm information, see Table 1 for details
FAULT
DESCRIPTION
POSSIBLE
SOLUTION
CAUSES
AngleNoCom
Abnormal
Abnormal angle Power off the control
angle
sensor
box and wait for 5S to
communication
power it on again
AngleNoChange The system
angle value is
unchanged
SoftLimit-E
SoftLimit-W
Exceed the
east-west soft
limit
1.
Tilt
sensor failure.
2.
Motor
stop working.
1.
Check whether
the appearance and
function of the motor
are normal
2.
Check whether
the cables from the
control box end to the
motor end are well
connected
tilt sensor failure Power off the control
box and wait for 5s to
power it on again
28 | Page
OPERATION & MAINTENANCE
MANUAL
Doc.
Rev.
Project
S kyLine O&M Manual
1 .4
PROJECT NAME
MotorOverCur
Motor
overcurrent
The motor is
blocked, the
resistance of the
support shaft is
too large, and
the shock
absorber is
damaged
1.
Check for
mechanical
obstructions
2.
Check Motor
vibration / noise.
MotorReversal
Motor reverse
rotation
The positive and
negative poles
of the motor
drive output are
reversed
EmergencyStop
Emergency
stop switch is
off
System time
lost
/
1. Check the polarity of
Motor section.
2.Upgrade the control
box firmware or modify
the motor rotation
direction through the
upper computer
Turn on the
emergency stop switch
TimeLost
System outage
time is too long
and button
battery is too
low
1.Update time by
upper computer
software
RTCError
RTC clock
failure
RTC clock
chip failure
1.Power off the control
box and wait for 5s to
power it on again
BatSOCLow
battery is low
1.
Bad
weather or
abnormal input
voltage
of control box
2.
Abnormal
charging
BatError
Battery failure
Undetectable
battery
1.
Check whether
the input voltage of the
control box is normal
300-1500vdc
2.
The upper
computer checks
whether the charging
is normal
Power off the control
box and wait for 5s to
power it on again
29 | Page
OPERATION & MAINTENANCE
MANUAL
Doc.
Rev.
Project
BatNoCom
Abnormal
battery
charging
Damage to onboard power
management
chip
S kyLine O&M Manual
1 .4
PROJECT NAME
Power off the control
box and wait for 5s to
power it on again
Table 1 Tracking abnormal alarm comparison table
Note: If the above suggested measures do not resolve the issue, please contact Arctech Solar for
further assistance.
MAINTENANCE
12. PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE
EVERY 6 MONTHS
1
YEAR
2
5
YEARS YEARS
VISUAL INSPECTION
MECHANICAL
Coating
Torque marks
Slew drivers and motor
· Corrosion
· Breaks
· Abnormal sounds
· Blockages
Dampers & Springs
Rotation bearings
ELECTRICAL
Grounding
Cables/Plugs
Controllers
Antennas
Wind sensors
TORQUE REVISION
5% trackers
Torque values
SLEW DRIVERS LUBRICATION
Check
If during checking is needed, lubricate.
Lubricate
30 | Page
OPERATION & MAINTENANCE
MANUAL
Doc.
Rev.
Project
S kyLine O&M Manual
1 .4
PROJECT NAME
12.1. BIANNUAL - VISUAL INSPECTION
Every 6 months the systems must be checked for small damage due to normal performance, natural events,
time-passing erosion, or other causes. Being aware of this deterioration can prevent plant downtime
consequently leading to overall yield improvement.
Both mechanical and electrical components must be checked and repaired or even replaced if any damage is
found.
MECHANICAL:
1.1.1 COATING – if corrosion appears on any surface or the galvanisation has been
damaged, it must be cleaned and repaired.
1.1.2 TORQUE MARKS – Arctech Solar selects high reliability fasteners but it is
recommended to check whether the marks on them have been displaced.
1.1.3 SLEW DRIVERS and motors– any abnormal noise could mean the system is not
working properly. In addition, it is recommended to check for signs of organic
intrusion.
1.1.4 DAMPERS – check for corrosion, dents, etc.
1.1.5 ROTATION BEARINGS – check that they remain on their original position and that no
damaged has been caused by friction.
ELECTRICAL:
1.1.6 GROUNDING – Grounding cable are not misplaced, broken or damaged.
1.1.7 CABLES/PLUGS - check if they are in good condition and plugs are connected
properly.
1.1.8 CONTROLLERS – they must remain as they were installed. The bottom plate of the AI
control box should be perfectly aligned with the edges prior to torqueing. Refer to
CONTROLLER CHECKLIST.
1.1.9 ANTENNAS – check for obstructions or general damage.
1.1.10 WIND SENSORS – Wind velocity sensor should be above the wind direction sensor.
Wind sensor holder should be toward north.
12.2. ANNUAL INSPECTION
Torque value inspection of 5% of the trackers randomly chosen. The percentage of fasteners to be checked in
one tracker is going to be based on the size of these fasteners according to the following table:
RANDOMLY CHECKING PROPORTION FOR THE FASTENERS IN ONE TRACKER
Fastener size
Inspection proportion
M20
M16
M12
M10
M8
100%
30%
30%
25%
25%
The values of the torques must be the same as the ones given in the installation manual. However, there will
be a maximum and a minimum value in order to increase the criteria of acceptance to an interval. Please refer
to torque value table in ‘3 general tracker description’
31 | Page
OPERATION & MAINTENANCE
MANUAL
Doc.
Rev.
Project
S kyLine O&M Manual
1 .4
PROJECT NAME
12.3. SLEW DRIVER LUBRICATION
The slew drive must be checked for reducing grease levels every 2 years with recommended grease infusion
every 5 years.
The way to inject grease is through the plug hole while rotating the slew driver.
RECOMMENDED TYPE OF LUBRICANT:
HF7B(150)-00#, Exxon Mobil SHC Polyrex series 005, Klueber PEG46-1200
.
CONTROLLER CHECKLIST
CONTROLLER VISUAL INSPECTION
OK
NOT
OK
COMMENTS
1 Correctly mounted and fixed
2 Fixation bolts in place with correct torque value
3 Perfectly sealed with no water filtration
4 Cables properly connected
5 No surface damage or corrosion
6 DC Power switch and safety button
7 No natural or organic disturbing elements
End of Manual
32 | Page