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Simple Wireless WiFi Bridge

The SunSpot WiFi Simple Wireless Bridge kit makes connecting field devices simple and you don’t have to be a wireless network specialist to use it. Connect your trackers to the Internet effortlessly and get all the benefits of remote monitoring.

SunSpotSimple

Click for enlarged view

There are no antennas to contend with because the antenna is housed in the radio itself, simply point it towards the opposite radios. Distances can conservatively be up to 1000 feet (longer distances available) with one or more Clients. The SunSpot WiFi is industrial and designed for outdoor use and can be mounted to a 1/2in. conduit to 2.5 in. pipe or use the window mounting kit. There are other bracketing types available.

Proven in Arizona’s 120F summers and Montana’s -20C winters without a single failure, SunSpot is low cost without any reduction in performance. The kit comes with the radios preconfigured and a rugged outdoor carrier class Ethernet cable.wiringPOE_LAN

The Access Point connects to your Local Area Network and is set up to receive an IP address automatically. If you have a restricted network typical in large companies which requires an IT department intervention, we provide instructions to IT Managers for MAC Address resolution and security information.

 

Contact us for large scale WiFi networks for solar fields.

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Amphenol

Wiring Pin Outs

Cable sets come in 3′, 5′ , 8′ and custom lengths complete with Amphenol 90deg connector.

http://trackeripm.us/?p=149

Wind Speed Protection Set Up

The Tracker IPm wind speed setup will accept pulse or 4-20mA  inputs from any commercially available anemometer. You can set it up in m/s or mph as long as you keep the engineering units the same for all the variables ie: meters/sec or mph.

Wind Speed Thresholds

There are 2 wind speed thresholds for each axis found in tab F IN.

  • The lower threshold variable is WIND_HIGH in m/s or mph.
  • The higher threshold variable is WIND_HIHI in m/s or mph.

Protection Positions

You must decide what position in degrees you want the motors to go when each of the thresholds are reached.

  • The lower threshold position variable is WIND_H_ALT for the Altitude motor or WIND_H_AZ for the Azimuth motor found in tab F IN.
  • The higher threshold position variable is WIND_HH_ALT for the Altitude motor or WIND_HH_AZ for the Azimuth motor found in tab F IN.
  • If the values for WIND_H_AZ and WIND_HH_AZ are zero then the azimuth drive will not got into protection mode. Altitude on the other hand will go to zero degrees elevation.

Protection Strategy

On a blustery day and the wind reaches the preset threshold momentarily, it would not make sense for the tracking motor to go in and out of protection mode. The Tracker IPm uses configurable dead bands and  timers to put the tracker into protection mode and leave it until the inclement weather passes.

Alarm Delay Timer

This timer requires the program wait for the respective threshold to be met for the specified time before protection mode is enacted.

  • WIND_ALMDELAY is configured in milliseconds ie 5000 = 5 seconds found in tab L IN.

Dead band

Once the WIND_HIGH speed has been met for the required time, the variable WIND_ALMDB (found in tab F IN) provides a dead band value in m/s or mph that keeps the Tracker in protection mode even though the wind speed has dropped below the WIND_HIGH threshold.

For example say your WIND_HIGH threshold is set at 30 mph and your WIND_ALMDB is set for 5 mph. The unit will go into HIGH protection mode when the wind reaches 30 mph (for the allotted seconds) and will remain in alarm until the wind speed drops below (30-5) 25 mph.

Dwell Timers

There are 2 dwell timer setting in seconds which determine how long the tracker will stay in protection mode after the wind has returned to an acceptable level.

  • WIND_H_DWELL for High threshold in seconds found in tab L IN.
  • WIND_HH_DWELL for High-High threshold in seconds found in tab L IN.

Analog Input

You can utilize the analog input as a primary or secondary wind speed input. The Tracker IPm will take the higher of the two inputs and execute the protection algorithm.

Secondly you can use the analog input with a handheld test meter to test your configuration in case there is no wind

Pulse Input

Refer to the wiring diagram for the proper wire locations on the Tracker IPm.

If your anemometer utilizes a reed switch, then this is a two wire set up. Simply connect one wire to terminal 17 (+) and the other to terminal 34.

For a Hall input this requires a three wire set up with the 3rd wire connected to terminal 18 (-). A pull up resistor may be required so check the manufacturer’s installation instructions for a 24VDC system.

