Nextracker NX Horizon

2.4.1 Short Rail

Installation Manual

Nextracker Inc.
6200 Paseo Padre Pkwy
PDM-000176 Rev. C
Fremont, CA USA
nextracker.com
Copyright and Trademarks
©2020 Nextracker Inc. All rights reserved. Nextracker, the logo, and other trademarks are trademarks of Nextracker
and may not be used without permission. The names of other companies, products and services are the property of
their respective owners.
Nextracker provides this documentation without warranty in any form either expressed or implied.
Nextracker may revise this document at any time without notice.
This document may contain proprietary information and should be respected as a proprietary document with
permission for review and usage given only to the rightful owner of the equipment with which this document is
associated.
No part of this document may be reproduced by any means without written permission by Nextracker.

FM18c
Contents
Foreword ....................................................................................................................................................................... 4
1.1 About this Manual ................................................................................................................................................. 4
1.2 Module Specifications .......................................................................................................................................... 5
1.3 Grounding ............................................................................................................................................................... 5
1.4 Summary of Tracker Operation ........................................................................................................................... 6
1.5 Tracker Ratings ....................................................................................................................................................... 6
1.6 Installation Safety ................................................................................................................................................... 6
1.7 Tools Needed for Installation ............................................................................................................................... 7
1.8 Tools Needed for Installation ............................................................................................................................... 8
1.9 Torque Marking Procedure .................................................................................................................................. 9

Task A. Install Piers ................................................................................................................................................... 10

Task B. Install Slew Drive .......................................................................................................................................... 11
Task C. Attach Motor to Slew Drive ......................................................................................................................... 14
Task D. Install Bearing Housing Assemblies............................................................................................................ 16
Task E. Torque Tube Installation .............................................................................................................................. 19
Task F. Align and Secure the Row .......................................................................................................................... 26
Task G. Install Dampers ............................................................................................................................................ 29
Task H. Install Module Rails ...................................................................................................................................... 38
Task I. Mount Modules ............................................................................................................................................. 42
Task J. Row Stowing .................................................................................................................................................. 46
Task K. Install SPC....................................................................................................................................................... 47

2. Commissioning .................................................................................................................................................... 54
3. Operations and Maintenance ............................................................................................................................ 54
4. Key Definisions ..................................................................................................................................................... 54

Revisions for this Manual ........................................................................................................................................... 55

Intro1g
Foreword

Foreword

1.1 About this Manual

This is the installation manual for NEXTracker NX Horizon, NX Horizon ST, and NX Horizon XTR products and
applies to projects using 2.4.1, 2.4.8, 2.4.9, and 2.4.10. It presents detailed installation requirements and
instructions, safety reminders, key steps, and other information. Best means and methods of work may
be determined by the installer.

Important Information
Notes, warnings, and critical items appear throughout this manual and provide important information.

NOTE: Notes contain information that makes assembling NEXTracker components

faster and easier.

WARNING: Warnings alert you to conditions that could lead to critical consequences.

CRITICAL: Critical notes give urgent and important information, and may also note
steps that are critical to installing components so they meet quality requirements.
Disregarding critical information may lead to accidental injury, loss of life, and
damage to equipment, tools or components; it may compromise the NEXTracker
warranty.

Using this Manual and Related Documents

This is a universal manual covering a Nextracker product and is one part of a product documentation
family. It references related documents, including the Construction Set and Part Number Reference List,
which provide project-specific configurations.
• The Construction Set is the document of record for project-specific location details. It outlines the
location of the tracker rows in the project site, including interior versus exterior tracker rows and
related parts. It also defines the specific mechanical tracker row configuration(s) used on each
specific project site, including dimensions, tolerances, and elevation views.
• The Part Number Reference List outlines the project-specific part numbers, names, and quantities
that are referenced in this installation manual.
The images and dimensions in this manual are for general reference to guide field assembly. The actual
parts installed may vary. The Construction Set and the Part Number Reference List are the documents of
record for project-specific, installed product part numbers and location details.

Intro1g
Foreword

Number callouts in this installation manual refer to parts listed in the Part Number Reference List, as
shown in Figure 1-1. Callouts may refer to a part number (example a below) or to an assembly
component (example b below).

10 Torque Tubes 20a Lower Damper Mount

a. Callout referring to part number b. Callout referring to assembly component

Figure 1-1: Numbered callouts that refer to part numbers and assembly components.

1.2 Module Specifications

This racking system may be used to mount a PV module complying with UL 1703 only when the specific
module has been evaluated for grounding and/or mounting in compliance with the included
instructions.
This system has been certified and listed to UL 2703 for electric ground, electrical bonding, fire
resistance, and mechanical load testing. Certification loads are 5 psf up, 10 psf down, and 5 psf
downslope.
The maximum weight allowed on the back of the modules is 0.8 kg per meter (0.53 lb per foot).
See the tables in each section for torque values for applicable fasteners used to mount modules.

1.3 Grounding
Modules are grounded through tracker components to the piers when fasteners are installed correctly.
The overall grounding of the entire racking system is to be investigated to meet the standards of the
latest edition of the National Electrical Code, NEC, to Article 690: Solar Photovoltaic Systems and Article
250: Grounding and Bonding.
The array pier is in direct contact with the earth and is to be installed based on the requirements of a
grounding electrode per Article 250. Any local electrical codes must be adhered to in addition to the
national electrical codes. Figure 1-2 shows the grounding path for modules.

Figure 1-2: Grounding path for modules.

