Assembly Manual SP160 - Slewing Drive

P.I. La Peña, Ctra.
NA-134, km 93 Ver - Rev

ENGINEERING DEPARTMENT
31230 Viana, Navarra (Spain) 1–4
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ASSEMBLY MANUAL
SP160 SLEWING DRIVE
This is a Preliminary Manual with generic

information.
It must be updated with particular details
for each Project at detailed design stage.
All rights reserved. Any copying or partial distribution of this document is prohibited without the written
authorization of NCLAVE. The specifications in this manual are subject to possible changes.
This is a Preliminary Manual with generic information. It must be updated with particular details for each Project at detailed design stage
P.I. La Peña, Ctra. NA-134, km 93 Ver - Rev
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CONTENT
REVISION CONTROL ................................................................................................................................ 3

GENERAL INFORMATION, RESPONSIBILITIES, SAFETY AND TRANSPORTATION ............................... 4
SP160 GENERAL INFORMATION ............................................................................................................ 5
GENERAL INFORMATION ................................................................................................................ 5
2.1.1. ENVIRONMENTAL CONDITIONS ............................................................................................. 5
SP160 SOLAR TRACKER ................................................................................................................... 6
2.2.1. MATERIALS AND APPLICABLE REGULATIONS ....................................................................... 8
MAIN COMPONENTS OF THE TRACKER ........................................................................................ 9
LIST OF TOOLS ......................................................................................................................................... 10
PRE-ASSEMBLY DEFINITIONS ................................................................................................................. 11
PANEL LAYOUT ............................................................................................................................... 11
LOCATION INFORMATION ............................................................................................................ 12
ELECTRICAL INSTALLATION ........................................................................................................... 12
INSPECTION OF GALVANIZED STEEL IN MECHANICAL COMPONENTS ................................. 12
BOLTS TIGHTENING TORQUE ......................................................................................................... 13
USE OF DIN 6923 NUTS ................................................................................................................... 14
STEP-BY-STEP ASSEMBLY ........................................................................................................................ 15
TOPOGRAPHICAL MARKING AND POSITIONING OF POSTS ................................................... 15
EQUIPMENT DISTRIBUTION ............................................................................................................. 15
INSTALLING POLES IN THE GROUND ............................................................................................ 16
5.3.1. TOLERANCES FOR RAMMING POLES INTO THE GROUND ............................................... 16
5.3.2. INSTALLATION WITH RAMMING MACHINE ......................................................................... 19
5.3.3. ALTERNATIVES TO DIRECT RAMMING .................................................................................. 19
5.3.4. TRENCHES ALONGSIDE POLES.............................................................................................. 20
ASSEMBLY OF THE CENTRAL POLE AND THE ROTATION MODULE .......................................... 21
ASSEMBLY OF THE ROTATION DRIVE UNIT................................................................................... 22
ASSEMBLING THE BEARINGS ......................................................................................................... 22
ASSEMBLING THE PHOTOVOLTAIC MODULES AND THEIR SUPPORT ...................................... 29
ASSEMBLY OF THE ELECTRICAL BOX AND ACCESSORIES ........................................................ 31
ANEMOMETER ................................................................................................................................ 32
ELECTRICAL ASSEMBLY .............................................................................................................. 33
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REVISION CONTROL
DATE
VER - REV DESCRIPTION ELABORATED REVISED APPROVED
(dd/mm/yy)
1-1 12-I-2017 INITIAL DOCUMENT VBG JAM MAI
Tolerances.
1-2 22-XI-2017 Twist. JAM MAI JSL
Procedures.
1-3 20-XII-2017 Updated pictures KZV MAI MGD
Module alignment.
1-4 01-II-2018 JAM MAI MGD
Twist.
Tilting bearing support

1-5 22-XI-2018 VVE MAI MGD
Slewing drive
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GENERAL INFORMATION, RESPONSIBILITIES, SAFETY AND