 

 

Quick Start Guide

Complete Wiring & Power Up the Tracker IPm

NOTE: A hard copy of the quick start guide for brush-less motors can be downloaded here: Quick Start Guide hard copy

download

Down Load Tracker IPm Configuration Software

To begin with, down load the I/O Tool Kit software and install it on your Windows PC.You will be sent a TRACKERvxxx.6PJ project file and a registration file by email. Save them in an accessible folder on your PC. The best location would be C:/Program Files/SixnetTools/Projects

Run I/O Tool Kit

Install Registration

File / Import / Registration Info…

Go to the folder where you placed the registration file. Select the file then Open / OK / Close pop-up

Open Project

SelectComm

Figure 1 – Click for an enlarged view

File / Open Project

Go to the folder where you placed the project file. Select the file then Open

 

 

Connect to the Tracker IPm through a Serial Connection

Connect the RS232 port of your PC to the System RS232 Port B of the Tracker IPm. Most new PCs sold today no longer have the 9 pin serial port but a serial to .usB converter is readily available from your local computer score.

.use the RJ45 to RS232 converter that comes in the box with the Tracker IPm to connect an RJ45 patch cable to the RS232 Port B found on the top of the controller.

This is the recommended method to configure your Tracker IPm beca.use it allows connection without IP address issues sometime found on local networks. IC Systems can better provide direct support if your Ethernet port is free to access the Internet.

Device / Select…

Select the radio button “.use com port”

See Figure 1. to the right. The only change you may need to make may be the COM number. See the drop down for all detected ports. OK

 

Connect to the Tracker IPm through an Ethernet Connection

discover

Figure 3 – Click for enlarged View

Tracker IPms are generally shipped with the Ethernet port configured for DHCP. If your local network requires a static IP address, then you will not be able to connect. For the initial configuration, you should determine the IP address assigned by your router by .using the auto connect tool shown to the right.

To discover the IP address: Operations / Auto Detect EtherTRAK Stations…

If you are unable to easily connect to the Tracker IPm then it is highly recommended to connect by serial cable as previo.usly described.

To continue : Device / Select…

SelectEth

Figure 2 – Click for enlarged view

Select the radio button “.use Ethernet”

See Figure 2. to the right. Enter the IP address. OK

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Set Operating Parameters

Operations / Test I/O

A-INs

Figure 4 – Click for an enlarged view

The pop-up is represented in Figure 4 which has been cropped to fit this document. At the bottom, the TD & RD LEDs are represented. If they are not indicating communications, then you are not communicating with the Tracker IPm and this will time out with an error.

There are a number of Tabs at the bottom which this document will have you select to view or set parameters.

 

 

 

 

 

 

Set the Pulses Per Rotation

Select Tab L IN

Unless your Tracker IPm came from the factory preconfigured you m.ust do the following:

See Figure 5. ALT01_PPR and AZI01_PPR represents the number of pulses over a 360 degree rotation for Altitude and Azimuth respectively.

L-IN

L In – Click for enlarged view

Some drives provide this number. The tracking hardware does not need to rotate 360 degrees, it is a theoretical number.

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Example- A Kinematic 3″ Slew with a br.ush motor has the following specifications:

Motor pulses per full rotation: 2:1
Planetary Gear ratio: 236:1
Worm Gear: 62:1

Total Pulses Per Rotation = 2 x 236 x 62 = 29,264

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High light the I/O Value you wish to change, type in the new number. Enter

Also shown is ALTITUDE & AZIMUTH Latency. Leave these at the default 100 for now. These are .used to tune large trackers to prevent overshooting the desired position.

 

 

 

 

Set Location Parameters

Select Tab F IN

See Figure 6. Arrows indicate “Required Information”

F-INlocation

F IN – Click for an enlarged view

  • SPA_ELEV Elevation in meters (zero for sea level)
  • SPA_LATITUDE Latitude in decimals
  • SPA_LONGITUDE Longitude in decimals
  • SPA_PAVG Average local pressure in millibars (ie 1013 at sea level)
  • SPA_REFRACT Atmospheric refraction at sunrise and sunset (.usually 1)
  • SPA_ROTATION Surface azimuth rotation (.usually zero)
  • SPA_Slope Surface slope measured from horizontal (.usually zero)
  • SPA_TAVG Average local temperature (ie 30 deg C)
  • SPA_TD Not required
  • SPA_TZ Not required

High light the I/O Value you wish to change, type in the new number. Enter

Set Limits and Operational Parameters

Continue on Tab F IN

See Figure 6a Arrows indicate “Required Information”

Soft Limits
Soft limits will limit the tracker’s travel through software. If the calibration is in correct then the soft limits will be off by the same amount. You should always .use mechanical limit stops to prevent over travel and damage to the tracker.

