ETATRACK active 1500

Installation guide

Before starting installation, please

read installation guide carefully!

1. Safety references
General
This installation instruction contains fundamental references, which are to be considered for
mounting and start-up. It is to be read therefore absolutely before assembly and start-up from the
mechanic as well as the responsible user, too. It should be at the installation site. This installation
guide refers to the tracking system ETATRACK 1500 active. There is not only under this section of
"safety references" the specified to consider general safety reference but also into other sections
inserted, special safety reference.

Reference markings

Safety references marked with this symbol can cause endangerments of

persons.

Safety references marked with this symbol can cause damages on

Attention
machines or its function.

Advices and information to facilitate working and secure perfect operational

Advice sequences.

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Training and qualification of the personnel
The personnel for installation, use and maintenance must exhibit the appropriate qualification for the
work. Area of responsibility, competence and monitoring of the personnel must be exactly regulated
by the user.

Safe working
All security references, present national instructions for accident prevention as well as internal
instructions for working, use and safety are to be followed.

Consequences
In case of ignoring the security references, endangerments of persons, environment and the
tracking system as well as total loss of requirement on compensation can be the consequence .

For example:
- Failure of important functions of the plant
- Endangerments of persons caused by mechanical effects.

Safety references for the user

Endangerments of electronic electricity are to be excluded. (see details for example in the regulation
of Verband der Elektronik = VDE, Germany).

Safety references for installation and maintenance

Before starting work at the tracking system make sure that the electricity supply has been switched
off. Please follow the instructions to stop the drive in this guide.

Inappropriate treatment

Working security of tracking systems is only guaranteed in case of normal application.

The limit values specified in the technical data are not to be exceeded!

Before installation of the solar modules

Refer to instruction manual of solar modules and inverters for details about electrical and mechanical
installation requirements.

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2. Delivery and storage

Delivery
Tracking systems ETATRACK active are supplied completely from the factory.
Due to high weight of each part of the construction care must be taken during unpacking and
handling.

It is absolutely necessary to wear security gloves and shoes!

3. Delivery contents

Mechanical parts:
-Mounting Pole (1 pc) Square tube 150x150x6, 2,75 m length (1a)
-Traverse (1 pc) Rectangular tube150x100x5, 4,20 m length (1b)
-Cross Beam (1 pc) Rectangular tube150x100x5, 0,90 m length (2)
-Pole connector (4 pcs) Steel angle 63x63x8, 295 mm length (3)
-Cross Beam con. (2 pcs) Steel angle 63x63x8, 330 mm length (3a)
-Hinge fixation (5 pcs) Steel angle 63x63x8, 213 mm length (4)
-Hinge lower part (6 pcs) Welded steel 200x70x120 mm (5)
-Hinge upper part (6 pcs) Welded steel 150x50x30 mm (6)
-Centre Rail (6 pcs) Square tube 50x50x4, 3,40 m length (7)
-Connecting tube (2 pcs) Square tube 40x40x4, 4,20 m length (8)
-Connection clamp (12pcs) Steel angle 50x50x5, 70 mm length (9)
-Upper motor fixation (1 pc) Steel angle 50x50x5, 70 mm length (10)
-Lower motor fixation (1 pc) Steel angle 276x276, 63x63 mm (11)
-Module fixation clamp(48 pcs) Stainless steel 50x50x1,5 mm (12)
-Standard parts (1 set) Bolts, washers, nut
-Linear motor (1 pc) (13)
-Controller fixation (2 pcs) (14)
-Grounding cable (1 pc) 16x500 mm
Controller
- Electronic box incl. Lead Acid Battery and Controller (15)

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4. Assembly preparation

Foundation

Before mounting the tracking system a suitable foundation is necessary. A surface foundation for the
tracking system has to be constructed to assure the correct operation for the indicated maximum of
module surfaces (see fig. 4.1)

Advice While setting mounting pole into foundation (1) take care of the exact adjust-
ment of cross holes into EAST – WEST direction!
To get the right adjustment use some helping material (see figure
hereunder).
South direction
(North direction for
Southern Hemisphere)
Wooden or metal strip

(1a) SOUTH

Cross drilling!

Fastening clamp

During drying-procedure of foundation please use wooden boards to support mounting pole.
In case of installation on flat roofs, stability can be effected with clamping belts.

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 Mounting pole (1a) SOUTH

Fastening clamp

80 cm

Diameter
220 cm
fig. 4.1 Dimensions of surface foundation

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 SOUTH

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5. Mounting
5.1 Required tools:
- 2x ring or open ended flat spanner 24 mm
- 2x ring or open ended flat spanner 10 / 13 mm
- 2x ring or open ended flat spanner 14 / 15 mm
- Level
- Rubber or plastic hammer
- Fastening clamp
- Torque wrench (refer to page 15 for nominal torques)

4x
South direction
(North direction for
Southern Hemisphere)

1b
1a

2 x 3a

5.2. Hardened foundation

9x
M16 x 190 mm

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 5.3 Preparing the rails and hinges

1 pc M12 x 95 mm

Scale 1:1

2 pcs M10 x 80 mm

Scale 1:1

The grounding cable will be installed on the upper traverse (17)

The tracking systems have to be grounded under the terms of the local standards

Teeth washer D8
Thin nut M8

Earthing cable

Thin nut M12

Teeth washer D12

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5.4 Fixation of rails on the beam

South direction
(North direction for
Southern Hemisphere)

Advice
Keep attention of lower mounting plate for drive (11)!