TRANSPORTATION
This manual is intended as a guide for the correct assembly of the Solar Tracker. Please, read it
carefully before starting assembly. The team undertaking the assembly of the solar tracker must be
qualified and specialized in this type of work. If you have any questions, please contact the Technical
Department of NCLAVE.
NCLAVE manufactures different models of solar trackers and several drawings for the same area
can be found in the manual; in each case the customer will choose the option that fits their tracker.
NCLAVE is only responsible for the items it supplies. The instructions given in this manual must be
followed faithfully; otherwise, the manufacturer is exempt from any liability. Modifications or
alterations made without authorization from the manufacturer, as well as the utilization of
unapproved spare parts, exempt the manufacturer from any liability related to the proper
functioning of the solar tracker and the safety of the persons handling the unit. Defects caused by
the negligence of untrained users and misuse of the components are not included in the warranty.
We recommend the exclusive presence of authorized personnel for the installation of the solar
tracker. Also, the people working in or travelling through the work zone are required to respect basic
safety standards for protection and prevention. They must be equipped with the required clothing
and personal protective equipment (helmet, gloves, harness, safety shoes, etc.) and take preventive
measures such as not standing under suspended loads, wearing gloves to avoid injury from
irregularities in the surfaces of ferrous materials, checking the moorings of the pieces, making sure
that slings and cables have sufficient strength to withstand the weight of the pieces to be raised and
any other measures that are applicable to the work being performed at all times.
It is strictly forbidden to commission the trackers without the approval of NCLAVE; the placement
and verification of an anemometer is also mandatory. The wind control network (anemometer) shall
be designed based on the needs of each installation.
It shall be the responsibility of the customer to supply power to the trackers. NCLAVE shall not be
liable for damages that may occur, for example, in a power outage in which the trackers are in
working position.
This document is confidential and registered; therefore, this document and / or its content, totally
or partially, can not be propagated, distributed, provided or analyzed by anyone.
NCLAVE has all rights reserved. Any copy or partial or total distribution of this document is
forbidden without written authorization from NCLAVE. The specifications included in this manual are
subject to possible modifications without prior notice.
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SP160 GENERAL INFORMATION

GENERAL INFORMATION
The SP160 single-axis polar tracker consists of three components:
1. The tracker
2. Control (optional)
3. Monitoring (optional)
2.1.1. ENVIRONMENTAL CONDITIONS
Do not install electrical boxes in any of the following locations:
- Locations exposed to temperatures of below -5º C or above 45° C.
- Locations exposed to drastic temperature or compensation changes.

- Locations exposed to ambient humidity of not less than 10% or more than 90%.
- Locations exposed to corrosive or flammable gases.
- Locations exposed to excessive dust, salt or metal particles.
- Locations that expose the station to impacts or vibrations.
- Locations exposed to direct sunlight.
- Locations exposed to reagents from the oil or chemical station.
- Always adequately protect the electrical module in the following places:
• Locations exposed to static electricity or other types of noise.
• Locations exposed to strong electromagnetic fields.
• Locations exposed to possible radioactivity.
• Locations near power lines
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SP160 SOLAR TRACKER

This document is intended as a guide for the correct assembly of the SP160 single-axis polar
tracker from NCLAVE. Before beginning installation, please read this manual very carefully. The team
responsible for assembling the structure should be qualified and specialised in this type of work. If
after reading this manual you still have doubts, contact the technical department of NCLAVE.
In order to meet the requirements of each customer, NCLAVE adapts the tracker design to their
needs. For this reason, it may be that the drawings accompanying this manual do not match your
tracker, as the number of modules or their orientation may differ.
This single-axis solar tracker, the SP160, consists of an electromagnetic group equipped with a
frame to hold the photovoltaic panels and a rotation system to rotate the panels to their optimum
position. This system consists of a rotation axis oriented North-South, with ±α±3º assembly tolerance in
the module alignment (α depending on the project).
This tracking system of the tracker has a monitoring program that uses astronomical calculations
in the PLC, which includes wind protection movements. In this way we maximize solar radiation from
dawn to dusk.
The support structure for the panel grid consists of structural profiles, called poles, made of hot-
dip galvanized steel (in accordance with the ISO 1461 standard). Mounted on these poles is a square
structural profile, onto which the grid of modules is fitted. The grid consists of structural profiles, with
length equal to the width of the grid, and clips for supporting and securing the panels.
The modules can be configured in different ways, according to the customers' needs.
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Below are images with a presentation model.
All measurements are variable depending on the project and needs of each customer (such as
the rotation angle, configuration and distance from the module to the ground), provided they fall
within the maximum allowable values for this tracker model.
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2.2.1. MATERIALS AND APPLICABLE REGULATIONS
The materials used in the tracker
- Steel for structures: S235, S275, S355.
All the steel parts that make up the structure are hot-dip galvanised according to the ISO 1461
and UNE EN ISO 14713 standards, or the corresponding regulations for the specific situation.
Directive 2006/42
Transmission actuators (rotation
UNE 18016:1894
modules, linear actuators, etc.)
EN 10204
D.M 2006/42/EC
B.T. 2006/95/EC
E.M.C 2004/108/EC
IEC 34-1
Motors IEC 34-5
IEC 34-6
IEC 34-7
IEC 34-9
IEC 72-1
2006/95/EEC
Electrical boxes
2004/108/EEC
Threaded rods for foundations DIN 17704
UNE-EN-755-9
Aluminium profiles
UNE-38337
UNE-EN-10025-2:2004
Steel plates
UNE-EN 10149-3:1995
Steel profiles UNE-EN -10162
UNE-EN-ISO 1461
Galvanisations
UNE-EN-ISO 14713
Corresponding DIN / UNE regulations.

