1Executive Summary
Calle Larga operates Alion Energy Storm Tracker (AST) single-axis trackers controlled by P4Q Electronics "Suntrack" electronics: 86 self-powered Tracker Control Units (TCU) — one per motor — coordinated by a single Network Control Unit (NCU) over a wireless Zigbee 2.4 GHz Modbus mesh. Each TCU is powered by its own dedicated 30 W auxiliary PV panel and LiFePO4 battery, so no power or communication cabling runs to the trackers.
The prospective vendor (Shanghai Solarsurges Technology Co., Ltd.) has stated that both the TCU and the NCU should be replaced. This brief confirms that position is technically forced: the Solarsurges field radio (Sub-1GHz / LoRa mesh) is not interoperable with the installed Zigbee network, so a partial or mixed fleet is not possible — the retrofit must swap the NCU and all 86 TCUs (plus the wind sensor unit) in one campaign.
Key compatibility picture: the self-powered architecture matches (no new field cabling); NCU supply voltage matches (220–230 VAC); PV modules are unaffected by a controller-only swap. The three items that decide feasibility are: (1) the replacement TCU's motor drive rating against the Alion 24 VDC slew-drive motors, (2) mating or re-terminating the motor connector present on all 86 motor pigtails (field-verified as WEIPU SP21 series 3-pin screw-coupling; P4Q drawings state Binder 99-5606-75-03), and (3) SCADA re-integration and Chilean RF homologation. Section 5 lists every point the vendor must confirm.
2Installed System
All values below are extracted from the original manufacturer documentation and as-built drawings held by iEnergia. Each claim carries its source document and page.
2.1 TCU — P4Q Suntrack "Self-Powered" tracker controller (×86)
| Identification & enclosure | |
|---|---|
| Manufacturer / model | P4Q Electronics (Suntrack), Self-Powered controller, Zigbee variant DS p.1,14 |
| Enclosure | Extruded aluminum 6060 + ASA covers; membrane keypad; external emergency stop; fuse holder; Gore-Tex vent DS p.2,5 |
| Dimensions / weight | 344 × 167 × 135 mm; 2.8 kg (3Ah) / 3.3 kg (6Ah) IM p.13–14 |
| Mounting | 4 holes 9.5 × 11.5 mm, screw spacing 317 × 129 mm, on bracket shared with aux PV panel IM p.21 |
| Protection / environment | IP65 / NEMA 3S; −10…+60 °C; altitude < 3000 m DS p.7 |
| Standards | CE; IEC 61000 EMC series; ASTM B117 (450 h salt mist); ETSI EN 300 328 (radio); IEC 62817 test reports on file DS p.11 |
| Power input (self-powered) | |
|---|---|
| Architecture | Dedicated auxiliary PV panel + LiFePO4 battery — no grid/AC connection at the tracker DS p.5,17 |
| Aux PV panel | 30 W / 36 V, monocrystalline, 645 × 345 × 25 mm, ≥ IP65, P/N ZPS2X36C001 ZPS dwg |
| Input voltage window | 26–40 VDC typical (50 V / 1.5 A absolute max) DS p.8 |
| Battery | LiFePO4 8-series, 25.6 V nominal, 3 Ah (8S1P) or 6 Ah (8S2P), CC-CV; fuse 10 A / 15 A. Installed size: TO BE CONFIRMED DS p.9–10 |
| Motor output | |
| Motor commanded | 24 VDC brushed (Alion slew-drive motor) DS p.8 |
| Max motor current | 6 A (3Ah pack) / 12 A (6Ah pack); electronics flag overcurrent > 15.5 A; PCB rated 300 W continuous @ 24 VDC DS p.8,16 |
| Duty limit | Max pulse 30 s at max motor current followed by 10 s rest (6Ah variant note) IM p.13 |
| Circuit | Connector (exact P/N) | Cable | Source |
|---|---|---|---|