Intro1g
Foreword

1.4 Summary of Tracker Operation

The NX Horizon is a self-powered solar tracker. Once a tracker is installed per this manual and
commissioned, the tracker will rotate to direct the photovoltaic (PV) modules toward the sun as its
position changes throughout the day. Tracker movement is controlled by the self-powered controller
(SPC). The tracker may be turned on/off directly, if necessary, by the disconnect switch/button on the
SPC box (see Task K).
Refer to NX Horizon Operations and Maintenance Manual (MKT-000005) before performing any
operations or maintenance activities on the product. Failure to comply with these instructions may void
the NEXTracker limited warranty and may result in property damage, personal injury, and/or loss of life.

1.5 Tracker Ratings

Tracker ratings are presented in Table 1-1. Direct current and grounding symbols are shown in Figure 1-3.
Table 1-1: Tracker ratings.

Rating Type NX Horizon

Maximum input voltage 30 VDC
Range of input operating voltage 10–25 VDC
Maximum input current (DC) 2A
Operating frequency range or single frequency N/A
Normal operation temperature –30°C to 50°C (–22°F to 122°F)

Direct current symbol Grounding symbol

Figure 1-3: Symbols

1.6 Installation Safety

In addition to general construction best practices, appropriate use of personal protective equipment
(PPE) is essential when handling heavy components and equipment that may be pressurized with
hydraulic fluid or air. Eye protection and ear protection must be part of the PPE.
Adherence to the safety instructions of all third-party vendors is recommended as well. Please be aware
of hazards resulting from projectiles, repetitive motion, noise, vibration, and other aspects of using
hydraulic, pneumatic, and power tools.
For any questions, contact your Nextracker site representative or contact us at:
Email: [email protected]
Phone: +1 (510) 770-2500
Address: 6200 Paseo Padre Parkway, Fremont, CA 94555 USA

Intro1g
Foreward

1.6 Blind Rivet Grip Sizing

Blind rivets of various grip sizes are installed depending on the row location and the wall thickness of the
torque tubes. Interior and exterior rows may use different torque tubes. Table 1 2 specifies the grip sizing
of the blind rivets for varying torque tube wall thicknesses and types of connections along the tracker
row. When installing blind rivets, check the Construction Set to verify torque-tube thickness and see
Table 1-2 for the blind rivet grip sizing to use.

Table 1-2: Blind rivet grip sizing.

Tracker Location Task Installed 2.5 mm 3 mm 4 mm

Torque tube to torque tube adapter E.1 Grip 4 Grip 4 Grip 6

Torque tube to torque tube E.2 Grip 4 Grip 4 Grip 4

Torque tube to upper damper mount without additional G.1 Grip 6 Grip 6 Grip 6
torque tube (end of row)
Torque tube to torque tube with upper damper mount G.1 Grip 6 Grip 6 Grip 6

NOTE: Apply cold galvanizing spray to all blind rivets once installed.

CRITICAL: All blind rivets should be in place and fully inserted before any blind rivets
are swaged.

NOTE: A correctly installed blind rivet must be flush or have up to three rings
remaining on the broken stem, as shown in Figure 1-5. A correctly installed blind rivet
should have a smooth swage on the head of the fastener. Excessive scoring on the
swaged head is a sign that tool maintenance is required.

Fully inserted, head up Securely fastened Incorrectly installed, must

against tube be redone

Grip2f
Foreward

1.7 Tools Needed for Installation

See Table 1-3 to review the tools needed to assemble the Nextracker NX Horizon.
Table 1-3: Tools needed for assembly.

Socket Wrenches
Hex bolt size M4 M6 M10 M12 M20
Socket wrench size, mm 7 10 15 18 30
Deep socket No Yes Yes Yes No
Hex Keys in the Following Sizes
Socket head cap screw size M8 M10 M12
Hex key size, mm 6 8 10
Rivet Tools
Application Install’n Install’n Install’n Power Power Power Pull Return
Gun Gun Nose Source Source Source Pressure Pressure
Option 1 Option 2 Option 1 Option 2 Option 3 Required Required
(psi) (psi)

½-in. blind rivet

2624PTD 2624 913F 940 HPU 5000 1800
(torque tube)

Site
M12 pin and specific,
collar SF-20 N/A confirm 913F 940 HPU 4200 2200
(pier and BHA) with NX

Standard
¼-in. pin and 20V
A1100 PB2500N Air N/A 90 90
collar (module) Compressor Battery

Other Required Tools Optional Tools

• Carpenter’s level or equivalent • Square
• Self-leveling laser and tripod • Tape measure
• Various torque wrenches needed with a range of 5 in-lb to 200 ft-lb • Torque mark pen
• Personal protective equipment • Scissor jack
• Cold galvanizing compound • Leverage bar
• Spud wrench

Tools1h
Foreward

1.8 Torque Marking Procedure

Torque fasteners must have torque markings, as shown in Figure 1-6.
• Torqued marks are made only after the fastener has been tightened with the specified torque
designated in the appropriate torque table for each task.
• Torqued marks should be applied with a clearly visible marking pen or paint pen.
• For a through-bolted connection, a continuous marking line should be applied that covers the nut,
bolt, and the part in contact with the nut, as shown in Figure 1-6.
• For a blind connection, the marking should be applied to the head of the bolt and the part in
contact with the head.
• For quality control (QC) checks, a measured torque value within a tolerance range of ±10% applies
to all fastener torque values and is acceptable with no re-work required.

Figure 1-6: An example of a properly torque-marked fastener.

Tools1h
Task A. Install Piers

WARNING: Refer to the Construction Set for motor pier placement tolerances.

A.1 Install Motor Piers

• Motor piers can be identified by the six holes in each flange.
• Motor pier design details are project specific. Install motor piers as specified by the Structural
Engineer of record and refer to the Construction Set for motor pier placement tolerances.

A.2 Install Array Piers

• Array piers can be identified by four vertical slots in each flange, as shown in Figure A-1.
• Array pier design details are project specific. Install array piers as specified by Structural Engineer of
record for the project and refer to the Construction Set for array pier placement tolerances.