Hardware
Quality 8.8
Steel grades (yield strength) 275, 355 N/mm2
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MAIN COMPONENTS OF THE TRACKER

Below are the main structural elements required for the assembly.
Plastic bearing
Torque tube
Electric box
Lever post
Photovoltaic modules
Purlins
Standard post
The machine drive (slewing drive) is located between poles, in the centre of the row, attached
to the tracker using a drive shaft profile.
Basically, the tracker is comprised of:
- SLEWING DRIVE
- PILE-DRIVEN POLES (STANDARD AND SLEWING DRIVE (HEB))
- ROTATION BEARING (PLASTIC BEARING)
- TORQUE TUBE
- PV MODULE SUPPORT PROFILE (PURLIN)
- PHOTOVOLTAIC MODULES
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LIST OF TOOLS
Below is a list of all the tools needed for assembling the structure, for both the electrical part and
the mechanical part (NCLAVE DOES NOT SUPPLY THESE TOOLS):
• UNLOADING RAMP, HANDLERS, UNLOADERS
• PILE DRIVERS WITH PILE RAMMING TOOLS
• DYNAMOMETER WITH MOORING CLAMP
• SLINGS OF DIFFERENT LENGTHS AND RESISTANCES
• TRACTEL LIFT
• TORQUE WRENCH (TORQUE: 70 Nm to 500 Nm)
• TORQUE WRENCH (TORQUE: 20 Nm to 80 Nm
• TORQUE WRENCH FOR THE TORQUE OF THE MODULES (TORQUE: 6 Nm to 50 Nm)
• DIFFERENT METRIC VESSELS FOR THE TORQUE WRENCHES
• STRING
• HANDY DEVICE
• ELECTRONIC LEVELS AND GONIOMETERS
• METRIC MEASURING TAPE
• OPEN-END SPANNERS AND RATCHET SPANNERS.
• SPANNERS FOR THE INDUCTIVES
• MULTIMETER
• ELECTRICIAN SCREWDRIVERS
• LASER POINTER
• DOUBLE SLOPE LASER LEVEL
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PRE-ASSEMBLY DEFINITIONS
PANEL LAYOUT
ALWAYS CHECK THE PANEL MANUFACTURER'S ASSEMBLY REQUIREMENTS.
Before building the SP160, it is important to consider the layout of the photovoltaic panels in the
tracker. Depending on the design, project and strings, the configurations may include:
• 1 VERTICAL MODULE (PORTRAIT)

• 2 HORIZONTAL MODULES (LANDSCAPE)
• 3 HORIZONTAL MODULES (LANDSCAPE)
This layout must be therefore taken into account for the correct assembly of the purlins that
support the photovoltaic modules.
The spacing between panels in any direction depends on the mechanical installation system
selected for them. This is usually between 22 and 24mm, but the tracker plans must be checked first.
CHECK THE ASSEMBLY LAYOUTS, MEASUREMENTS AND DISTANCES ON THE ASSEMBLY PLANS AND
DETAILS PROVIDED FOR THE TRACKER
Two vertical modules
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LOCATION INFORMATION
Before any installation, a location study has to be performed:
• Property boundaries
• Rights of way
• Artificial limitations prior to installation (pipes, underground cables, etc.)