| MOTOR | Field-verified (13-Jul-2026): WEIPU SP21 series, 3-pin, screw-thread coupling, CE marked — contacts numbered 1/2/3 (see photos below). ⚠ P4Q documentation specifies Binder 99-5606-75-03 (3-pin bayonet) — the installed connector differs from the documented part. Pinout per documentation: Pin 1 → Motor − · Pin 2 → Motor + · Pin 3 → NC (pin count/numbering consistent with field unit; polarity to be re-verified on site). Motor-side terminations: insulated crimp receptacles 6.35 × 0.81 mm (2.5 mm²) | 2 × 16 AWG, UL 2464, UV-protected, 1650 mm; cable gland M16×1.5 IP68 | Field photo · C16003#38 · IM p.24 |
| DC POWER + (from aux panel) | MC4-compatible female — non-standard part, Sungold Solar P/N FL02701 | PV1-F 2.5 mm² 0.6/1 kV, ~500 mm; gland M12×1.5 IP68 | C16003#01 · IM p.24 |
| DC POWER − | MC4-compatible male | PV1-F 2.5 mm², ~450–500 mm | C16003#02 |
| COMM (local service, RS-485) | Panel: WEIPU SP1312/S4C · aerial plug: WEIPU SP1310/P4 Type I. Pin 1 3V3 · Pin 2 RS485 power · Pin 3 RS485 − · Pin 4 RS485 + | service use only (USB-RS485 converter) | IM p.25 |
| ZB (radio) | Zigbee antenna, 300 mm flying lead, hangs loose downward | — | IM p.24 |
2.2 Control & sensing (inside the TCU)
| Microcontroller | Atmel ATxmega128A3U; USNO SPA solar-position algorithm, computational error < 0.015° DS p.12 |
| Inclinometer | Internal, Kionix KX-023 3-axis, 0.2° accuracy @25 °C — no external position sensor on the tracker DS p.12 |
| Tracking precision | 0.1°; backtracking supported IM p.12 |
| Firmware updates | Local, from SCADA/NCU, or from PC over the field network (remote-update tooling used on site) DS p.13 |
2.3 Field communications
Installed field network: Modbus over Zigbee 2.4 GHz (ETSI EN 300 328), 128-bit AES, 250 kbps, ~1200 m line-of-sight,
mesh topology — every TCU can act as a router; the NCU is the network coordinator.
DS p.11 · IM p.17
Any replacement using a different radio (e.g. Sub-1GHz / LoRa) cannot coexist with the installed fleet — mixed operation is not possible.
Any replacement using a different radio (e.g. Sub-1GHz / LoRa) cannot coexist with the installed fleet — mixed operation is not possible.
2.4 NCU — P4Q Suntrack Network Control Unit X12092#09 (×1, plant-wide)
| Function | Gateway tracker network ↔ SCADA; centralizes positions/alarms; wind-alarm logic sends fleet to safe position; cleaning-position groups 1–8 via disconnect terminal block NCU p.3,10,24 |
| Enclosure ("control box") | Safybox BRES-54 hot-pressed polyester, 500 × 400 × 200 mm, IP66 / IK10, RAL-7035, −30…+120 °C, door opens >180°; ~10.5 kg installed; wall/frame mounted outdoors, connectors at bottom via double-membrane seals + antenna bulkhead BRES cat. · NCU p.11,23 |
| Power input | 100–240 VAC nominal (90–264 VAC range), 50–60 Hz; < 0.80 A @115 V / < 0.60 A @230 V; plant feeds 230 VAC NCU p.10 · PLA-COM-01 |
| Internal PSU | Delta DRC-24V30W1AZ: 24 VDC / 1.25 A / 30 W, DIN rail, Class II double-isolated Delta DS p.1–2 |
| Protections | RCCB EPP DE F63 40 A / 30 mA + MCB C6 + 2× surge arresters EPP DE PS20 (Uc < 320 V, Imax 40 kA, IEC 61643-1); internal 320 V varistor Site photo · NCU p.10 |
| CPU | CPU-Control Suntrack 32H; status LEDs (SW On / Comm / Alarm / Prog); internal RTC backup battery NCU p.25–27 |
| Downstream (to TCUs) | Zigbee 2.4 GHz coordinator serving all 86 TCUs + wind sensor unit; gateway module Digi ConnectPort X2 (XBee→Ethernet); external 2.4 GHz antenna (ZANT24CWFIX) NCU p.13 · Digi DS |