CRITICAL: NEXTracker has multiple product lines with various tube to tube tolerances.
Refer to Construction Set for site tolerances. Pier height plans should be adjusted based
on the product line that is used.

a. Sample motor pier b. Two sample array piers

Figure A-1: Sample motor pier and array piers.

A1c
Task B. Install Slew Drive

B.1 Install Slew Drive Brackets to Motor Pier

1. Place the slew drive brackets on the motor pier as shown in Figure B-1. Insert the M12 pins.
2. Hand tighten the M12 pins and collars—do not swage these fasteners at this point. M12 pins and
collars will be swaged after row alignment in Task F.

1a Slew drive bracket

(2 total)

North

2
M12 pin
3 (12 total)

M12 collar Motor pier

(12 total)

Figure B-1: Install slew drive brackets to motor pier.

ChapterCodeGoesHere
Task B. Install Slew Drive

B.2 Install Slew Drive Assembly

WARNING: The slew drive assembly weighs 99 kg (218 lb). Lift the assembly close to
the slew drive to ensure stability.

NOTE: Ensure correct slew drive assembly is installed. Interior slew drive assemblies are
visually smaller and installed on specific rows depending on site conditions. See
Figure B-2 for the two slew drive assembly types. Refer to Construction Set for where
each type will need to be installed.

1. Place the specified slew drive assembly on the slew drive mount so that the motor mounting
location points east, as shown in Figure B-3.
2. Insert and hand tighten the M20 bolts, flange nuts, and washers. Fasteners will be secured after row
alignment in Task F.

NOTE: Torquing of the bolt head is acceptable when securing the slew drive to the
slew drive mount. See Table B-1 for torque values.

4
Standard slew drive assembly

4
Interior slew drive assembly

Figure B-2: Ensure correct slew drive assembly is installed.

B1d
Task B. Install Slew Drive

4
Slew drive
assembly

1d M20 bolt
(4 total)

1c
M20 washer
(4 total)

East

1b M20 flange nut

(4 total)

Figure B-3: Install the slew drive

Table B-1: Torque values for applicable fasteners

Construction Fastener Type and Torque, Torque, Torque,

Joint Description
Task Part Number Reference in.-lb ft-lb N-m

B.2 Slew drive bracket to slew M20 bolt (1d), flange nut — 175 240
drive (1b), washer (1c)

B1d
Task C. Attach Motor to Slew Drive
1. Ensure proper motor mounting orientation shown in Figure C-1 and place the antenna on the motor
with the antenna flange facing the slew drive.
2. Attach the motor and antenna mount to the slew drive using M12 SHCS, as shown in Figure C-2.
Figure C-2 shows a motor O-ring. See Table C-1 for torque values.

CRITICAL: Ensure correct motor mounting orientation as shown in Figure C-1.

CRITICAL: The exposed motor connector head must always be covered with a
weatherproof cap until the self-powered controller cable connector is attached.

Protective
vent on left Connector
head

31
Gen 2.5 Motor

Figure C-1: Motor connector head with vent on left for Gen 2.5.

1a
SPC Antenna
Mount

31
Gen 2.5 Motor

Figure C-2: Attach the motor to the slew drive.

WARNING: Ensure the O-ring maintains a proper seal on the motor adapter plate
before installing the motor.

C2c
Task C. Attach Motor to Slew Drive

1a
Motor O-ring

Figure 3: Motor O-ring

Table C-1: Torque values for applicable fasteners

Construction Fastener Type and Part Torque, Torque, Torque,

Joint Description
Task Number Reference In.-lb ft-lb N-m
C Motor to slew drive M12 SHCS (32) — 45 60
assembly

C2c
Task D. Install Bearing Housing Assemblies

CRITICAL: Ensure correct BHA type is installed depending on row location. Light BHAs
are used on only interior rows. See Figure D-1 for the two BHA types and refer to the
Construction Set for row distinction.

1. Place the bearing housing assembly (BHA) brackets on the array pier; loosely insert the M12 pins and
collars, as shown in Figure D-2.
There are two pairs of slots on the pier. The installed position of the pier determines which holes are
used for bracket installation. If the pier is offset to the north, the southern slots should be used; if the
pier is offset to the south, the northern slots should be used.

NOTE: Determination of slots in the pier is defined by the installed position of the pier
(i.e. if pier offset is to the south, place brackets on northern slots).

8a 8a
BHA handle 5 toggles 3 toggles Light BHA
handle

8d 8d
BHA bracket Light BHA
bracket

Figure D-1: Standard BHAs (left) will be installed on exterior and edge rows while light BHAs (right) are used on interior rows.

NOTE: Standard BHA handles have 5 toggles and thicker brackets marked with a red
stripe. Light BHA handles have 3 toggles and thinner brackets with no marking

CRITICAL: Exterior row BHAs require the use of M12 washers in the foot of the BHA. Two
M12 washers are used per BHA. See the Construction Set for exterior, edge and
interior row distinction.

D3c
Task D. Install Bearing Housing Assemblies

3 8d
M12 collar
BHA bracket
(4 total)
(2 total)

2 M12 pin
(4 total)

Figure D-2: Brackets must be installed on the same side of the pier.

2. Level the brackets in the east–west direction; see Figure D-3. Visually align the brackets relative to
one another, north to south, and ensure the flat upper surfaces form a plane; see Figure D-4. Hand
tighten the M12 pins and collars—do not swage these fasteners yet. M12 pins and collars will be
swaged after row alignment in Task F.
3. Insert the M12 pins through the slots of the BHA handle and mount on top of the brackets, as shown
in Figure D-4. Exterior rows require M12 washers to be installed with the pins; see Figure D-5. Hand
tighten the M12 pins and collars—do not swage these fasteners yet. M12 pins and collars are
swaged after row alignment in Task F.