Attachment of third upper hinge deviates from

the other five hinges! (See fig. 5.4)

Before tightening the screws align module fixation in parallel line

Dimension „X“: depends on position of fixation holes in the PV modules.

X = Distance between holes – 71.4 mm

12pcs
M12 x 140 mm

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 Reinforcement Profile

View from North to South

(from South to North for Southern
Hemisphere)
Free leg of angle has to point down on
the Eastern (Western for Southern
Hemisphere) side.

Fig. 5.4 Arrangement of lower motor fixation

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5.5. Mounting of solar modules

Each solar module is to be fastened with 4 pcs fixation clamps(12) at the

Centre rails (7). Please start with the following steps:

- Attach the fixation clamps on the module fixations

- Put in the screws M8 x 110 mm from the top into the drillings given at the

centre rails

- Connect the centre rails with connecting tubes (8), connection clamps (9)

as well as upper motor fixation (10).

- Fixation of solar modules

Advice

Before final tightening of screws please check easy swivelling feature. In case of
difficulties the adjustment of the hinges or rails could be not correct. The module
frame has to be aligned right-angled.

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5.6 This instruction shows how to install
the part motor.

Parts list
No. Part Qty.
1 actuator A-R Type 36“ 1
2 screw M12x80, 8.8 1 3
3 screw M12x65(top hole), 8.8 1 7
4 bushing D12 1
5 big washer D12, 3D 1 9
7
6 Bushing 12/16 4 6
7 washer D12 4 6
8
8 self lock nut, M12, 8 2
9 cable straps ( spare ) 3

Upper motor fixation

Attention:
Tighten self lock
nuts only up to
35Nm!

8
6
5
7
7
1

Down Motor fixation

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 5.7 Installation of the controller box

Controller with controller fixation and M4 nut installed on the mounting pole. Distance from
upper edge mounting pole ca. 660 mm.

5.8 Linear motor, motor and gearbox

Attention Cable conduit and water drainages have to

point downwards to avoid that water
penetrates in gearbox housing.

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6. ETATRACK active Controller

Warning:

Wrong wiring (e.g. wrong polarity!) can cause damage of electric or electronic com-
ponents! Components might not fail directly after installation – pre-damages can
result in malfunction after some time of operation.
It has to be made sure, that installation is made by qualified personnel only.
In case of any doubt during installation the supplier has to be contacted.
Damages caused by wrong wiring are not covered by warranty!

Attention:

It has to be made sure, that the voltage of the battery is checked after three month in
stock (including shipping from LORENTZ). The voltage should not drop down below
12.6v, otherwise the battery has to be recharged. Where appropriate, necessary data
wiring has to be taken into account (6.6-6.7).

View inside Controller

Controller Board Battery

Cable Actuator Cable Photovoltaic (PV)-Module

and Data Connection

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 6.1 Overview Controller Board V16/17
Indication Lights:
[a] LED “Power”: Flashes in automatic mode an is permanently on in manual. Off during
reference travel. (See 6.3)
[b] LED “Moving”: Flashes during movement.
[c] LED “Batt. Low”: Flashes if battery voltage is low. (See 6.4)
[d] LED “Error”: Flashes if data communication is missing in Slave operation. (See 6.6)
When data is received again, LED “Error“ goes off.

Control Elements:
[e] Jumper “N, S“: Choosing the hemisphere. N=North, S=South
(Factory setting: Northern hemisphere)
[ f ] Button “West”: In manual mode move one step west.
[g] Button “East”: In manual mode move one step east.

[h] Switch “Manual, Auto”: Change between manual and automatic mode
When changing from manual to automatic mode, the Tracker moves to the
current position. During low battery condition, manual mode can not be chosen.
(See 6.4)
(Factory setting: Manual mode).
Indication Lights
Connections:
[ i ] Terminal “RX-TX“: Connection of data
wiring for Master-Slave operation
Power Moving Batt.low Error V17
[ j ] Terminal “Actuator 2”: Connection of
actuator 2
[k] Terminal “Batt. Solar”: Connection of the [ l ] Actuator Jumper
PV-module (Solar, see 6.4 and 6.5), the Actuator Factory Setting
Red Slave
battery is connected by factory.
[m] Slave Jumper
S
N

[n] Battery Fuse

West

East
Fuse 7.5A

Control Elements
Manual
Auto
Actuator 1 Batt. Solar
A B
Connections

RX TX Actuator 2
S A B
ETATRACK Active
www. .de

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6.2 Installation of the Controller

Take note of the wiring diagram 6.5 the inside view of the controller 6.
Necessary tools: Screwdrivers 0.5x3mm and PH2