| Upstream (to SCADA) | Ethernet — Modbus TCP to the plant monitoring system (GreenPowerMonitor) via fiber/switch in the inverter station; internal 5-port Ethernet switch (Sixnet SLX-5ES-1); fixed IP on plant LAN; published register map covering the 86 motor addresses PLA-COM-01 · map revD |
| Environment | −25…+65 °C operating NCU p.10 |
| Standards | EMC 2004/108/CE — EN 61000-6-2/-6-4, EN 55011, EN 61000-4-x series; CE NCU p.29 |
2.5 Wind / weather sensing — Suntrack RSU
| Unit | Suntrack RSU (Remote Sensor Unit), ASA enclosure 348 × 276 × 190 mm, IP67, −25…+70 °C RSU DS p.1–6 |
| Power | 90–264 VAC single-phase, 12.5 W typical (internal Delta 24 V/10 W PSU) RSU DS p.7 |
| Sensors | Anemometer ANEMO4403 (+ snow sensor type 260-700 documented); up to 5 sensor inputs (RS-485 / analog / digital) RSU DS p.1,4 |
| Comms | Zigbee to NCU (wireless variant installed); alarms trigger fleet safe-position RSU DS p.1 |
2.6 Plant-level layout & PV modules
| Trackers | 81 trackers: T00S–T49S (50, south field) + T13N–T44N excl. T27N (31, north field) PLA-T-01 |
| Motors / TCUs | 86 motors = 86 TCUs, monitoring IDs 1–86. Five trackers carry two motors each: T00S, T01S, T26N, T28N, T49S PLA-T-01 (Note 3) |
| Strings | 353 strings of 29 modules (per combiner-box table CB01–CB18) ≈ 10,237 modules PLA-T-01 (derived) |
| Tables (mesas) | Tables of 5 or 6 modules (interior/exterior types per layout symbology) PLA-T-01 |
| Tracker mechanics | Alion AST: ballasted single axis, rotation > ±60°, A-frame on concrete track, slew drive + geared table coupling, Storm-Lock (Geneva) stow lock; one drive can operate up to 120 modules Alion DS p.2 |
| Module envelope (tracker) | Framed & frameless supported; string voltage ≤ 1500 V; module current ≤ 15 A Alion DS p.2 |
| PV module | Longi LR6-72PD 350–370M, 72-cell mono PERC, double-glass bifacial. Exact wattage variant: TO BE CONFIRMED Longi DS |
| Dimensions / weight | 1971 × 990 × 6 mm; 27.3 kg Longi DS |
| Electrical (360M @STC) | 360 W; Voc 48.5 V; Isc 9.45 A; Vmp 39.9 V; Imp 9.02 A Longi DS |
| System ratings | Max system voltage DC 1500 V (IEC); series fuse 20 A; Class II Longi DS |
| Junction box / leads | IP67, 3 diodes; output cable 4 mm², 300 mm Longi DS |
| Relevance to retrofit | Controller-only swap — modules, clamps and purlins are untouched. Module data provided for electrical context (string-powered options, aux panel siting). |
2.7 Tracker structure & mounting interface (Alion AST)
Structural data for any vendor that needs to fix hardware (brackets, sensors, controller mounts) to the tracker. Source: Alion layout set 0325_ast_ienergiacallelarga, project 00325, dated 05-22-2018, sheets S5.0–S5.4, plus the Alion proforma BOM of 25-May-2018.
Drawing status: every Alion sheet is stamped "PRELIMINARY — NOT FOR CONSTRUCTION". No later Alion structural revision has been found.
Treat dimensions as nominal and verify critical interface dimensions on site before fabricating brackets.
Not a conventional torque-tube tracker. The 50 mm round tube (labelled "torque tube" on the drawings, "drive tube" in the BOM) is a
rotating drive shaft. The slew drive at the row end spins it. Pinion gears on the tube engage the riveted stainless tooth strip of the
arc gear under each A-frame, and the table pivots on the Ø12 mm clevis pin at the A-frame apex. The tube turns many revolutions
for a single stroke of the table, so it does not hold a fixed angle relative to the modules.