• Natural variables such as wetlands, wind, rain, snow, temperature variation, seismic history,
etc.
• Geotechnical report detailing field topology and soil composition.
There are also several other key elements that should be considered:
• Maintenance of Access Roads: Access to the field will be along the rows of trackers to enable
maintenance.
• Module cleaning: Cleaning of the photovoltaic modules must be included as part of the
maintenance program of most of the sites.
ELECTRICAL INSTALLATION
It is the customer's responsibility to determine the field wiring diagram before any construction.
All equipment that requires power and / or communications for commissioning and subsequent
normal operation of the tracker, must be provided with them.
INSPECTION OF GALVANIZED STEEL IN MECHANICAL COMPONENTS

All the tracker's components are made of galvanized steel to prevent corrosion. Although
NCLAVE carries out thorough quality control inspections, some components may become scratched
during shipment. The components should therefore be inspected previously, so that any scratches to
the steel can be coated with paint or zinc spray if necessary. These will be repaired by the company
responsible for performing the assembly tasks.
There may also be pieces with accumulated galvanisation in some areas, which must be
checked before assembly, removing any existing excess, if it exists, and will be covered with paint or
zinc spray if it is necessary.
These works are part of the process of installing the tracker and must be carried out by the
company in charge of the assembly.
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BOLTS TIGHTENING TORQUE

Below is a table indicating the tightening torque for the most common bolts, to serve as a
reference:
Tightening torque (Nm)
Tightening torque (Nm)
REFERENCE quality Stainless steel
quality 8.8
A2-70
M6 (rigid joints) 7 10
M8 (clamps)* 10 10
M8 (U-bolts) 17 17
M10 (joints without contact between the surfaces) 20 20
M12 (plastic bearings) 40 40
* Subject to changes depending on the PV module manufacturer.
• Rigid joints are considered when the pieces to be joined are in contact, or the separation among
them is so small that when is tightened to the correct torque they get in contact completely.
• Joints without contact are considered when the pieces to be joined will be not in contact after
tightening to the correct torque. In this case if they are tightened excessively they could break
or deform.
Initial pre-tensioning strengths might be reduced due to possible variations in temperature,
internal stress, friction or the effect of non-rigid elements between joints.
Therefore, when following the "check list", the same tightening torque shall be applied and under
the same temperature conditions as those followed during the assembly process. The admissible
tolerances when following the installation "check list" are:
• The tolerance of the tightening torque for rigid joints must be ±15%
• The tolerance of the tightening torque for joints with no contact must be +0/-15%
NCLAVE reserves the right to modify the tolerance values described in this document
The screws must be tightened with calibrated tools with an impact head, with the purpose of
preventing any form of erosion on the edges of the screw due to wear on the head. The tool head
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must be replaced when damage is detected on the edges of the screw. The final torque will be
applied with a calibrated and certified torque wrench.
NCLAVE will not be responsible for damaged screws during the assembly process or for repairs or
derivative works.
At the site, materials will be stored in a dry place, especially screws, nuts and bolts.
USE OF DIN 6923 NUTS

It’s very important to take into account this note about using the Self-locking Nuts DIN 6923.
This nuts dispose of a flange with grooves which makes it a self-locking mechanism when is
tightened, without the need of any kind of washer.
This system will work correctly ONLY IF THE BOLT IS TIGHTENED WHILE THE NUT REMAINS STATIONARY,
so the grooves grip the piece and fix the set of pieces.
NCLAVE reserves the right to modify this procedure
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STEP-BY-STEP ASSEMBLY
Described below is the procedure to be followed for the correct and satisfactory assembly of the
SP160 solar tracker.
TOPOGRAPHICAL MARKING AND POSITIONING OF POSTS

The staking out work shall be done based on the topographical survey conducted on the site.
The area to be staked out must be clear and free of foliage so as to avoid interrupting the marking
work.
You must take into account the distance between posts in the same row, the distance between
trackers and the slope of the terrain.
The number of points to be staked depends on the ground

slopes and the installation team needs.
The staked points indicate the location of the centre or the
corner of the posts. NCLAVE advises to mark a post outer
corner.
The minimum number of points to be staked
topographically will be for the end pole and the central pole
(rotation module support) and its two adjacent poles. We
recommend marking some intermediate poles so as not to
have spans of more than 20 m where the string would not be
taut, leading to error.
From this minimum staked points, through different systems

