ZOMEWORKS Track Rack UTRF-072 Manuel utilisateur
UTRF-072 Track Rack™
Assembly Instructions
1011A Sawmill Road W, PO Box 25805, Albuquerque, M 87125 USA
(505) 242-5354 / (800) 279-6342 / FAX (505) 243-5187
E-mail: [email protected]
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 5% 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. Aluminum “shadow plates” vary the amount of sunlight hitting both canisters.
When the rack is not directly facing the sun, the canister farther from the sun absorbs more
heat and builds pressure. This forces the fluid to move to the other canister, resulting in
movement of the rack. Tracking is the result of a constant search for equilibrium. This process
is effective throughout a very wide temperature range, and works well even in hazy and
intermittent light conditions.
Choosing A Location
Choose a location where the tracker will receive clear, unobstructed light throughout the day.
Keep in mind that the sun rises and sets north of east and west in the summer, and rises and
sets south of east and west in the winter. It is particularly important that your Track Rack™
receive morning light that is unshaded by structures, trees, bushes, etc. As the rack starts the
day facing west (the position as of the previous sunset), clear morning light is required to “flip”
the rack to the east. Morning shadows will delay wake-up time.
Trackers and Wind
The shock absorbers are the first line of defense for the Track Rack™ against wind. They
prevent sudden gusts from pushing the rack off-course, as well as restricting any violent
movement that may harm the rack and modules. The shocks yield to a constant force by
design, thus promoting tracking and, as a result, will be affected in a constant wind-loading
situation. The bumper bolts are the second failsafe in the structure. They prevent catastrophic
failure from occurring by limiting the overall travel of the Track Rack™.
Part ames
1) Gimbal
) Axle
3) Seasonal Adj. Bar
4) Shock Mounting Arm
5) Truss Tube
6) Rail Slider
7) Canister Slider
8A) Canister Set
8B) Transfer Tube
9) Mounting Rail
10) Shock Absorber
11) Counterweight Arm
1 ) 5 lb Counterweight
13) Shadow Plates
14) Storm Collar
Recommended Tools:
•18” Adjustable Wrench (or 1-1/ ” open-end
wrench)
•( ea) 1-1/8”, 15/16”, 3/4”, 9/16”, and 7/16”
Open-End Wrenches
•Tape Measure
•Rubber Mallet (to protect finish)
•( ea) 6' Stepladders
•15' Rope (medium weight)
•Permanent Marker
•5/3 ” Allen Wrench (provided)
•Ratchet Straps for Storm Collar (or similar)
•Two Sawhorses (not required, but useful)
•Large, flat-blade screwdriver
Pole Installation
Zomeworks can only provide general guidelines for the design and installation of the
mounting pole. Our recommended hole diameters and depths are based on “typical soils”. For
installations in sandy or muddy areas, for tall mounting poles, or for any situation different
than what is described in these instructions, you should consult a local structural engineer.
Large trackers can receive very high wind loads – so a sufficiently strong pole and foundation
is crucial. The height of the pole must provide adequate ground clearance for the rack and
mounted modules. Zomeworks can provide assistance for spacing multiple racks to avoid
shading.
OTE: ZOMEWORKS CORPORATIO ASSUMES O LIABILITY FOR THE STRUCTURAL I TEGRITY OF
THE POLE A D ITS I STALLATIO . SOIL A D WI D CO DITIO S VARY. IF THERE IS A Y DOUBT,
CO SULT WITH A LOCAL STRUCTURAL E GI EER. TALK TO YOUR CERTIFYI G E GI EER BEFORE
THE POLE IS I STALLED!
•The correct pipe (to be provided by customer) is as follows:
UTRF-07 Schedule 40 – 6” nominal
•Heavier steel pipe (sch 80 or sch 1 0) can be used as long as outer diameter is 6.6 5”.
•Using the chart provided below, find the MI IMUM acceptable pole height above your
finished grade. The suggested pole height will provide approximately 8” of ground
clearance with the largest module arrays installed. It is strongly recommended that the
pole height meet our minimum specifications.