The controller uses a PV-module for controlling the daily movement and to charge the controller battery.
In systems with LORENTZ PS-Pump Controller in solar-direct operation (not PSK-Controller),
the controller can be connected to one of the PV-modules of the solar generators in parallel.
For all other applications, a separate PV-module has to be used, to ensure functionality.
Data of the PV-module to be used:
• Voc max: 50V
• Vmp min: 16V
North of 45°N resp. south of 45°S:
• Pmp min: 20Wp
South of 45°N resp. north of 45°S:
• Pmp min: 10Wp
Connection:
• Open the controller box
• Remove the cover of the left cable inlet, insert cable of the actuator
• Close the inlet with the rubber cap provided with the actuator cable
• Connect the 5-pole plug of the actuator to the 5-pole socket “Actuator2”
[ j ] on the controller board
• Check, that the jumper “Actuator“ [ l ] is set
• Insert the cable of the PV-module through cable inlet
• Connect the PV-module cable to the terminal “Solar“
[k] of the controller board (Take care about polarity)
• Insert one of the included battery fuses (7.5A) into the socket [n] of the controller board
• LED “Power” [a] illuminates, the Tracker stays in position
• Execute reference movement according to 6.3
• Check correct operation (see 7.)

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6.3 Reference Movement (Northern Hemisphere)
• Switch the controller to automatic mode [h], reference movement
starts (Initialisation of the linear actuator)
• Tracker moves a few degrees to west (actuator moves out)
• Tracker moves to east position (actuator moves in)
• Tracker moves to west position (actuator moves out)
• Tracker moves to south position (middle position)

• Tracker moves in steps to the west position (during several hours)

• Correct tracking only from the following day of reference movement
• Reference movement takes place each time the voltage supply [k] is
disconnected and reconnected.

6.4 Function and Operation

Tracking Movement: (Automatic mode)
• Sunrise: Tracker moves from the south position (middle position) to
the east position
• During the day: Tracker moves in 12 steps to the west position
• Sunset: Tracker moves to the south position (middle position)

• Battery voltage below 12V: LED “Battlow“ [c] flashes, Tracker moves
to the south position (middle position) and stops the tracking
movement until the battery voltage reaches 12,8V again.
Manual Mode:
• Switch [h] is set to „Manual“
• LED „Power“ [a]: permanently on
• Pushbutton “West“ [ f ]: Movement of the Tracker in steps towards
west
• Pushbutton “East“ [g]: Movement of the Tracker in steps towards east
• Switching [h] to automatic mode: Tracker moves to the current
position

6.5 Wiring Diagram

PV-Module:
Pmp min: 10/20 Wp
Voc max: 50V
Vmp min: 16V Controller Board
V16/17

Battery 12V 5Ah

(included in controller box)
SensorMotor Batt. Solar
AB

RX TX S AB
Sensor Motor

Linear Actuator
Actuator 2

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6.6 Master-Slave Operation (Only valid for V17!)
For the synchronisation of several Trackers in an application, there is the option of a Master-Slave
operation. With this, one controller (Master) forces the other controllers (Slaves) to the current position.
Installation:
• Installation of the controllers according to 6.2, 6.5
• Connection of the controllers via data interface RX-TX [ i ]
• First controller in data string in declared as Master (Jumper “Slave“ is not set [m])
• Further controllers ar declared as Slave (Jumper “Slave“ is set [m])
• 2-pole transmitting interface “TX“ of the Master-Controllers 2-pole receiving interface “RX“
of the first Slave-Controller ( take care of the polarity!)
• Reviewing interfaces “TX“ of further Slave-Controllers can be connected to the transmitting
interface of Slave-Controllers. (see 6.7)
Operation:
• Master-Controller sends the current position information every 5 minutes
• In manual mode no data is sent
• 45 minutes no signal at Slave-Controller: Tracker moves to the south position (middle position),
LED “Error“ [d] flashes
Technical Parameter Master-Slave
Number of Trackers max. 25pcs.
Number of receivers (RX) at one transmitter (TX) max. 2pcs.
Wiring distance between receiver and transmitter max. 20m
Wiring min. 2x 0,75mm²
Cable type shielded or unshielded

6.7 Wiring Diagram Master-Slave Operation

Jumper “Slave“ is set

Master Slave Slave

Slave Max. 2 Slave-

Slave
Controller at
each Slave
TX-Interface

Optional further Slave-Controllers

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 Nominal torques for Bolts ETATRACK active

Screw dimension Strength Torque [Nm]

M16 8.8 (Steel) 230

M12 8.8 (Steel) 93
M10 8.8 (Steel) 54
M8 8.8 (Steel) 27,3
M6 Stainless Steel A2 5,9 - max. 11,3

We recommend an unique control of the screw connections

approximately 6 months after installation.

Comments:

All connection elements for parts of the tracker: steel, zinc coated,
strengthening class 8.8

Screws for standard fixation of solar modules: M6, high grade steel A2

All data are standard values in accordance with the producer’s data which are not
obligatory

As this manual is only a suggestion from our side, the local technical firm has to
verify the installation very carefully.

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