(laser, GPS, strings) we could pinpoint the situation of the
intermediate posts. If all posts situation are located and staked, we proceed to the next item.
EQUIPMENT DISTRIBUTION
As the situation of the post are located and staked, the firstly needed material can be distributed
near their final situation.
The distribution is done with suitable machinery that is adapted to the terrain and the traffic
constraints that exist between the rows.
The distributed material will be the absolutely necessary in order to the beginning of the
installation. The material never will remain distributed, unless they will be used immediately.
Equipment will be stored in a dry area, especially bolts.
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INSTALLING POLES IN THE GROUND

It is essential for the subsequent assembly and operation of the tracker that the top edge of all
the poles run along the same straight line. For this reason, we have to be very careful with possible
unevenness in the ground.
Maximum uniform slopes of 10%, with no hills or stream beds in the North-South direction. Any
terrain that differs from the previous specifications must be analyzed by the Engineering Department
of NCLAVE.
If the ground is irregular, we must study the slopes of the land so that the straight line formed by
the top edge of the tracker poles meets the following requirements:
- Minimum ramming/propping length
- Minimum/maximum height of the pole above the ground

The rest of the poles will be driven according to the initial staking out (maintaining parallelism and
perpendicularity between rows), to the height of the plane formed by the tops of the poles.
We can get this height in several different ways: Laser, string, etc.
5.3.1. TOLERANCES FOR RAMMING POLES INTO THE GROUND

This document explains the general tolerances that must be met for ramming the poles. You must
contact the NCLAVE´s engineering department to check installation tolerances. NCLAVE will provide
plans with a complete description of the dimensions and tolerances for each project. Only NCLAVE
has full authority to validate the ramming of the poles.
5.3.1.1. AXIAL TOLERANCE

The maximum permissible tolerance for the deviation of the poles in the driving work, with respect
to the vertical alignment axis, is ±1º in the North-South direction, or ±5 cm (2 inches) in standard posts
and ±2.5 cm (a inch) in lever posts from the head of the pole with respect to its theoretical position
(which includes both vertical sinking and the pole's displacement from its theoretical coordinates).
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5.3.1.2. LATERAL TOLERANCE
The maximum permissible tolerance for the deviation of the poles, with respect to the alignment
axis, will be β = ± 1º in the East-West direction, or X = ±2 cm on standard posts from the head of the
pole with respect to its theoretical position (which includes both vertical sinking and the pole's
displacement from its theoretical coordinates).
5.3.1.3. TWIST TOLERANCE
The TWIST tolerance of each pole is very important, because if it is not complied with, it would put
strains on the rotation profile and limit the rotation permitted by the bearing.
The maximum permissible twist of the upper section of each pile must be requested to and
validated by NCLAVE and is considered 4º unless otherwise specified.
The maximum twist for HEA piles is ±0.5º.
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5.3.1.4. HEIGHT TOLERANCE
The height tolerance for every pole (with respect to the other poles) is very important, because if
it is not complied with, it would put strains on the rotation profile.
If cutting and/or machining becomes necessary, follow the instructions established for the
procedure.
The maximum height tolerance of the upper section of each exterior pile is ±30 mm.
The maximum height tolerance of the upper section of the HEB is ±10 mm.
5.3.1.5. NORTH/SOUTH AXIAL TOLERANCE
The maximum tolerance for the reference point of each pile to that of the next pile is ±20 mm.
We must also take into account that the maximum tolerance between the HEB and the last pile is
also ±20 mm.
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5.3.2. INSTALLATION WITH RAMMING MACHINE
Poles are the main piles on which the tracker is supported.