Anything that must tilt with the modules must mount on the Z-purlins, the arc gear or the pivot arm, never on the 50 mm tube or the A-frame, which are fixed. S5.0/5 · S5.3 · BOM
Anything that must tilt with the modules must mount on the Z-purlins, the arc gear or the pivot arm, never on the 50 mm tube or the A-frame, which are fixed. S5.0/5 · S5.3 · BOM
| Part | Dimension / spec | Source |
|---|---|---|
| Drive ("torque") tube | Ø50.0 mm OD / 47.0 mm ID (1.5 mm wall), 5,110 mm long, 6-module table. Pinion-pin holes 25 / 209 / 662 mm from each end, plus 2,456 and 2,654 mm. 5-module table tube is a separate part (BOM 61089). Its length is not shown on S5.3: TO BE CONFIRMED. Tube material is not stated on the sheet. | S5.3/8 |
| Coupling tube (between tables) | Ø75.0 mm OD / 72.0 mm ID, 1,057 mm long, 980 mm between hardware slots | S5.3/4 |
| Pinion gear | Ø110 outer · Ø91 · Ø82 · Ø50 bore (fits the tube), 70 mm wide, Ø7.5 mm pin through tube. Cast stainless steel | S5.3/5 |
| Bushing | Ø90 flange / Ø59 body, 18 mm, 4 × M6. Cast ZA27. Seats in the Ø60 mm hole of the A-frame tie | S5.3/7 · S5.2/1 |
| Lock gear (Storm-Lock) | 115 × 87 mm plate, 2.5 mm, 4 × M8. Cast ZA27 | S5.3/6 |
| Arc gear | 1,111 mm wide (1,065 / 977 mm inner) × 556 mm deep. 1.2 mm sheet, riveted SS tooth strip (4.8 mm SS rivets). Pivot arm on top: 4 × M6 per pivot-arm bracket each side, 2 × M6 at the arc gear each side | S5.3/1–3 |
| A-frame | Legs 1,050 mm, 39° apex, 785 mm base. Pivot = Ø12 × 80 mm stainless clevis pin at the apex. Tie/leg 1.2 mm ASTM A653. Foot 2.0 mm ASTM A1011 Gr 50, hot-dip galvanized, epoxied to the track | S5.2/1–3 |
| Z-purlin (2 per table) | 6,138 mm long (6-module table), 78 × 44 mm section. Ø7 mm holes (7 in plan, 5 in elevation) plus 20 × 3 mm slots (20). M6 at each arc gear, 4 shear tabs per arc gear | S5.2/4–5 |
| A-frame spacing | 6-module: interior table 3,588 mm (2 A-frames), exterior table 2 × 2,247 mm = 4,493 mm (3 A-frames). 5-module: interior 3,021 mm, exterior 2 × 1,716 mm = 3,433 mm | S5.0 · S5.1 |
| Module height above grade | 1,254 mm at 0° · 537 mm at ±45° · 366 mm at ±60° | S5.0/5 |
| Slew drive + motor (×86) | SE5C, 62:1, 12 mm input shaft (BOM 60094). Round male-male adaptor weldment (60183), 2 drive-shaft spacer tubes each (60195). Bracket 3 mm A1011 Gr 50 on a ≥342 kg concrete base, 2 × M10 J-bolts. Motor: Dunker GR53×30 + PLG52 gearbox, 126.5:1 (60093) | BOM · S2.18–19 |
| Controller (P4Q TCU) mounting | Always above the slew drive, under the modules. End rows (details 4–6): TCU on Unistrut rails fixed to the lower flange of the end-row Z-purlin, 4 × Ø9 mm field-drilled holes. Typical rows (details 7–9): TCU + aux panel on Unistrut rails carried by purlin extensions (C-channel, BOM 60086). No field drilling specified. | S5.4 |
| Sheet material | 1.2 mm ASTM A653 CS Type B, 345 MPa min. yield, G90 pre-galvanized or Galvalume per ASTM A792. Fasteners M6 zinc-flake | S5.3 notes |
Downloads: Alion structural extract (P0.1, S2.18–S2.19, S4.0, S5.0–S5.4) · Alion project BOM 25-May-2018. The full 36-sheet layout set and the Alion mechanical installation manual are available on request.