Side View

Figure D-3: Level the brackets. In the east-west direction.

NOTE: Ensure that the flat upper surfaces of the brackets form a level plane along the
row from north to south. It is acceptable if the brackets do not line up front to back of
the pier.

D3c
Task D. Install Bearing Housing Assemblies

Top view

Acceptable

Figure D-4: Align the brackets north to south.

2
8a
M12 pin
BHA handle

3
M12 collar

Figure D-5: Attach the BHA handle to the brackets. Interior and edge row BHAs do not use the M12 washers.

1a
M12 washer
(2 per BHA)

Figure D-6: Exterior row BHAs require M12 washers to be installed with the pins.

D3c
Task E. Torque Tube Installation

E.1 Attach Torque Tubes to the Slew Drive Assembly

NOTE: Torque tube type and location are project specific. Refer to the Construction
Set for locations and to Table 1-2 for correct associated blind rivet sizes.

1. Starting at the slew drive, insert swaged ends of the torque tubes into the slew drive assembly, as
shown in Figure E-1. Ensure that the module rail alignment holes on the torque tubes face up.
2. See Table 1-2 for blind rivet sizing and fasten the torque tube to the slew drive assembly (Figure E-2).
Apply cold galvanizing spray after the fastener has been installed.

Slew drive assembly

10
Torque tube
(swaged end)

Figure E-1: Insert torque tube.

NOTE: All torque tubes will use 8 blind rivets for each torque-tube to torque-tube-
adapter connection (16 total per row).

See Construction Set for torque tube locations and Table 1-2 for correct associated
blind rivet sizes.

NOTE: Ensure the rail alignment hole is clear from torque tube adapter to torque
tube. Use a pry bar for the alignment hole positioning.

NOTE: Apply cold galvanizing spray to all blind rivets once they are installed.

E8c
Task E. Torque Tube Installation

Figure E-2: Insert blind rivets into the torque tube adapter holes.

WARNING: See Table 1-2 for correct associated blind rivet sizes.

WARNING: All blind rivets should be in place before any blind rivets are swaged.

E.2 Install Torque Tubes

NOTE: Torque tube type and location are project specific. Refer to the Construction
Set for type and location details.

NOTE: Torque tubes weigh between 67–105 kg (148–232 lb), depending on length
and wall thickness.

1. Moving from the slew drive outward, slide the swaged end of the torque tube into the non-swaged
end of the adjacent torque tube (Figure E-3). Ensure that the module rail alignment holes on the
torque tube face upward.
2. See Table 1-2 for blind rivet sizing and fasten the torque tubes using the appropriate blind rivets
(Figure E-4). Apply cold galvanizing spray to each blind rivet after the fastener has been installed.
3. Continue steps 1 to 3 until the row is complete.

E8c
Task E. Torque Tube Installation

10
Torque tube
(non-swaged end)

Figure E-3: Slide the torque tube into the adjacent torque tube.

Blind rivet
(6 total)

Figure E-4: Fasten torque tubes using the appropriate blind rivets.

NOTE: Apply cold galvanizing spray to all blind rivets once they are installed.

WARNING: See Table 1-2 for correct associated blind rivet sizes.

E8c
Task E. Torque Tube Installation

E.3 Install BHA Module Rails

NOTE: Assembled BHA module rails can be placed onto torque tubes before torque
tube fastening.

1. Using the rail alignment tab and the torque tube alignment hole as guides, place the alignment tab
of the BHA module rail into the alignment top hole. Slide the BHA pin through the BHA handle, as
shown in Figure E-5.
2. Insert the U-bolt into the BHA module rail from under the torque tube and align the module rail.
Hand tighten the nut and the jam nut, shown in Figure E-6. Do not fully torque until BHA module rails
are aligned.

NOTE: Use a digital level across the length of the BHA module rail. Ensure that each
rail is level (within 1.0 degree) relative to the rail that it shares a module with. This
applies to all rail types—module rail, BHA module rail, and first module rail.

1a
BHA module rail

Front view
BHA pin

Pin notch facing

downward

Figure E-5: Install BHA pin and rail.

E8c
Task E. Torque Tube Installation

8e
M10 serrated
flange

8c
U-bolt

Figure E-6: Securely fasten the BHA rail.

3. Ensure that the notched ends of the BHA pin are fully inserted and protruding from the rail, as shown
in Figures E-7.
4. Align each rail so that they are parallel within ±1°. See Figure E-8 for details.
5. Once the BHA rails and pin have been aligned, see Table E-1 for torque values. Once serrated
flange nuts are secured, place and torque the jam nut according to Table E-1. See Figure E-9.

NOTE: The jam nut is shipped separately from the BHA.

CRITICAL: Ensure that both notches of the BHA pin are fully inserted through their
respective BHA rails before fully fastening BHA rails. See Figure E-7.

E8c
Task E. Torque Tube Installation

1a

ALIGNED NOT ALIGNED

Pin end
recessed

Figure E-7: Ensure that each end of the BHA pin is fully inserted and protruding from rail.

CRITICAL: Visually check that BHA rails are installed perpendicular to the torque tube
as shown in Figure E-8.

E8c
Task E. Torque Tube Installation

Top view BHA rails ⊥ to torque tube

Figure E-8: Visually ensure that the BHA module rails are installed square to the torque tube.

1a
Jam nut

Figure E-9: Install BHA rail.

Table E-1: Torque values for applicable fasteners.