Therefore, the installation process must be carried out with
great care.
A hydraulic pile driver must be available to perform these

operations. The most suitable power rating will be associated
with the hardness of the terrain and the time available to
complete the task.
In general, two people will perform these tasks. One,
handling the control panel of the pile driver and another one
positioning the pole, checking the verticality of the pole in the
North-South and East-West direction at regular intervals.
This machine uses a special mould with a notch in the shape of the pole
and hits its head repeatedly, progressively driving it into the ground to the
required depth. It is not permitted to use moulds that are empty and/or that
have gaps that would warp the pole heads during the driving work
Only NCLAVE may reject or validate the poles based on any warping after the driving
If the pole heads are badly warped, NCLAVE recommends not going down to the theoretical
driving depth and taking advantage of the extra distance to make the repair.
5.3.3. ALTERNATIVES TO DIRECT RAMMING

When direct ramming is not possible, there are alternatives for fixing the poles in the ground that
are included and explainded in a procedure.
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5.3.4. TRENCHES ALONGSIDE POLES
Once the poles are set into the ground at the installation site, avoid digging ditches alongside
them, as the strength and compactness of the land, originally assessed by the characteristics of the
soil, would be considerably reduced and the poles would not function properly in the structure.
If it is unavoidable and necessary to dig a ditch, the person doing so must ensure a minimum
distance of 1 m from the E-W face of the pole and 1 m from the N-S face of the pole and then, once
the ditch has been closed, check the firmness of the soil that has been moved to ensure the
consistency of the impacted poles, either compacting the ground or filling in with concrete.
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ASSEMBLY OF THE CENTRAL POLE AND THE ROTATION MODULE

After ramming the central profile (HEB) where the rotation module will be placed, use M20 screws
to attach the module supports to it, allowing for regulation at the slotted holes and the holes over
the HEB profile.
Once the supports are assembled, put the rotation module into place as shown in the image.
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ASSEMBLY OF THE ROTATION DRIVE UNIT

Before putting the drive profiles into place with the cams, you must assemble the rotation module
as shown in the image. If it does not match the image it can be regulated with tools, turning the
module until it matches what is shown in the figure.
Take special care to assemble the driving set on the correct side, as indicated in the figure, using
the proper screws. Apply Loctite or similar to the M14 screws.
ASSEMBLING THE BEARINGS
A. STANDARD BEARINGS ASSEMBLY
After setting the poles into the ground, the next step is to assemble the bearings and rotation
profiles.
If the poles have been installed correctly (within tolerances), the ability to adjust the support and
the bearing will allow you to get within the correct alignment tolerances for proper operation.
The installation procedure is as follows:

• STEP 1A: Preassemble the 3 bushings and the two plastic beraing lower flanges on the bearing
support.
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• STEP 2A: The preassembled bearing support is installed on the post. ADJUSTED (it is not
necessary to apply the tightening torque until completing alignment).
• STEP 3A: Fix (by applying the corresponding tightening torque) the first and last bearing
support of the row.
B. TILTING BEARINGS ASSEMBLY

Tras la fijación de los postes en el terreno el siguiente paso es el montaje de los cojinetes, y perfiles
de giro.
After fixing the posts in the field the next step is the bearings assembly and torque tubes.
On trackers sited on slopes above 5,2%, tilting bearings will be assembled throughout the tracker.
If the posts have been installed within the tolerances mentioned, the ability to adjust the bearing
support will allow the tracker to be installed within the alignment tolerances for proper operation. The
installation procedure is as follows:
• STEP 1B: Preassemble the 3 bushings and the two plastic beraing lower flanges on the Tilting
base plate.
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• STEP 2B: Put the tilting bearing support on the post and, subsequently, install the preassembled
kit on the previous point. ADJUSTED (it is not necessary to apply the tightening torque until
completing alignment).
• STEP 3B: Fix (by applying the corresponding tightening torque) the first and last bearing
support of the row.
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• STEP 4: Assemble in your position the intermediate bearing supports using a laser pointer
(pipelaser or similar) and a target. Tolerance ± 0.5cm (¼ inch)
• STEP 5: Assemble the lower hemisphere of the bearing and the tube sections. Check that the
components are clean at the time of assembly, and that there are no objects in the rotation
area that could hinder the movement of the tracker. If you notice a tube with a sharp arrow
in the longitudinal direction, install it with a convex side facing up, so that the own weight
remedies the curvature.
• STEP 6: Make the coupling of the tubes by installing the clamps.
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The twist of each torque tube must be checked. If the angle of rotation exceeds 3º in the total
length of the tracker, but being within the prescriptions of the applicable regulations, the correction
during assembly of trackers in the joints must be carried out according to the procedure "Procedure
of turning axis adjustment" (in case of application of this procedure, contact NCLAVE for additional
information).
Hexagonal bolt
Clamps
Flat washer Hexagonal nut
The torque tube aligned with the transmission assembly will be joined by clamps according to
the following image:
Bolt DIN 7540K 6,3x19
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Joined the transmission set to the next length of the torque tube, we will assemble the rest of
the tubes as indicated above. The type of joints between tubes is in a detailed plan.Once checked
that all parts are at the same height and position respect to the axes, with a margin of ± 2mm,
fastening bolts of the support to the lever post will be tightened to the torque indicated above.
When we have both sides of each row with the torque tube assembled and screwed in its
central part we will revise / check the alignment of itself, and at that time you can tighten 100% the
screws of the bearing support and the 4 DIN screws 7540K 6.3x19.
• STEP 7: Assembly the upper half sphere and reinforcement upper flange.
• STEP 8: ONLY ON TILTING BEARING SUPPORT: At the possibility of small inclinations, it is necessary
to install block plates so that the torque tubes do not slide longitudinally along the bearings due to
slopes or wind. Once the row is assembled, these stops will be placed in contact with the half spheres,
as indicated in the following figure.
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• STEP 9: The ends of the torque tubes of each row must be closed with plastic cap supplied for
that purpose.
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ASSEMBLING THE PHOTOVOLTAIC MODULES AND THEIR SUPPORT