2.8 Current TCU installation — location & fixings
| Interface | Dimensions / fasteners | Source |
|---|---|---|
| Location | One TCU per slew drive (86). It sits at the drive point of the row, above the slew drive, under the modules, on the tilting table, so it rotates with the tracker (internal inclinometer). Mount it vertically on a flat surface, out of direct sun, with the TCU X-axis parallel to the tracker rotation axis | S5.4 · IM p.19,22 · photo |
| TCU body | 344 × 167 × 135 mm, 2.8 kg (3 Ah) / 3.3 kg (6 Ah) | IM p.13–14 |
| TCU → aux panel | 4 flange holes 9.5 × 11.5 mm on a 317 × 129 mm pattern. Fixings supplied with the TCU: 4 × self-tapping screw 4.2 × 25 DIN 7981 A2, 4 × washer Ø4.3 DIN 6798A A2, 4 × large washer Ø4.3 DIN 9021 A2, 4 × U clip nut (for DIN 7970 screws), clipped onto the panel frame. Torque 1.7 N·m. Do not use the mounting holes for grounding | IM p.10,21 |
| Aux panel | 645 × 345 × 25 mm, 2.8 kg. Frame rail 20 mm. Holes 6 × 9 mm slots: 317 mm apart across, at 75 / 204 / 244 / 484 mm from the top edge | ZPS dwg |
| Panel → tracker, typical rows | Unistrut rails ("Universal sheet strut, P4Q", BOM 61526, qty 182 ≈ 2 per TCU) on purlin extensions (C-channel, BOM 60086, qty 162). Each extension bolts to the Z-purlin with nut + bolt through the lower 2 holes at the arc gear. No drilling is specified.
Panel-to-rail hole pair not drawn; the 244 / 484 mm holes are free: TO BE CONFIRMED ON SITE | S5.4/7–9 · OP-MIP-501 p.26 |
| Panel/TCU → tracker, end rows | Unistrut rails fixed to the lower flange of the end-row Z-purlin (table next to the slew drive) through 4 × Ø9 mm field-drilled holes. Ø9 mm suits M8 | S5.4/4–6 |
| Fasteners in the Alion BOM for this scope | M8 × 16 (364) · M8 × 25 (304) · M8 × 45 (40) · M8 nuts (708 = 364 + 304 + 40). All class 8.8, zinc-flake/B695. Per-TCU set: 4 × M5 × 30 hex bolt + 4 × M5 nut + 4 × M5 × 10 socket cap screw (each qty 344 = 86 × 4). Which bolt goes on which joint is not stated in the BOM: TO BE CONFIRMED ON SITE | BOM |
| Motor connection | 1,600–1,650 mm motor pigtail from the TCU to the slew-drive motor, below it. Route and tie the cable to the structure so it can't snag during rotation | E1.2 · IM p.22 |
For a replacement TCU: the simplest retrofit keeps the existing purlin extensions and Unistrut rails. The new controller (and panel, if it has one) should either reuse the 317 × 129 mm pattern, or come with an adaptor plate that bolts to the existing rails with M8 hardware. It must sit within the motor-cable reach (~1.6 m) of the slew-drive motor.
S1Vendor: state exactly what each bracket carries (sensor, controller, panel), its mass and wind area, whether it must tilt with the modules, and the intended attachment point (Z-purlin / arc gear / pivot arm / A-frame / track). Provide a bracket drawing for interface check.Vendor
3Proposed System — Solarsurges
Extracted from the Solarsurges Company Profile & Product Brochure (EN, 12 pages, doc. dated 2026-07-06). The brochure is a company-profile document: it does not state connector types, cable specifications, pinouts, dimensions, weights or mounting details — those gaps are flagged and consolidated in Section 5.
| TCU — Surge Track S350 (closest match to installed architecture) | |
|---|---|
| Power supply | Self-Powered or String-Powered (current-source technology, "no pony panel needed") Bro p.3 |
| Aux PV panel (self-powered) | 60 W / "customizable" — voltage window TO BE CONFIRMED Bro p.3 |
| Battery | LiFePO4, 25.6 V, 3.4 Ah / 6 Ah, CC-CV Bro p.3 |
| Motor type | Brushless / Brushed — voltage & current rating TO BE CONFIRMED Bro p.3 |
