ZOMEWORKS UTRF-072 Track Rack™ Assembly Instructions 1011A Sawmill Road NW, PO Box 25805, Albuquerque, NM 87125 USA (505) 242-5354 / (800) 279-6342 / FAX (505) 243-5187 E-mail: zomework@zomeworks.
Thanks! Thank you for your purchase of a Zomeworks Track Rack™. The Zomeworks Track Rack is an ingenious and economical way to increase the annual output of photovoltaic modules by an average of 25% over those mounted on a fixed array. Tracker Operation The Track Rack™ changes its orientation to the sun by shifting a mass of refrigerant between canisters on the east and west sides through a copper tube located at the southern-most end of the canisters.
Part Names 1) Gimbal 2) Axle 3) Seasonal Adj.
• • • Heavier steel pipe (sch 80 or sch 120) can be used as long as outer diameter is 6.625”. Using the chart provided below, find the MINIMUM acceptable pole height above your finished grade. The suggested pole height will provide approximately 28” of ground clearance with the largest module arrays installed. It is strongly recommended that the pole height meet our minimum specifications.
Attaching Axle to Gimbal • • • • • Orient the Axle so that the Shock Mounting Arms are hanging below. (Note location of the Seasonal Adjustment bolt hole). Align the center hole (3/4”) of the Axle with the holes on the Gimbal tabs. Insert the 3/4” x 4-1/2” hex bolt and flat washer (see diagram) on one side of the axle and the lock washer and hex nut on the opposite side. When the rack is fully assembled, the axle bolt must be tightened to approximately 100-120 ft-lbs.
Bumper Bolt Installation • • • • • The Bumper Bolt Assembly consists of a 1”-8 x 5” hex bolt, a Ø2-1/2” x 3-1/2” rubber bumper, and a 1” hex jam nut. Screw the 1” bolt into the Shock Mounting Arm until the jam nut touches the square nut as shown. The rubber bumper does not need to be tightened between the bolt head and the jam nut. It should be able to twist easily. Tighten the jam nut to at least 100 ft-lbs torque. This is a high stress component and should be checked periodically.
Pre-Installing Sliders • • • • • • • • Depending on the specific configuration of your rack, it will come with different sizes and quantities of Sliders. The two types of Sliders are shown below. Some rack configurations may include a set of Extruded Rail-type Sliders that are designed to mount on the reinforced midsection of the Truss Tube. The square tube section of these sliders is noticeably wider. If your rack comes with the wider Extruded Rail Sliders, install those first.
• • Before fully tightening bolts, align the rack visually to remove any twist and by measuring across the diagonals as shown. This will make the rails and modules easier to install. With rack aligned, tighten bolts. * - Some rack configurations come with a Protector Angle. This is a long section of steel angle that spans between both canisters and protects the copper tube when rail length is insufficient to do so. If this is provided with your rack, install it now.
Rack Model UTRF-072 Truss Tube Half Spacing Distance 42 3/4” 21 3/8” Method 2: Take a look at the layout drawing provided in the instruction packet. There is a dimension showing the distance from the cut end of the Extruded Rail to the centerline location of the Rail Slider. With the Extruded Rail in the correct orientation – the 3/8” slot facing the outside edge of the Rail Slider, and either the 1/4” or 5/16” slot on top (depending on hardware used) – mark a line.
Installing Modules • • • • • For modules mounted in landscape orientation, the first module should be installed flush with the edge of both Extruded Rails. For modules mounted in portrait orientation, the module mounting hole should be located 1” from the cut end of the Extruded Rail. Make any required adjustments to get the hex bolts lined up with the module mounting holes before installing the hex nut. Once the module is in place, tighten backing nut to no more than 75 in-lb (6.25 ft-lb) torque.
• • • Tighten jam nut firmly. The 25-pound weight should be installed at a point approximately 1/2 the way down the Unistrut®. Fine adjustments are best made after monitoring the performance of the rack. See diagram (above) for placement of hardware. Installing Shadow Plates • • • Two Shadow Plates are provided with the UTRF-072. The plate that has a Zomeworks sticker is designed to be installed on the NE corner of the rack.
• • • • • Pay attention to balance when installing additional components (inverters, wires / conduit, etc.) Track Racks™ will work within a range of Counterweight adjustments. If the tracker is not going through the full travel range, • MORE MOVEMENT HIGHER raise the Counterweight. • (POSSIBLE) FASTER WAKE-UP • MORE EASILY BLOWN Keeping the Counterweight low will make the tracker OFF-COURSE • "SEARCHING" FOR SUN more stable in wind.
• Inspect the pivot bolt area of the Axle-Gimbal junction for wear. Signs of excessive movement may indicate that the bolt has worn down. Another indication of wear is that the bolt, even when tightened properly, repeatedly comes loose. If this is the case, replace the bolt. PROPER MAINTENANCE IS THE RESPONSIBILITY OF THE CUSTOMER! HIGH WINDS: Trackers should be tied in horizontal position if high-wind events are anticipated. The Storm Collar can be used in conjunction with tie-down straps.
without the shocks, they may be defective. IMPORTANT: Do not leave the tracker defenseless without shocks – a strong wind could easily damage it. The rack can easily be tied down by using the Storm Collar and customer-provided tie-downs or ratchet straps. • TRACKER DOES NOT HIT THE BUMPER STOPS 1. Trackers are very effective even if they don't track all the way to the bumper stop. The bumper stops are set for approximately 90° of rotation. 2. To increase the amount of rotation, raise the counterweight.
Some problems can be solved with a simple on-site adjustment. Please contact Zomeworks Corporation at the address and phone number below before returning your product. You must have an RMA number to return the product for warranty repair. If possible, return only the parts that are defective or damaged. Reuse your original packing material, if it's available, or call the factory for further instructions.