Construction Fastener Type and Torque, Torque, Torque,

Joint Description
Task Part Number Reference in.-lb ftb N-m

E.3 Bearing housing rail to M10 serrated flange nut (8e), — 18 24.4
U-bolt jam nut (8f)

E8c
Task F. Align and Secure the Row

F.1 Align the Torque Tubes and Secure the Row

1. Align all BHAs and torque tubes in the north-to-south, east-to-west directions and vertically down the
row. Adjust components as needed to achieve alignment within the tolerances defined in the
Construction Set.
CRITICAL: NEXTracker has multiple product lines with various tube to tube tolerances.
Refer to Construction Set for site tolerances. If the tube is outside of the referenced
tolerances, use the pier slots to adjust the height of the BHA. See Figure F-1 for
measurement details.

2. Ensure each BHA handle is correctly positioned relative to the slew drive and the end of the row, as
shown in Figure F-1. Placement must fall within ±6.3 mm (0.25 in.) of the stated distances. Ensure that
the minimum space between the BHA handle and the module rail is maintained. Do not push the
BHA handle all the way up to the rails.

Figure F-1: Tube to tube deflection is measured by comparing angles at the center of tubes. Refer to Construction Set for site
tolerances.

All temperatures
35 mm (1.4 in)

Figure F-2: The measurements shown are used for all temperature ranges to determine accurate BHA placement and correct
handle position.

F1e
Task F. Align and Secure the Row

F.2 Secure Fasteners

1. Once the row has been aligned, swage all M12 pins and collars.
2. Secure all previously hand-tightened fasteners; see Table F-1 for a checklist of items to confirm
proper procedure.
3. Torque all fasteners according to values given in tables at the end of each task.
4. M12 fasteners are semi-permanent and require specialized tools to uninstall. Confirm proper
alignment before swaging.
Table F-1: Checklist to confirm proper procedure.

Task Fasteners
F Secure M12 pins and collars.
B.2 M20 bolt, washer, and nut; see Table 1-2 for torque requirements.
B.1 Secure M12 pins and collars.

CRITICAL: Ensure that both ends of the BHA handle are resting flush on the BHA
bracket, without gaps, before swaging. If there is a gap, adjust the brackets as
needed. Never use the rivet tool to pull a gap closed. Ensure the rivet tool nose is at a
90-degree angle to the bracket before swaging. If swaging is performed while there
is a gap between hoop and bracket, or when the nose is misaligned (as shown in
Figure F-3), components and tools may be damaged.

Ok to swage Do not swage

Ok to swage Do not swage

F1e
Task F. Align and Secure the Row

Figure F-3: Examples of when it is okay to swage and when you should not swage.

WARNING: If M12 pins and collars need to be removed, use a grinder or hydraulic
cutting tool.

WARNING: Check security of M12 pins and collars after installation via visual
indicators that show proper swaging, as shown in Figure F-4.

a. M12 collar unswaged b. M12 collar swaged

Figure F-4: Visual indicators of proper swaging: an M12 collar unswaged and swaged.

F1e
Task G. Install Dampers

G.1 Install U-Bolt to Upper Damper Mount

NOTE: Damper placement is project specific. Interior and exterior rows have varying
damper quantities. See the Construction Set for details.

NOTE: Upper damper mounts are placed on the side of the pier closest to the slew
drive.

1. Dampers installed on a row are shown in Figure G-1.

22
Dampers

Figure G-1-1: Double damper after assembly is completed.

2. Place the upper damper mount under the torque tube on the side of the pier closest to the slew
drive, so that the arm is away from the BHA, as shown in Figure G-2.
3. See Table 1-2 (in installation manual) for blind rivet sizing; place blind rivets on both sides of the
double upper damper mount into the torque tube (Figure G-3). Do not fasten until U-bolt is securely
attached.

G2b
Task G. Install Dampers

Double upper
damper mount arm

Slew Drive

Figure G-1-2: Place each double upper damper mount under the torque tube, on the side closest to the slew drive, and at
the correct distance from the pier.

Blind rivet
(2 total)

Figure G-1-3: Place double upper damper mount on the torque tube using blind rivets.

CRITICAL: Do not fasten blind rivets until after U-bolt is securely installed.

WARNING: See Table 1-2 for correct associated blind rivet sizes.

4. Insert and hand tighten the nuts to the U-bolt (Figure G-4). Torque only after proper alignment is
confirmed. See Table G-1 at the end of Task G for torque values.

G2b
Task G. Install Dampers

19b
U-bolt

1a
M10 serrated
flange (2 total)

Figure G-1-4: Insert and hand tighten the U-bolt.

5. Once the U-bolt has been installed, fasten blind rivets using the rivet tool.
6. After the fasteners have been installed, apply cold galvanizing spray to each blind rivet.

G2b
Task G. Install Dampers

G.2 Install Lower Damper Mount to Pier

1. Install the lower damper mounts in the slotted holes on the bottom of the pier. Measure the vertical
spacing from the bottom of the BHA bracket. Vertical spacing and orientation detailed in the
Construction Set and shown in Figure G-5. Figure G-6 shows proper mounting.

Measurement found in
the Construction Set

Figure G-1-1: Install the lower damper mounts with the correct vertical spacing.

CRITICAL: Ensure correct damper mount spacing. See Construction Set for
dimensions.

NOTE: Double damper piers require two lower damper mounts on the same pier.
Refer to Construction Set for details on damper mounting locations.

G2b
Task G. Install Dampers

20a
Lower damper mount

2
3
M12 pin

M12 collar

Figure G-1-2: W-Beam / C-Channel Pier M12 pin and collar installation for both W-beam and C-channel piers.

2. Once the bracket has been aligned, secure with hardware and swage M12 collars.

G2b
Task G. Install Dampers

G.3 Install Damper to Damper Mounts

CRITICAL: Damper orientation in visuals is for reference only. Ensure the damper
orientation is correct as shown in Figure G-7 and check each damper for an “UP”/
“TOP” label on either the rod or body end.