Soft limits can be set inside or outside the travel range of the mechanical limits. There are good reasons to .use either strategy.

Inside will save wear on the limit switch mechanisms however if you intend to .use the Auto Cal Option then the soft limit for the minimum travel for both altitude and azimuth m.ust be outside the minimum mechanical switches. You can configure soft limits differently for both minimum and maximum travel.

F-INopts2

Figure 6 – Click for enlarged view

  • ALT_MAX_DEG default 90 deg. sets maximum upward travel limit
  • ALT_MIN_DEG default is zero, sets minimum upward travel limit (can be a negative number)
  • ALT_DB default is 0.2, sets the difference between the sun’s AL location and the tracker in degrees before a movement is made (smaller is more accurate but runs the motor more often)
  • AZI_MAX_DEG default 360 deg. sets maximum Westward travel limit
  • AZI_MIN_DEG default is zero, sets minimum Eastward travel limit
  • AZI_DB default is 0.2, sets the difference between the sun’s AZ location and the tracker in degrees before a movement is made (smaller is more accurate but runs the motor more often)

f you wish to utilize Auto Calibration do not enter a value for soft limits that would prevent the Tracker from contacting the minimum travel limit switches. See Auto Calibration section.

Analog Position Input

The present position of the drive can be determined from a pulse input (e.g., a Hall sensor) or from an analog input. If you are .using an analog feed back to position one or both of your motors enter the Scale Factor.

  • ALT_SCALE
  • ALT_OFFSET
  • AZI_SCALE
  • AZI_OFFSET

The analog inputs are 4-20 mA channels with a raw range of 0-32767. Example; a 90 deg inclinometer which is 4mA at Zero degrees and 20mA at 90 degrees would be 0.0027467 (90/32767).

If you have 4mA at Zero degrees and 20mA at 360 degrees then your Scale Factor would be 0.0109866 (36/32767).

SCALE determines the span of travel based on the signal. OFFSET is a constant in degrees which allows the .user to adj.ust the starting point or the Zero Position.

PV = SCALE * RAW_INPUT + OFFSET

Note: .using analog inputs m.ust be enabled by turning ON this option on Tab D I. The controller will accommodate one Axis being analog and the other pulse DI.

  • ALT_ANALOG
  • AZI_ANALOG

Sunset Stow Position

If you wish to have the Tracker go to a predefined position at sunset, enter the position in degrees. Enter -1 to stay in last position at sunset. If you wish to utilize Auto Calibration at each sunrise do not enter a value that would prevent the Tracker from making the minimum travel limit switches. See Auto Calibration section.

  • ALT01_STOW
  • AZI01_STOW

Soft Calibrate

D-OUT-Calibrate

D OUT – Click for an enlarged view

Select Tab D OUT

 

See Figure 7. The Tracker IPm is shipped in the manual mode for both Azimuth and Altitude. In order to calibrate, the following registers should read

  • ALT01_AUTO MAN
  • ALT01_CALIBRATE ON
  • AZI01_AUTO MAN
  • AZI01_CALIBRATE ON

To change the I/O Value, simply high light the register and toggle by clicking the OFF – ON at the top left of the pop-up.

To adj.ust the position the tracker is pointing, toggle the OFF – ON at the top left of the pop-up for these registers.