| Communication | Sub-1GHz / LoRa Mesh / RS485 / Bluetooth · Modbus RTU · zero-config self-forming mesh Bro p.3 |
| Protection / environment | IP67; −35…+60 °C; altitude < 4000 m Bro p.3 |
| Tracking | < ±1° accuracy; range −60…+60°; astronomical algorithm + position sensor; backtracking; night return Bro p.3 |
| Consumption | 0.05 kWh/day Bro p.3 |
| Protections | Overcurrent; over/under-voltage; wind / snow / rain modes (require sensors) Bro p.3 |
| Other TCU variants | AC150/350/450 (90–264 VAC) · DC24 (24 VDC) · S350-MD0X string-powered multi-drive Bro p.9–11 |
| Motor Drive Unit (MD0X) | 24 V rated, 150 W rated, IP65, −30…+60 °C Bro p.11 |
| Connectors / cables / dimensions | NOT STATED IN BROCHURE — TO BE CONFIRMED |
| NCU | |
|---|---|
| Power supply | 220 VAC / 24 VDC Bro p.4 |
| Communication | Sub-1GHz / LoRa Mesh / RS485 / 4G / Ethernet Bro p.4 |
| Protocols | Modbus RTU / MQTT — Modbus TCP server not explicitly stated: TO BE CONFIRMED Bro p.4 |
| Protection / environment | IP65; −30…+60 °C; < 4000 m Bro p.4 |
| Features | Edge computing (local aggregation & anomaly detection); GPS; bulk parameter config; broadcast control; OTA firmware for NCU and TCUs; historical data query; weather-station integration Bro p.4 |
| Enclosure / PSU / protections | NOT STATED — TO BE CONFIRMED |
| Ecosystem | |
| SCADA | SurgeTrack Solar SCADA — on-premise / cloud / mobile; Golang+Vue stack, MySQL + TDengine + Redis, TLS Bro p.5 |
| Weather station | Ultrasonic wind speed/direction, temperature/humidity, laser snow depth, tipping-bucket rain gauge, acoustic hail flux Bro p.6 |
| Control logic | Auto-stow at 18 m/s wind; adaptive cadence; smart backtracking; AI tracking (+1–8% claimed, 2 GW fleet validation claimed) Bro p.7 |
| Drive architectures | 1C1C (one controller per motor, 0.1°) and 1C2C (one controller drives two motors, ±0.3° sync, −50% controllers, −40% cabling) Bro p.8,11 |
| Certifications stated | ISO-9001, CE, IP67 test, EMC, built-in surge protection Bro p.2,12 |
| Not stated | IEC 62817 · Chile RF homologation (SUBTEL) · UN38.3 · warranty terms — TO BE CONFIRMED |
4Compatibility Matrix
Verdict per row: ✅ compatible ⚠️ needs adapter / verification ❌ mismatch TO BE CONFIRMED. Scope: controllers only — Alion tracker mechanics and Longi modules remain in place.
4.1 Input power & cabling
| Item | Installed (P4Q Suntrack) | Proposed (Solarsurges) | Verdict |
|---|---|---|---|
| TCU supply architecture | Self-powered: 30 W/36 V aux panel + LiFePO4 25.6 V — zero field cabling | S350 self-powered (60 W / customizable panel) or string-powered; LiFePO4 25.6 V | ✅ matches |
| Reuse of existing aux panels | 86× ZPS2X36C001, 30 W / 36 V, MC4 leads (input window today 26–40 V) | "60 W / customizable" — acceptance of 30 W / 36 V input not stated | TO CONFIRM |
| Motor drive | 24 VDC brushed, ≤ 6 A per TCU, overcurrent flag > 15.5 A | Brushed supported; MD0X drive 24 V / 150 W; main-TCU ratings unstated | ⚠️ verify current |
| NCU supply | 100–240 VAC (230 VAC on site), 24 VDC internal rail | 220 VAC / 24 VDC | ✅ |
| Cable gauges | Motor 2×16 AWG (1650 mm pigtail); panel PV1-F 2.5 mm²; captive to TCU glands | Not stated | TO CONFIRM |
| Weather sensor power | RSU: 90–264 VAC, 12.5 W | Weather station power not stated | TO CONFIRM |
4.2 Connectors
| Item | Installed | Proposed | Verdict |
|---|---|---|---|
| Motor connector | WEIPU SP21 series 3-pin screw-coupling (field-verified 13-Jul-2026; P4Q docs state Binder 99-5606-75-03 bayonet — installed part differs). Pinout 1 = M−, 2 = M+, 3 = NC; motor-side 6.35 mm crimp receptacles | Not stated | ⚠️ mate SP21 or re-terminate |