1. Dampers are oriented based on type. Ensure damper orientation is correct (see Figure G-7).
2. Attach the dampers to the upper and lower mounts (Figures G-8 and G-9) by installing the spherical
rod ends on the M10 carriage bolts followed by the castellated nut torqued to snug tight.
a. Snug-tight condition requires all plies in the connection to be pulled into firm contact and the
nut tightened sufficiently to prevent removal without a wrench.
3. Tighten the castellated nut to align a slot with the carriage bolt hole and insert the cotter pin (Figure
G-10a). Bend the cotter pin prongs in opposite directions to secure its fit (Figure G-10b).

CRITICAL: Ensure that there are no gaps between any components along the
carriage bolt.

CRITICAL: Hole in carriage bolt must be aligned with castellated nut slot to allow for
cotter pin installation.

Rod up

Body up

Or

Rod down
Body down

Figure G-1-1: Dampers oriented based on type.

G2b
Task G. Install Dampers

22
Dampers

Figure G-1-2: Damper attachment at the BHA.

19d
Castellated nut
19d
Castellated nut

a. Attach damper to upper mount b. Attach damper to lower mount

Figure G-1-3: Torque castle nut to snug tight.

G2b
Task G. Install Dampers

19d
Hole for
cotter pin
Castellated nut

19e
Cotter pin

a. Install cotter pin in carriage bolt hole prongs b. Spread cotter pin

Figure G-1-4: Cotter pin installation through the castellated nut and carriage bolt.

G2b
Task G. Install Dampers

G.4 Place End Cap on the Torque Tube

1. Place the end cap on the torque tube. Ensure that the tabs snap into corresponding holes, as
shown in Figure G-11.

1a
End cap

Figure G-1-1: Place end cap on the torque tube, making sure tabs snap into holes.

Table G-1: Torque values for applicable fasteners.

Construction Fastener Type and Torque, Torque, Torque,

Joint Description
Task Part Number Reference in.-lb ft-lb N-m

G.1 U-bolt to upper damper M10 serrated flange — 20 27

mount (19c)

G.3 Damper to damper Castellated nut (19d) — Snug tight

mount

G2b
Task H. Install Module Rails

H.1 Install First Module Rails

NOTE: The first module rails on either side of the slew drive assembly (Figure H-1) are
different module rail types from the remaining row module rail. Refer to Part Number
Reference List for part specifics.

1. Insert the module rail alignment tab into the torque tube alignment hole (Figure H-1).
2. Level the module rail and torque the through bolt to the torque value shown in Table H-1. See Figure
H-2.

CRITICAL: Do not use an impact gun to torque the bolt. An accurate torque value
must be measured.

NOTE: Use a digital level across the length of the module rail. Ensure that each rail is
level (within 1.0 degree) relative to the rail that it shares a module with. This applies to
all rail types—module rail, BHA module rail, and first module rail.

Torque tube
alignment hole

27a
First module rail

Figure H-1: Insert the module rail alignment tab into the torque tube alignment hole.

H8c PDM-000123 Rev. A

Task H. Install Module Rails

27c
M8 through bolt

Figure H-2: Install first module rails.

NOTE: Bolt should be installed at the bottom of the tube and parallel (within ±10°) to
the rail.

H.2 Install Module Rails

CRITICAL: Ensure correct rail type is installed depending on row location. Light rails
are used only on interior rows. See Figure H-3 for the two rail types and refer to the
Construction Set for row distinction.

1. Move each module rail into place by inserting the module rail alignment tab into a torque tube
alignment hole (Figure H-4).
2. Once aligned, securely fasten the module rail through bolt. Refer to Table H-1 for torque values
(Figure H-5).

NOTE: Use a digital level across the length of the module rail. Ensure that each rail is
level (within 1.0 degree) relative to the rail that it shares a module with. This applies to
all rail types—module rail, BHA module rail, and first module rail.

CRITICAL: Do not use an impact gun to torque the M8 through bolt. An accurate
torque value must be measured.

NOTE: Bolt should be installed at the bottom of the tube and parallel (within ±10°) to
the rail.

H8c PDM-000123 Rev. A

Task H. Install Module Rails

25a 25a
Module rail Heavy module rail

Corner tab (4 per rail)

Figure H-3: The standard version (left) has no corner tabs while the heavy version (right) has corner tabs.

25a 25a
Module rail Heavy module rail

End flange hole End flange hole

(4 per rail) (4 per rail)
+
Corner tab
(4 per rail)

Figure H-4: The wide module rails feature end flange holes. Standard version (left) has no corner tabs while the heavy version
(right) has corner tabs.

25a
Module rail

Figure H-5: Align the module rail on the torque tube alignment hole.

H8c PDM-000123 Rev. A

Task H. Install Module Rails

25a
M8 through bolt

Figure H-6: Tighten the M8 through bolt of the module rail.

Table H-1: Torque values for applicable fasteners.

Construction Construction Joint Fastener

Joint Description Fastener Type and
Task Task Description Type and
H.1 First module rail strap to TTA strap (27b), Through — 13 17.6
torque tube bolt (27c)
H.2 Module rail strap to Torque tube strap — 13 17.6
torque tube (25b), Through bolt
(25c)

H8c PDM-000123 Rev. A

Task I. Mount Module

I.1 Install Module

1. Place the module on top of module rails so that the holes in the frame align with the appropriate
module rail holes; see Figure I-1.
2. Insert ¼-in. pin through the module frame and module rail; see Figure I 2.
3. Swage collars onto the ¼-in. pin; see Figure I-3.

NOTE: Use a digital level across the length of the module rail. Ensure that each rail is
level (within 1.0 degree) relative to the rail that it shares a module with. This applies to
all rail types—module rail, BHA module rail, and first module rail.