  • ALT01_UP Moves the altitude drive towards the horizon 90 degrees*
  • ALT01_DN Moves the altitude drive towards the zenith 0 degrees*
  • AZI01_UP Moves the azimuth drive towards the west (in the northern hemisphere)*
  • AZI01_DN Moves the azimuth drive towards the east (in the northern hemisphere)*

*(The UP & DN nomenclature is based on degrees, yet is counter intuitive to the .user. This will be changed in the next software revision)

See also AUTO CAL

D-OUT-track

It is recommended that once you have calibrated one axis, you put it into service before calibrating the other axis. To start tracking, the registers should read

  • ALT01_CALIBRATE OFF
  • ALT01_AUTO AUTO
  • AZI01_CALIBRATE OFF
  • AZI01_AUTO AUTO
  • TRK01_TRACK Track – This enable the SPA calculation and would not need to be turned off for calibration

Close the tool kit. The values are retained in non-volatile memory in case of a power loss. You should be tracking…

Power Supply Wiring Diagram

 

Single Phase AC

PowerSupply 1P

Three Phase ACPowerSupply 3P

 

 

 

 

 

 

 

 

Auto Calibration

Requires version 3.00 and higher

This assumes that all Location and both axis Motor set up has been completed, wiring is completed and you are ready to track the sun.

Sometimes solar trackers can lose position due to mechanical slop, hysteresis or external forces. By enabling and configuring Auto Cal, the Tracker IPm now utilizes the lower limit switch to recalibrate the tracker each day. You store the memorized calibrated value of the limit switch in a non-volatile register which is passed to the present position value “Pv” whenever the switch is closed.

Tech Tip:

This will permit the tracker to recalibrate itself every morning or permit an operator to easily recalibrate remotely. Simply drive the tracker to the lower limit switch in Manual and return it to Auto and it is re-calibrated.

Set Up

You do not have to know the exact position of the lower limit switch to set it’s value. Simply estimate and calibrate it using the sun using this procedure.

Azimuth (Disregard for Single Axis or Parabolic Trough)

1. Either through the I/O Tool Kit’s Test I/O (Tab VDO) or Web Control, ENABLE Auto Calibration by turning on AZI01_AUTO_CAL.

2. Enter the approximate (estimated) azimuth in degrees of the minimum limit switch in AZIxx_ZERO. It does not have to be exact.

3. Now move the tracker to contact the limit switch. Put the Tracker IPm into MANUAL by turning off AZI01_AUTO and turning on AZI01_CALIBRATE.

4. Turn on AZI01_DN and wait for the tracker to stop moving when it contacts the limit switch. This is indicated by AZI01_ZMIN changing to On.

5. Turn off both AZI01_DN and AZI01_CALIBRATE

6. Turn on AZI01_AUTO. This should return the Tracker IPm to automatic tracking. This is when you calibrate the limit switch and you can do this any time while the tracker is in Auto.

7. If the tracker is not on sun, enter a value in degrees (including decimals) to AZI01_CORRECTION. The number can be a rough estimate and can be plus or minus depending which direct you want to go. By looking at the results, you can change this number as many times as needed until the tracker is on sun while AZI01_AUTO is in AUTO. Then you are done with azimuth Auto Cal. The next time the tracker contacts the limit switch it will add the correction to the limit switch’s azimuth and render it’s exact position in memory.

8. The calibration is complete. By repeating steps 3 – 6 you can prove the accuracy of the calibration.

Note the soft limit AZI_MIN_DEG and the AZI_MIN_DEG set  in I/O Tool Kit’s Test I/O (Tab VFI)  or Web Control must be a lower value than the calibrated value of the minimum limit switch otherwise the tracker will never reach the limit switch.

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Altitude (same procedure)

1. Either through the I/O Tool Kit’s Test I/O (Tab VDO) or Web Control, ENABLE Auto Calibration by turning on ALT01_AUTO_CAL.

2. Enter the approximate azimuth in degrees of the minimum limit switch in ALTxx_ZERO.

3. Now move the tracker to contact the limit switch. Put the Tracker IPm into MANUAL by turning off ALT01_AUTO and turning on ALT01_CALIBRATE.

4. Turn on ALT01_DN and wait for the tracker to stop. This is indicated by ALT01_ZMIN changing to On.

5. Turn off ALT01_DN and ALT01_CALIBRATE

6. Turn on ALT01_AUTO. This should return the Tracker IPm to automatic tracking. This is when you calibrate the limit switch but you can do this any time.

7. If the tracker is not on sun, enter a value in degrees (including decimals) to ALT01_CORRECTION. The number can be a rough estimate and can be plus or minus depending which direct you want to go. By looking at the results, you can change this number as many time needed until the tracker is on sun while ALT01_AUTO is in AUTO. The next time the tracker contacts the limit switch it will add the correction to the limit switch’s azimuth and render it’s exact position in memory.