The panel support profile is supplied cut, drilled and galvanized to measure depending on the
tracker model, the number of panels and their positioning on the rotation shaft profile.
The distances, measurements and position of the profile will be defined for each project.
Therefore, check these first to mount the profiles at the correct distances. The assembly method is
described next.
The module support profiles (PURLINS) will be secured to the rotation shaft profile with a U-bolt
and a reinforcement plate.
TOLERANCE OF PANEL
TORQUE PLANE ALIGNMENT:
TUBE
panel plane angle ( ) α
must stand within ± 3º of
reference angle
PURLINS
M8 NUT
CLOSURE
BRACKET
RIVET
U-BOLT
The distances, measurements and position of the profile will be defined for each project.
Therefore, check these first to mount the profiles at the correct distances.
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 Before tightening this connection 100%, verify the perpendicularity between the purlin and
the rotation profile in the same row.
 Pay special attention to the alignment of the panels on the same row, since these must be
fully parallel.
 Solar modules (supplied by the customer) will be mounted on the purlins that have been
previously assembled.
 The system used to secure the solar modules to the purlins will be specific to each project as
there are different variables, such as the arrangement of modules, manufacturer
specifications, etc. REFER TO THE GENERAL PLAN FOR THEIR CORRECT ASSEMBLY.
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ASSEMBLY OF THE ELECTRICAL BOX AND ACCESSORIES

The electrical cabinet is supplied and assembled as described below.
U-BOLTS M8
TORQUE TUBE
ELECTRICAL BOX
NUTS M8
THE ELECTRICAL BOX MUST RECEIVE AS LITTLE SOLAR RADIATION AS POSSIBLE TO KEEP IT AT THE
LOWEST POSSIBLE TEMPERATURE, SO IT MUST ALWAYS BE INSTALLED:
• (In the Northern hemisphere) ON THE SOUTH FACE OF THE SLEWING DRIVE
• (In the Southern hemisphere) ON THE NORTH FACE OF THE SLEWING DRIVE
- Check layout and construction plans -
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ANEMOMETER
The anemometer support should be placed at a height above that of the tracker grid (5-7
meters). The customer can choose whether to place a post in the ground or in any of the plant
infrastructure such as the inverters' prefab plant. With respect to the post, ensure that there are no
elements that might hinder the effect of the wind on the sensor, and separate it sufficiently so that it
does not cast a shadow over the modules.
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As an OPTIONAL element (depending on the option chosen by the customer) there is the NCLAVE
wind control system, with a digital display which you can place in the electrical module itself or any
other installation on the solar farm. Several trackers are connected in the terminal box of the electric
module; see the electrical diagram of each module prior to making the connections.
It is strictly forbidden to operate the trackers without the protection and connection of an
anemometer calibrated to the project wind speed values. Otherwise NCLAVE is not responsible for
any damage that may occur. You must also ensure that the wind signal reaches all the trackers on
site.
The customer must ensure the proper functioning of the anemometer, recording the checks
performed in writing. NCLAVE leaves open the modification of the maximum wind limit value so that
it may be lowered (for example to 1 km/h) and its proper functioning verified. After, leave it at its
project values.
A switch will be mounted for wind simulation and to check the correct functioning of the
anemometer using the options of each master electrical module for wind or basic and advanced
stations.
ELECTRICAL ASSEMBLY
After completing the mechanical assembly, proceed with the assembly of the electrical
installation. Follow the steps below for this:
• STEP 1: Assembly of electrical box in each tracker.
• STEP 2: Installation of wiring (sensors and motor).