| Aux panel connector | MC4-compatible pair (female is non-standard Sungold FL02701) | Not stated | TO CONFIRM |
| Service port | WEIPU SP1312/S4C RS-485 (PC + USB converter) | Bluetooth / mobile / PC debugging; physical port unstated | ✅ functional equivalent |
| NCU cable entries | BRES-54 membrane seals + antenna bulkhead | Enclosure/entries not stated (IP65) | TO CONFIRM |
4.3 Communications
| Item | Installed | Proposed | Verdict |
|---|---|---|---|
| Field network NCU↔TCU | Modbus over Zigbee 2.4 GHz mesh, AES-128 | Sub-1GHz / LoRa mesh / RS485 / Bluetooth — no Zigbee | ❌ not interoperable |
| Consequence | Full-fleet swap required in one campaign: 1 NCU + 86 TCUs + wind sensing (consistent with the vendor's stated position — mixed operation impossible) | ⚠️ plan accordingly | |
| RF regulatory (Chile) | 2.4 GHz ISM, ETSI EN 300 328 (operating today) | Sub-1GHz band & SUBTEL homologation not stated (Chile band plan 915–928 MHz) | TO CONFIRM |
| Upstream to plant SCADA | Ethernet Modbus TCP to GreenPowerMonitor; published 86-address register map | Ethernet / 4G available; protocols listed Modbus RTU / MQTT | ⚠️ Modbus TCP + map to confirm |
| Wind protection chain | RSU + anemometer → NCU wind alarm → fleet safe position | Weather station → NCU; auto-stow at 18 m/s | ✅ equivalent (threshold config to confirm) |
4.4 Module & mechanical compatibility
| Item | Installed | Proposed | Verdict |
|---|---|---|---|
| PV modules | Longi LR6-72PD double-glass bifacial (1971×990×6 mm, ≤1500 V, Imp ≈ 9 A) on Alion clamps | Controller-only retrofit; vendor claims module-type adaptability | ✅ unaffected |
| Tracking range | Alion AST rotation > ±60°; TCU tracks with internal inclinometer | −60…+60° range; astronomical + position sensor | ✅ range matches |
| Stow interlock | Storm-Lock (Geneva mechanism) engages at stow | Stow logic parameters not stated | TO CONFIRM |
| TCU mounting | Bracket on A-frame; 4 holes, 317×129 mm pattern, shared with aux panel | Dimensions / mounting not stated | TO CONFIRM |
| Dual-motor trackers | 5 trackers (T00S, T01S, T26N, T28N, T49S) run 2 motors = 2 TCUs each today | 1C2C mode: one controller, two synchronized drives (±0.3°) | ✅ opportunity — verify fit |
| Environmental rating | TCU IP65, −10…+60 °C / NCU IP66 IK10 | TCU IP67, −35…+60 °C / NCU IP65 | ✅ TCU better ⚠️ NCU box |
4.5 Certifications
| Item | Installed | Proposed | Verdict |
|---|---|---|---|
| CE / EMC | CE; IEC 61000 series (test reports on file) | CE, EMC claimed | ✅ nominal — request reports |
| Tracker-controller qualification | IEC 62817 test reports on file | Not stated | TO CONFIRM |
| Radio certification | ETSI EN 300 328 (2.4 GHz) | Not stated; Chile homologation unknown | TO CONFIRM |
| Battery transport | UL1642 cells; IATA lithium procedures documented | LiFePO4 stated; UN38.3 not stated | TO CONFIRM |
Bottom line. (1) Self-powered architecture matches — no new LV cabling, provided aux-panel reuse and motor-current
margins are confirmed. (2) The single hard physical interface is the motor connector on 86 pigtails — field-verified as WEIPU SP21 series screw-coupling (documentation states Binder 99-5606-75-03).
(3) Modules are untouched. (4) The decisive mismatch is the radio: Zigbee vs Sub-1GHz forces a one-campaign full-fleet swap
plus SCADA re-integration and Chilean RF homologation.
5Open Questions — Vendor Checklist
Every item marked TO BE CONFIRMED above maps to this checklist. V = answer expected from Solarsurges · iE = iEnergia internal verification.