8. The calibration is complete. By repeating steps 3 – 6 you can prove the accuracy of the calibration.

Note the soft limit ALT_MIN_DEG and the ALT_MIN_DEG set  I/O Tool Kit’s Test I/O (Tab VFI)  or Web Control must be a lower value than the calibrated value of the minimum limit switch otherwise the tracker will never reach the limit switch.

Standard Calibration 2 Axis

Standard Calibration is the simplest method of calibrating directly from tool kit.

This assumes that all Location and both axis Motor set up has been completed, wiring is completed and you are ready to track the sun.

Tech Note:

If you want to use Auto Cal do not use this procedure otherwise make sure Auto Cal is not enabled. See registers ALT01_AUTO_CAL and AZI01_AUTO_CAL on the same tab.

Select Tab D OUT

See Figure 7 below. In order to calibrate, the following registers should read;  (Disregard I/O Tag Names beginning with AZI for Single Axis or Parabolic Trough)

  • ALT01_AUTO                       MAN
  • ALT01_CALIBRATE                 ON
  • AZI01_AUTO                       MAN
  • AZI01_CALIBRATE                  ON
  • TRK01_TRACK                          ON

To change the the Auto/Manual & Calibrate registers, simply high light the register and toggle by clicking the OFF – ON at the top left of the pop-up.

To move the tracker to On-Sun, toggle the OFF – ON at the top left of the pop-up for these registers one axis at a time.

  • ALT01_UP Moves the altitude drive towards the horizon 90 degrees*
  • ALT01_DN Moves the altitude drive towards the zenith 0 degrees*
  • AZI01_UP Moves the azimuth drive in the clockwise direction.
  • AZI01_DN Moves the azimuth drive towards in the counter-clockwise direction.

It is best to calibrate one axis at a time and put it back into Auto immediately (the sun keeps moving). Make sure that the CALIBRATE register is turned off. You are now tracking.

TRK01_ENABLE must be on. This is set by a switch or jumper wire between terminal 5 and terminal 17. LED 9 with light when this circuit is complete.

Next Step: Auto Calibration

Set Night Storage Position

Sunset Stow Position

If you wish to have the Tracker go to a predefined position at sunset, enter the position in degrees.

Caution: Entering 0 (zero) will cause the tracker to stay in last position at sunset.

If you wish to utilize Auto Cal at each sunrise do not enter a value that would prevent the Tracker from making the minimum travel limit switches. See setting that would disable Auto Cal below. Disregard I/O Tag Names beginning with AZI for Single Axis or Parabolic Trough.

  • ALT01_STOW
  • AZI01_STOW

Settings that Disable Auto Cal

  1. Entering a Zero in AZI01_STOW or ALT01_STOW which causes the tracker to remain in place at night. In the morning the tracker will probably go to a value higher that the Minimum Limit Switch.
  2. Entering a value higher than the Minimum Limit Switch position in AZI01_STOW or ALT01_STOW which causes the tracker to  go to a position that never encounters the switch.
  3. Entering a Minimum Soft Limit that prevents encountering the Minimum Limit Switch.

 

Next Step: Calibration

 

Set Location Parameters

This information is important for the accuracy of the tracking system. If you do not know the location’s Latitude, Longitude and elevation, then any GPS device including an automobile GPS  can give you what yo need.

Find your Latitude & Longitude by City

Select Tab F IN

See Figure below. Arrows indicate “Required Information”

  • SPA_ELEV Elevation in meters (zero for sea level)
  • SPA_LATITUDE Latitude in decimals
  • SPA_LONGITUDE Longitude in decimals
  • SPA_PAVG Average local pressure in millibars (ie 1013 at sea level)
  • SPA_REFRACT Atmospheric refraction at sunrise and sunset (usually 1)
  • SPA_ROTATION Surface azimuth rotation (usually zero)
  • SPA_Slope Surface slope measured from horizontal (usually zero)
  • SPA_TAVG Average local temperature (ie 30 deg C)
  • SPA_TD Not required
  • SPA_TZ Not required

High light the I/O Value you wish to change, type in the new number. Enter

If your latitude is below 23 1/2 deg. N then see:   Considerations for Latitudes between 23 ½ N and 23 ½ S

Next Step: Set Limits and Operational Parameters