•The MI IMUM recommended hole
depth is 1/3 the total length of the
pole – 1/3 in the ground, /3 above
the ground.
For example: 8' above grade, 4'
below grade – 1 ' total length.
•Center pipe in hole, use a level or
plumb line to insure pipe is vertical.
•Fill the hole with concrete (3000 psi
minimum strength), and recheck
verticality.
•The pipe may be filled with concrete
for added strength (only to
approximate ground level)
•Allow concrete and pipe to set for a
MI IMUM of 36 hours before
installing Track Rack™
Rack Assembly Instructions
Attaching Gimbal to Pole
•Place Gimbal on top of pole.
•Orient Gimbal so that 3/4” x ” bolts are facing true
south (adjust for magnetic declination)
•Tighten bolts to 75-100 ft-lbs torque in turns
to insure both are tight.
3/8” x 9” HEX BOLT CA BE I STALLED TO PROVIDE
ADDITIO AL RESISTA CE TO UPLIFT A D TWIST.
THIS MAY ALSO BE A REQUIREME T OF THE
PERMITTI G AUTHORITY.
•With Gimbal oriented properly (set bolts pointed true
south), use pre-drilled 7/16” holes as a guide to drill through the pipe on both sides.
•Slide the 9” hex bolt through the Gimbal and pipe, install flat washer and tighten first
hex nut. Tighten second nut against first.
MOU TI G POLE RECOMME DATIO S
Model UTRF-07
Sch 40 Steel
Pipe (A) 6" (6
5
8
" OD)
Minimum Pole
Height (B) 96"
Minimum Pole
Depth (C) 48"
Ground
Clearance at
45° Tilt
8"
Minimum Hole
Diameter (D) 4"Ø
Maximum Rack
Dimensions (as
viewed from
above)
1 4" E-W
110" N-S
Capacity
(Module Area) 7 ft²
C
B
D
A
SLOPE AWAY
FROM POLE
FOR DRAINAGE
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/ ” 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
100-1 0 ft-lbs.
•For the purposes of assembly, it is only
necessary to tighten the bolt / nuts lightly.
Installing Seasonal Adjustment Arm
•Bolt Seasonal Adjustment Arm to Axle and
Gimbal as shown.
•For the purpose of installing subsequent
components, set axle to a shallow tilt.
•After final assembly and adjustment, tighten
bolts to 75 ft-lbs.
Bumper Bolt Installation
•The Bumper Bolt Assembly consists of a
1”-8 x 5” hex bolt, a Ø -1/ ” x 3-1/ ”
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.
•Install Bumper Bolt on second Shock
Mounting Arm.
Installing Truss Tubes
•Using 5/3 ” Allen wrench provided, make
sure that the set screws on each Truss
Tube bearing are backed out.
•Install Brass Spacer on north end of
axle (if not already installed). This
spacer prevents the Truss Tube from
eventually making contact with the end
plate of the Axle, which will inhibit
tracking.
•Slide Truss Tube on to the north end of
the Axle until the bearing is snug against
the bushing and axle end cap. Tighten set
screws.
•The Truss Tubes should be spaced so that the center-to-center distance is 4 -3/4”.
(The inside-inside distance will be 40-3/4”).
UTRF-07 4 3/4”
•Slide second Truss Tube on to the south end of the Axle. Using a tape measure, space
the southern Truss Tube so that the center-to-center distance (as measured from the
square tube sections) is correct. Tighten set screws. Adjustments may need to be
made when installing subsequent components.
•ote: The correct orientation of the Truss Tubes is with the square tube hanging below
the Axle and the bearings facing away from each other.
•ote: At this point the Truss Tubes may be quite a bit out of alignment. This is because
the bearings are designed to “swivel” in their housing. This feature allows the bearings
to tolerate misalignment and also prevents flex in the rack from damaging the bearings.
