ZOMEWORKS UTRK-040 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) Upper Axle 3) Lower Axle 4) Extruded Rail 5) North Bearing Plate 6) South Bearing Plate 7) Shock 8) 25 lb Counterweight 9) Counterweight Arm 10) Bumper Bolt 11) Canister Mounting Tab 12) Canister/s 13) Shadow Plate/s 14) Wake-Up Fin 15) Transfer Tube Recommended Tools: • • • 12” Adjustable Wrench (1-1/2” capacity) Open-End Wrenches: 7/16”, 1/2”, 9/16”, *3/4”, *15/16”, 1-1/2” Socket Wrench: 3/4”, 15/16” (Not Heavy-Duty Wall) – for seasonal adjustment bolt, and bearing bolts, respect
• The correct pipe (to be provided by customer) is as follows: UTRK-040 • • • Schedule 40 – 3” nominal Heavier steel pipe (sch 80 or sch 120) can be used as long as outer diameter is 3-1/2”. Using the chart provided below, find the MINIMUM acceptable pole height above your finished grade. The suggested pole heights will provide approximately 3' of ground clearance with the largest module arrays installed. It is strongly recommended that the pole height meet our minimum specifications.
North Cross Arm Assembly • • • • • • • • • • • The North Cross Arm Assembly consists of two Extruded Rail sections joined by the North Bearing Plate and Counterweight Arm. The North Bearing Plate has two weldedon square nuts for mounting the shock/s. Orient the Extruded Rail sections so that the 1/4” slot is on the top. Pre-install two of the 3/8” x 1-1/4” round head bolts in each rail section. Pre-install two 5/16” x 3/4” hex bolts in each rail section.
If there is access to a flat surface (garage / shop floor, saw horses with plywood, etc.), Method 2 makes the alignment / installation of the modules quite a bit easier. The completed sub-assembly can then be lifted on to the pole and tightened in place. Method #1 Attaching Gimbal to Pole • • • Place Gimbal on top of pole. Orient Gimbal so that the welded channel “leans” towards true south (adjust for magnetic declination). Tighten bolts to 60 ft-lbs torque in turns to insure both are tight.
Attaching Cross Arms • • • • • The Cross Arms are bolted to the flange bearings by 5/16” x 1” hex bolts. Don't forget the spring lock washers under the bolts! If the bearing is turned in its housing, it may be necessary to twist it into alignment in order to fit the 5/8” bolt head in to the clearance hole in the Bearing Plate. Start bolts by hand, and tighten to 9 ft-lbs (108 in-lbs) torque. Note the Counterweight Arm and Shock mounting nuts on the North Cross Arm.
Module Installation NOTE: Modules must be installed so that they are balanced on the rack. At least 1/4” space between modules is recommended. • • • • • • • • • Make sure that the Axle Assembly is at its shallowest tilt angle, this will make installation easier. Square the Cross Arms as best as you can. Some force is required to swivel the bearing in its housing. Measure the distance between the module mounting holes along the long edge.
Method #2 Module Layout • • • • • • • • • Lay the modules face-down on a flat surface (plywood on sawhorses, shop floor, large workbench, etc.) as they will be configured on the rack. Leave at least 1/4” space between adjacent module edges. The outside to outside distance of the module array must be 115” or less. This is necessary to allow at least 2” between the canister and the outside edge of the module. Pre-install the required number of 1/4” hex bolts in the extruded rail.
Axle Installation • • • • • Install Axle Assembly as shown. Orient that bearings so that the grease fitting can be accessed from underneath the rack. Adjust the length of the Axle Assembly to fit between Cross Arms. 5/16” hex bolts should be tightened to 9 ft-lbs (108 in-lbs) torque. 3/8” axle set bolts can now be tightened to approximately 20 ft-lbs. Bumper Bolt Installation • • The Bumper Bolt does not need to be tightened between the head of the bolt and the jam nut.
Shock and Counterweight Installation • • • • • Bolt the upper half of the Shock to the Cross Arm using the 1/2” x 2” hex bolt and hex nut. Do not tighten down on the urethane bushing – there should be enough play to allow free movement of Shock eye (approx. 1/16”). Attach the lower half of the Shock using the 1/2” x 2-1/2” hex bolt and hex nuts. Using two 3/4” wrenches, tighten the nuts to 4050 ft-lbs torque. Install the counterweight as shown.
• • • • • • Orient the Canister Set so that the unit with the wake-up fin is on the west side of the rack (with the wake-up fin underneath the rack). The transfer tube is designed to enter from the bottom (underside) of each canister. Remove the 1/4” hex nuts and square washers from the top of the Canister Mounting Tabs and open up the strap. Align the Canister as necessary in order to find a place for the strap clamps.
Balancing and Counterweight Adjustments • • • • • • • Balancing and set-up is crucial to getting the most out of your Track Rack™ Start by ensuring that the module rails are installed equidistant from the center axle. Pay attention to balance when installing additional components (inverters, wires / conduit, etc.) • MORE MOVEMENT HIGHER Track Racks™ will work within a range of • (POSSIBLE) FASTER WAKE-UP Counterweight adjustments.
Maintenance • • • • • Bearings with grease fittings should be lubricated with a general-purpose bearing grease twice a year. Paint touch-up will be necessary to prevent rusting. Sand off all rust prior to painting. Use a high-quality enamel or Rustoleum® type paint. If the Track Rack™ is installed in a corrosive climate, check the axle and bearings frequently for rust or corrosion; you may need to grease the bearings 3 to 4 times per year and keep the axle coated with grease or a corrosion inhibitor.
• TRACKER IS SLOW TO WAKE UP 1. Check that your tracker is getting full, early morning sun shining underneath the framework. The wake-up fin (under the west-side canister) must see the sun. 2. Check that modules and electrical components are balanced over the center axle. 3. Check that bearings are lubricated and move easily. NOTE: If the Track Rack™ is installed in a corrosive climate, check the axle and bearings frequently for rust / corrosion. 4. The shock/s may be sticking when collapsed or extended.
ZOMEWORKS TRACK RACK™ LIMITED WARRANTY Zomeworks Corporation guarantees, to the original owner, its Track Rack™ passive solar tracker and fixed racks against defects in materials and workmanship for TEN YEARS from date of purchase. Shock absorbers and bearings are warranted against defects in materials and workmanship for TWO YEARS from date of purchase. This warranty is limited to the repair or replacement of the Track Rack™ or fixed rack in compliance with the instructions provided by Zomeworks.