• STEP 3: Adjustment of tracker and operational testing.
Replacing or modifying any element of the electrical system will require the commissioning of the
system before its start-up.

Assembly Manual SP160 - Slewing Drive

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Assembly Manual SP160 - Slewing Drive

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P.I. La Peña, Ctra.

NA-134, km 93 Ver - Rev

This is a Preliminary Manual with generic

REVISION CONTROL ................................................................................................................................ 3

1-1 12-I-2017 INITIAL DOCUMENT VBG JAM MAI

1-3 20-XII-2017 Updated pictures KZV MAI MGD

Tilting bearing support

GENERAL INFORMATION, RESPONSIBILITIES, SAFETY AND

SP160 GENERAL INFORMATION

2.1.1. ENVIRONMENTAL CONDITIONS

Do not install electrical boxes in any of the following locations:

- Locations exposed to temperatures of below -5º C or above 45° C.

- Locations exposed to drastic temperature or compensation changes.

- Locations exposed to corrosive or flammable gases.

- Locations exposed to excessive dust, salt or metal particles.

- Locations that expose the station to impacts or vibrations.

- Locations exposed to direct sunlight.

- Locations exposed to reagents from the oil or chemical station.

- Always adequately protect the electrical module in the following places:

• Locations exposed to static electricity or other types of noise.

• Locations exposed to strong electromagnetic fields.

• Locations exposed to possible radioactivity.

• Locations near power lines

SP160 SOLAR TRACKER

Below are images with a presentation model.

2.2.1. MATERIALS AND APPLICABLE REGULATIONS

The materials used in the tracker

- Steel for structures: S235, S275, S355.

Threaded rods for foundations DIN 17704

Steel profiles UNE-EN -10162

Corresponding DIN / UNE regulations.

Steel grades (yield strength) 275, 355 N/mm2

MAIN COMPONENTS OF THE TRACKER

Basically, the tracker is comprised of:

- PILE-DRIVEN POLES (STANDARD AND SLEWING DRIVE (HEB))

- ROTATION BEARING (PLASTIC BEARING)

• PILE DRIVERS WITH PILE RAMMING TOOLS

• DYNAMOMETER WITH MOORING CLAMP

• SLINGS OF DIFFERENT LENGTHS AND RESISTANCES

• TORQUE WRENCH (TORQUE: 70 Nm to 500 Nm)

• TORQUE WRENCH (TORQUE: 20 Nm to 80 Nm

• TORQUE WRENCH FOR THE TORQUE OF THE MODULES (TORQUE: 6 Nm to 50 Nm)

• DIFFERENT METRIC VESSELS FOR THE TORQUE WRENCHES

• ELECTRONIC LEVELS AND GONIOMETERS

• METRIC MEASURING TAPE

• OPEN-END SPANNERS AND RATCHET SPANNERS.

• SPANNERS FOR THE INDUCTIVES

• DOUBLE SLOPE LASER LEVEL

• 1 VERTICAL MODULE (PORTRAIT)

Two vertical modules

• Artificial limitations prior to installation (pipes, underground cables, etc.)

• Geotechnical report detailing field topology and soil composition.

INSPECTION OF GALVANIZED STEEL IN MECHANICAL COMPONENTS

BOLTS TIGHTENING TORQUE

M10 (rigid joints) 33 45

M10 (joints without contact between the surfaces) 20 20

M12 (rigid joints) 57 77

M12 (plastic bearings) 40 40

M14 (rigid joints) 91 125

M14 (joints without contact between the surfaces) 60 60

M16 (rigid joints) 140 190

M16 (joints without contact between the surfaces) 80 80

M20 (rigid joints) 273 380