36
¼-in. pin

37
¼-in. collar

Figure 1: Install modules on rails.

Figure I-2: Insert ¼-in. pin through the module frame and module rail.

I8b
Task I. Mount Module

CRITICAL: Do not attach cable trays or shields to the underside of the panels. The
maximum weight capacity attached to the back of modules is not to exceed 0.8 kg
per meter (0.53 lb per foot).

Before swaging After swaging

Figure I-3: Visual indication showing proper swaging for ¼-in. collars.

I.2 Module Wiring

CRITICAL: Installers must carefully and strictly adhere to the module manufacturer
safety information for the proper installation, maintenance, and handling of their
modules. All module manufacturer instructions and requirements must be read and
understood before attempting to install, wire, and operate and/or service the
module and accompanying electrical equipment.

CRITICAL: This procedure provides simplified, schematic examples of recommended

wire management configurations to avoid contact with tracker mounting
components. All wire management must comply with NEC/IEC standards and local
AHJ requirements for maintaining wires (service loops, cable trays, raceways, etc.).

1. For half-cell module-to-module connections, wires can be routed through the panel rails secured
along module frames to ensure no contact between wires and panel rails. Route wires outside of the
panel rail if length allows adequate clearance from components.
2. For full-cell module-to-module connections, connect wires along or near the edge of modules
depending on module technology.
3. For modules across the BHA gap, shorter leads may require a jumper wire to bridge the BHA gap
which spans approximately 200 mm depending on selected module width. All wires must be
secured a minimum of 400 mm away from the center of the module to provide adequate
clearance from the BHA.
4. Secure cables as needed along module frames using wire clips and/or supports through the unused
mounting holes to avoid interference with tracker components and shading on module rear side.

I8b
Task I. Mount Module

200-mm
BHA gap

Conductors

400 mm
MIN

Figure I-4: Half-cell monofacial and bifacial module wire schematic.

200-mm
BHA gap

Conductors

400 mm
MIN

Figure I-5: Full-cell monofacial module wire schematic.

I8b
Task I. Mount Module

200-mm
Conductors BHA gap

Figure I-6: Recommended bifacial full-cell wiring to minimize rear-side obstruction.

NOTE: Modules with split junction box configurations often have shorter leads and
may require a jumper wire to bridge the BHA gap.

I8b
Task J. Row Stowing

CRITICAL: Once modules have been securely installed, rotate the row to lockout
stow.

1. Plug the hand-held motor controller, shown in Figure J-1, into the tracker motor and rotate the array
to lockout stow.
2. Use a level on the PV panel closest to the motor to set the array angle, as shown in Figure J-2.

NOTE: Lockout stow is within ±5° of maximum allowable tracker angle with the
leading edge of the module toward the direction called out in the Construction Set.
Maximum allowable angle is project specific but is within 5° of the torque tube
touching the BHA hoop.

Figure J-1: Gen 2.5 hand-held motor controller.

Leading edge
of module

Figure J-2: Set the angle of the array in site-specific construction stow direction.

J2f
Task K. Install SPC

K.1 Installation of SPC to Controller Mount

1. Attach SPC to the Controller Mount using M8 serrated flange cap screws. Hand tighten all M8 screws
before torquing (Figure K-1).

NOTE: Remove the plastic packaging of SPC prior to installation.

WARNING: The battery used in this device may present a risk of fire or chemical burn
if mistreated. Do not disassemble, heat above manufacturer’s maximum
temperature limit, or incinerate. Replace battery with NEXTracker-approved battery
only. Use of another battery may risk fire or explosion.

CRITICAL: Hand tighten all M8 cap screws prior to apply final torque value in Table K-
1 when attaching SPC to Controller Mount. Do not use impact gun and do not over
torque.

Controller Mount
13
13d
M8 Screws
(4 total)

SPC 39
Figure K-1: Attach SPC to Controller Mount using M8 cap screw. Hand tighten all before torquing.

K6a
Task K. Install SPC

K.2 Install Controller Mount

1. Position the saddle on the torque tube adapter (TTA) and install the integrated Controller Mount
assembly to the TTA using M10 serrated flange nut and U-bolt (Figure K-3).
2. Hand tighten the Controller Mount to the torque tube. Do not torque M10 nuts yet.
a. The Controller Mount must be hand tightened to allow for adjustments and proper leveling.
b. For the standard flat mount, use digital level to ensure Controller Mount is parallel (±1˚) to first
module or first module mounting rail if is not mounted yet.
NOTE: Controller Mounting locations depend on geography. Sites in the Northern
Hemisphere mount on the southern side of the slew gear facing west. Sites in the
Southern Hemisphere mount on the northern side of the slew gear facing east.

CRITICAL: Ensure U-bolts are installed on the horizontal portion of the TTA and ensure
that this portion is even and not deformed by the adjacent bent portion.

3. The distance between the TTA saddle to the end of the TTA towards the torque tube must be 270mm
+/-10mm (Figure K-2).
4. Apply a digital level against the leveling reference surface on the Controller Mount. Install the SPC
and mount perpendicular to the first module.
a. Center the digital level directly above the torque tube on the first production module or first
module rail, then press the reference (“REF”) button.
b. After setting the reference surface on the digital level, set the digital level on the Controller
Mount leveling surface. Adjust the Controller Mount to get a readout of 90 (+/-0.5) degrees.
c. Keep the digital readout window always pointed away from the slew drive to avoid any offset
from the level.
CRITICAL: The Controller Mount must be installed perpendicular (90° ± 0.5° with a
digital level) to the first production module. Failure to do so will result in interrow
shading and reduced power production.

K6a
Task K. Install SPC

TTA Saddle

End of TTA

Figure K-2: Space the end of the TTA to the TTA saddle at a distnace of 270mm +/-10mm.