A · Motor drive & power (critical)
A1Maximum continuous and peak motor current of the S350 TCU (and MD0X drive) at 24 VDC. Installed motors run ≤ 6 A with a > 15.5 A overcurrent flag.V
A2Can the S350 charge from the existing 30 W / 36 V aux panels (input window 26–40 VDC today), or does it require its stated 60 W panel?V
A3If new aux panels are required: dimensions, weight, connector type, and bracket interface for 86 positions.V
A4Confirm installed battery size (3 Ah vs 6 Ah packs) by field check / purchase records.iE
A5Motor duty cycle supported (pulse / rest profile) vs the installed limit of 30 s @ max current + 10 s rest.V
B · Connectors & cabling (critical)
B1Motor connector: does the new TCU mate the WEIPU SP21 series 3-pin screw-coupling connector (field-verified; P4Q documentation states Binder 99-5606-75-03 — sample a few more trackers to confirm fleet uniformity) directly, via adapter cable, or does it require re-terminating 86 motor pigtails?V
B2TCU-side cable set: lengths, gauges, glands supplied? (today: motor 2×16 AWG 1650 mm; panel PV1-F 2.5 mm² ~500 mm)V
B3Aux-panel connector type (standard MC4?). Note the existing female is a non-standard MC4-compatible part.V
B4Physical wired service port (RS-485) available besides Bluetooth? Connector type?V
B5NCU enclosure: model, IP/IK rating, dimensions, cable entries, antenna bulkhead. Is an outdoor cabinet (≥ IP66, like today's) included?V
C · Communications & SCADA (critical)
C1Exact Sub-1GHz operating band and channel plan; SUBTEL (Chile) homologation status for TCU, NCU and any 4G module.V
C2Does the NCU expose a Modbus TCP server over Ethernet (not only Modbus RTU / MQTT)? Provide the full register map.V
C3Who performs the plant-SCADA (GreenPowerMonitor) re-integration, and is SurgeTrack SCADA mandatory or optional?V / iE
C4RF coverage design for 81 trackers on this layout: is one NCU still sufficient (as today), or are repeaters / multiple NCUs proposed?V
C5Weather station: sensor list, accuracy, mounting and power; can the existing anemometer be reused?V
C6Is the wind-stow threshold configurable? (brochure fixes 18 m/s; site threshold must match the Alion structural specification.)V
D · Mechanical & site integration
D1TCU dimensions, weight and mounting pattern; adapter plates for the existing 317 × 129 mm bracket or new brackets for 86 positions?V
D2Inclinometer: internal or external? Accuracy? Mounting-orientation constraints on the Alion A-frame.V
D31C2C applicability to the 5 dual-motor trackers: these are two independent drives on one long single-axis tracker — not a dual-axis system.V
D4Stow behavior compatibility with the Alion Storm-Lock mechanism: stow angle and approach profile.V
D5Backtracking commissioning: who loads row-geometry parameters and validates tracking after the swap?V / iE
E · Certifications, quality & commercial
E1IEC 62817 design-qualification report for the proposed TCU (exists for the installed unit).V
E2EMC / CE test reports (not only marks) and surge-immunity class.V
E3UN38.3 + IATA documentation for LiFePO4 packs shipped to Chile.V
E4Warranty term and RMA process (brochure states none).V
E5OTA firmware security model (signing, rollback) for TCU and NCU.V
E6Contactable references for retrofit projects on third-party trackers (brochure lists one "tracking system upgrade" project).V
E7Spare-parts availability commitment (years) for the proposed hardware generation.V
6Annex — Drawings & Photos
Every figure references its source document and page. Additional documentation (full manuals, datasheets, Modbus maps, IEC 62817 reports) can be shared on request under NDA.
Original documents — cabling & connections (download)
Original manufacturer PDFs covering the cable assemblies and connection interfaces of the installed TCU, provided for direct engineering verification of connector and cable compatibility.
| Document | Content | Size | Download |
|---|---|---|---|
| ASSY-C16003#38 Rev A — Motor cable | Motor cable assembly: Binder 99-5606-75-03 connector, pin/color table, 2×16 AWG UL2464 cable, gland M16×1.5, crimp receptacles. Note: installed connector field-verified as WEIPU SP21 series (see §2.1 photos) | 138 KB | PDF ↓ |
| ASSY-C16003#01 Rev A — Power (+) cable | Aux-panel power (+) cable: MC4-compatible female (Sungold FL02701), PV1-F 2.5 mm² 0.6/1 kV, gland M12×1.5 | 100 KB | PDF ↓ |
| ASSY-C16003#02 Rev A — Power (−) cable | Aux-panel power (−) cable: MC4-compatible male, PV1-F 2.5 mm² | 113 KB | PDF ↓ |
| ZPS2X36C001 — Aux PV panel drawing | 30 W / 36 V auxiliary panel: dimensions, cable set (2× PV1-F 2.5 mm²), MC4-compatible connector pair | 93 KB | PDF ↓ |
| D002-PS17026 Rev A — TCU Installation & Maintenance Manual | Full installation manual: mounting pattern, cable glands, electric connection (§4.5 — motor, power, comms, antenna), maintenance | 1.1 MB | PDF ↓ |