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. The correct orientation is with
the tab on the top side of the Truss Tube. The included drawing may specify whether
the tab should be on the left or right side. If this is the case, install as directed. If not,
the orientation is not critical.
•Next, install any regular-size
Extruded Rail Sliders.
•Finally, install the four Canister
Sliders so that the outside edges
are flush with the ends of the
Truss Tube. The correct
orientation is with the tabs on
the top side and the
overhanging section of the tabs
facing towards the middle of the
rack. See drawing.
•Bolts should be tight enough to
clamp securely on to the Truss
Tube without crushing the square
tube wall.
•With bolts adequately pre-loaded, tighten jam nuts.
•Extruded Rail Sliders will be aligned and tightened in a later step.
Canister Installation
•Important ote: Fluid is driven between canisters via 1/4” copper tube. When
removing the Canister Set from the package and when straightening the transfer
tube, be careful to not crimp it. We recommend that at least two people handle
the canisters to prevent any damage.
•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.
•Bolt the Canister Set to the Canister Sliders with the 3/8” hardware provided. See
drawings below.
•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.
Extruded Mounting Rail Installation
•Description: The Zomeworks Extruded Rail is
designed to be mounted to the sliders using 3/8”
round-head, square-neck bolts. The edges of the
extrusion are different – one side has a slot to
accommodate standard 1/4” hex bolts and the other
*5/16” hex bolts (see diagram at right). When
installing rails on to the Truss Tube pay attention to
this orientation!
*- Zomeworks only provides 1/4” hardware for modules. For specific modules, 5/16”
hardware can be supplied by the customer / installer.
•In order to mount the Extruded Rails in the correct spot, use a permanent marker to
layout the position of the Rail Sliders. This can be done a couple of ways:
Method 1: Find the center of the Extruded Rail. Mark lines the “Half Distance” away on
both sides of center. Refer to the table below to find the correct distance. These marks
will coincide with the centerline spacing of the Truss Tubes.
Rack Model Truss Tube
Spacing
Half
Distance
UTRF-07 4 3/4” 1 3/8”
Method : 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.
Pre-Installing Mounting Hardware
•Now that the Extruded Rails have been marked,
slide the provided module mounting hardware (1/4”
or 5/16” x 5/8” hex bolts) into the tracks at the
approximate mounting locations. It is only necessary
to locate the bolts in the general area of the module
frame holes – this will make the installation of the
modules easier. Also slide two 3/8” round head bolts
to the center of the marked lines.
Installing Rails on Truss Tubes
•Using the marked lines as a guide, align the Extruded Rail to the Rail Sliders. Install
one flat washer and Nylock nut. Loosely tighten the nut.
•In the process of installing the rails, use a measuring tape to verify that the rails are
square and parallel with the rack.
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. 5 ft-lb) torque. When installing subsequent modules, refer to
the layout drawing for the correct spacing between modules, this is usually 1/ ”.
•When all modules have been installed, verify that everything is square and the
modules are equidistant from the center axle. Tighten hardware if necessary.
• Use the cable clamps ( ) provided to route the copper transfer tube along the
underside of the module mounting rails.
Shock Absorber Installation
•The UTRF-07 comes with 4 Shock
Absorbers.
•ote: These shocks are very stiff. To
extend the shock for mounting, it may
be necessary to bolt the upper end of
the shock to the rack and hang on the
bottom to get it to extend.
•Use the Loctite® provided and attach
shock to the Truss Tube and Shock
Mounting Arm as shown in diagram.
•Make sure to leave 1/16” space
between bolt head and hex nut to
allow for free movement of urethane
grommets.
•Tighten the hex jam nut (on top) and
the pair of nuts (bottom) to 75 ft-lbs.
•This is high-stress connection and should be
checked periodically.
Installation of the Counterweight
•The Counterweight assembly bolts to the 1” square
nut welded on the north-end Truss Tube, directly
underneath the bearing.
•Making sure the 1” all-thread rod is fully engaged
with the threads of the square nut, turn the Unistrut®
so that the open face is pointing towards the
mounting pole.
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