13c M10 nut

(4 total)
Controller Mount 13

13g TTA Saddle

U-bolt 13b

a. Installation of flat controller mount on TTA

13c M10 nut

(4 total)

13g TTA Saddle

U-bolt 13b
b. Installation of tilted controller mount on TTA

Figure K-3: Install the controller module to TTA. Hand tighten Controller Mount to torque tube using M10 nut.

K6a
Task K. Install SPC

K.3 Install Smart Panel on Controller Mount

1. Place Smart Panel on the panel mount bracket. Insert M6 serrated cap screw through both the
panel frame and the bracket. (Figure K-4). Secure with M6 serrated nuts and torque to value in Table
K-1.
2. Once SPC box and mount are properly positioned and leveled, torque the M10 nuts to value in
Table K-1.

NOTE: Some projects use an angled panel mount as shown in Figure K-4. Installation
instructions are the same for this mount.

NOTE: To avoid shadow on the first production panel, install the smart panel
+/- 1.0-degree relative to it.

Smart Panel 35
13e M6 screw
(4 total)

Nut 13f

a. Installation of smart panel on flat controller mount

13e M6 screw Smart Panel 35

(4 total)

Nut 13f

b. Installation of smart panel on tilted controller mount

Figure K-4: Installation of Smart Panel to the controller mount

K6a
Task K. Install SPC

K.4 SPC Wiring

1. Insert and screw in the antenna cable on the SPC box. Attach the PV cables from the SPC panel to
the SPC box. See Figure K-5.
2. Connect the antenna to the SPC antenna mount. See Figure K-6.
3. Connect the motor cable from the SPC box to the motor. See Figure K-7.
4. Use a drip loop to secure the motor cable and antenna to the motor. Ensure that the cables have
enough slack for tracker movement. See Table K-2 for minimum bend requirements.

NOTE: Cable management at SPC must consider the minimum bend radius
requirements shown in Table K-2.

NOTE: Secure motor, antenna, and PV cables (with zip ties or the equivalent) to
motor or Smart Panel mounting bracket so they are not loose but allow enough slack
for the full range of daily tracker movement. See Table K-2 for minimum bend radius
requirements for cables.

CRITICAL: Ensure correct motor orientation and connection. See Figure K-7.
For Gen 2.5 motors, the protective vent will be left of the motor connector head and
the right-angle connector of the motor cable must point down.

CRITICAL: Do not use any part of the SPC box (lid, battery door handle, etc.) to
secure cables. Do not route any cables through openings in the Smart Panel bracket.
Keep cables away from any sharp edges of mounting components.

Antenna
connector

PV connectors
Motor cable

Figure K-5: Attach appropriate cables to the SPC box.

K6a
Task K. Install SPC

43
Antenna 43a
M3 screws

33
(2 total)

SPC antenna
mount

Figure K-6: Connect the antenna and insert into the SPC antenna mount.

Vent

Gen 2.5 Motor

Connection

Motor cable

Figure K-7: Motor cable connector head.

Table K-1: Torque values for applicable fasteners.

Construction Fastener Type and Torque, Torque, Torque,

Joint Description
Task Part Number Reference in-lb ft-lb N-m
SPC box to Controller M8 hex screw (15e) 90 — 10
Mount
K.1
Controller Mount to U-bolt (15b) and M10 nut 141 — 16
torque tube (15c)
Smart panel mount to U-bolt (13b/14b) and 141 — 16
TTA M10 nut (13c/14c)
K.2
Smart panel to bracket M6 cap screw (15e) and 75 — 8.5
serrated nut (13f)

K6a
Task K. Install SPC

Table K-2: Minimum bend radius requirements.

Cable Connection Description Minimum Bend Radius

Motor cable 4.33 in. (110 mm)
SPC panel cables 2.56 in. (65 mm)
Antenna cable 2.36 in. (60 mm)

K6a
2. Commissioning
Prior to scheduling at NEXTracker commissioning team to arrive on site, the mechanical installation
contractor must complete, sign, and send the following documents with photographs to the project
manager:
• OPS-000054 Mechanical Checklist
• OPS-000023 Pre-Commissioning Checklist

3. Operations and Maintenance

Prior to performing any operations or maintenance on any components of this system, refer to the O&M
manual. Failure to comply with the following instructions may void the NEXTracker limited warranty and
may result in property damage, personal injury, and/or loss of life:
• MKT-000005 NX Horizon Operations and Maintenance Manual

4. Key Definitions
Term Definition
BHA Bearing housing assembly.
Blind rivet Blind oversized mechanical fastener. Blind rivet fasteners, or blind rivets, are
torque-less fasteners that are swaged using specialized tools. Blind rivets come in
various grip sizes according to use. Refer to Table 1-3 for blind rivet grip sizing.
PV Photovoltaic.
SPC Self-powered controller.
Swage, Swaging Process of changing shape or diameter of material. Swaged end of torque tube is
the end with the smaller diameter. Swaging fasteners is done with a specialized
tool that reduces the collar diameter to create a clamping force.
Interior/exterior piers versus The project-specific Construction Set specifies the type and location of each pier.
interior/exterior row Symbols used for interior and exterior piers are shown here:

Interior rows are identified using interior motor and array piers, including those that
use one or two exterior piers.
Exterior rows are identified as any row that uses all exterior motor and array piers.

BkCh2-3 1f
Revisions for This Manual

Revision Notes Effective Date

A Initial release. 06/21/2018
B Addition of 2.4.9 and updates made to Tasks C, D, E, H, I, J, K. 03/31/2019
C Updated to new company logos and formatting. Updated Task K to 11/18/2020
be consistent with current product.

Back18c
 Nextracker Inc.
6200 Paseo Padre Pkwy
Fremont, CA USA
nextracker.com