ZOMEWORKS UTR-020 TRACK RACK User manual

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UTR-020 TRACK RACK™
ASSEMBLY INSTRUCTIONS
TOTAL SQUARE FOOTAGE OF PANELS NOT TO EXCEED
20 SQUARE FEET – DOING SO WILL VOID WARRANTY
1011 Sawmill Road NW, PO Box 25805, Albuquerque, NM 87125 USA
[phone] / [phone] / FAX [phone]
E-mail: [email protected]
ZOMEWORKS

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TABLE OF CONTENTS
Cover Page Page 1
Table of Contents Page 2
About Trackers Page 3
UTR-Series Parts list and Recommended Tools Page 4 - 5
UTR-Series Pole Installation Page 5 - 6
Step 1: Laying out canister set Page 7
Step 2: Bottom Rail Attachment Page 7 - 8
Step 3: Attaching the Axle Assembly Page 9
Step 4: Top Rail Attachment Page 10 - 11
Step 5: Mounting the tracker on the pole Page 11
Step 6: Shock and Bumper-Bolt Installation Page 12
Step 7: Shadow Plate Installation Page 13
Step 8: J-Clip Attachment Page 14
Step 9: Panel Installation Page 15
Step 10: Counterweight Installation Page 16
Step 11: Balancing the Tracker Page 17
Step 12: Seasonal Adjustment Page 17
UTR-Series Tracker Troubleshooting Page 18 - 19
ZOMEWORKS Limited/Extended Warranty Page 20

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ABOUT TRACKERS
The UTR-Series Tracker is an ingenious and economical way to increase photovoltaic efficiency an average of
25%. Photovoltaic panels mounted on a tracker will be much more efficient than the same panels mounted on a
fixed rack when the tracker follows the sun for at least 6 hours a day. Because a tracker relies on a differential
of solar heat gain in the canisters, it will react quicker on a bright sunny day than it will on a partially cloudy
day.
CHOOSING A LOCATION
Choose a location where the tracker will receive the sun all day. Clear exposure throughout the day with an
unobstructed and clear view of the sun is required. Locate the Track Rack™ where it will receive the earliest
morning sun. The rack needs the early morning sun to “wake up”, or return to the eastern position, so it is
important to place your Track Rack™ where it won’t be shaded in the morning by structures, poles, trees,
bushes, etc. Remember that the sun rises and sets north of true east /west in the summer and south in the winter.
You will be able to adjust your Track Rack™ for the winter & summer solstice accordingly.
TRACKER OPERATION
The Track Rack™ is moved by the shifting weight of the liquid refrigerant from the east or west canisters
through the copper transfer tube located at the south side of the assembly. The aluminum “shadow plates”
shade the canister closest to the sun. The other canister grows warmer and shifts the weight to the cooler
canister, tilting the Track Rack™ until it points exactly at the sun and shades the canisters equally. The tracker
will not track without the shadow plates.
TOTAL TRAVEL
The rack is designed to travel through a 90°arc and is still very effective down to 60°of rotation. A Track
Rack™ is only stable if the axle is above the center of gravity. If the axle is below the center of gravity, the
Track Rack™ will be unstable. Even in calm, sunny weather it will be hunting for, but overshooting, the sun.
To make the tracker stable, lower the center of gravity by moving the counterweight down. A Track Rack™
with its center of gravity perfectly adjusted will reach its stop in the afternoon at about the same time all the
refrigerant has moved to the west canister. It should not strain hard against the bumper stops. If the center of
gravity is too low the tracker won’t turn all the way to the bumper stops. If the center of gravity is too high the
tracker will be unstable in the wind. There is broad latitude of adjustment that works for most Trackers.
SHOCKS AND THE BUMPER STOPS
The shock absorber is the first line of defense for the Track Rack™ against wind. It’s meant to 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 stop is the second failsafe in the structure. It prevents
any catastrophic failure from occurring by limiting the overall travel of the Track Rack™.

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UTR-Series Parts List and Recommended Tools
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2
3
4
5
6
7
8
9
10
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CUSTOMER PROVIDED POLE
Shadow Plates (#1) Quantity Axle Assembly / Gimbal Can (#7 & 8) Quantity
44" long Aluminum Shadow Plates (38" spacing) 2 ea. Axle Assembly 1 ea.
1/4"-20 x 3/8" ZP Round Head Slot Machine Screw 4 ea. 1/8" x 3" Cotter pin (pre-attached) 1 ea.
1/4" ZP Fender Washer 4 ea. Gimbal Can 1 ea.
1/4" SS Lock Washer 4 ea. Shaft collar 1 ea.
5/32” Allen wrench 1 ea.
Bearings (#2) Quantity
1/2" x 1 1/2" Yellow ZP Hex Bolt (Set Bolt) 1 ea.
3/4" insert bearings (pre-attached) 2 ea. 1/2" x 1 1/2" ZP Hex Bolt 1 ea.
1/2" ZP Flat Washer 2 ea.
Canister (#3) Quantity
1/2” ZP Lock Washer 1 ea.
44" x 2" Canister 1 set 1/2" ZP Hex Nut 1 ea.
3/8" x 1" Yellow ZP Hex Bolt 1 ea.
Top Rail (#4) Quantity
3/8" Yellow ZP Flat Washer 1 ea.
Top Rail assembly w/U-Brackets 1 ea. 3/8" ZP Lock Washer 1 ea.
5/16" x 3" ZP Hex Bolts 2 ea.
5/16" ZP Flat Washers 4 ea. Bottom Rail (#9) Quantity
5/16" ZP Nylock Nuts 2 ea. Bottom rail assembly 1 ea.
3/8" x 1" ZP Hex Bolt 4 ea.
Bumper Bolt (#5) - (all parts are pre-attached) Quantity
3/8" ZP Flat Washer 8 ea.
5/8" x 4" ZP Hex Bolt 1 ea. 3/8" ZP Nylock Nut 4 ea.
Rubber Hose ( 3" ) 1 ea.
5/8" ZP Jamb Nut 1 ea. Miscellaneous ( #10 ) Quantity
UV Pull Tie Straps 4 ea.
Shock Absorber (#6) Quantity
Small Shock 1 ea.
5/8" x 3" ZP Hex Bolt 1 ea.

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5/8" ZP Hex Nut 1 ea.
Loctite Tube 1 ea.
Module Mounting Hardware ( x # of modules ) Quantity Counterweight Bar & Counterweights ( #11 & 12 ) Quantity
2" Stainless Steel J-Clip 4 ea. 5/8" ZP All Thread Bolt ( 17 1/4" long ) 1 ea.
1/4"-20 x 5/8" SS Hex Bolt 4 ea. Rubber Hose ( 5 1/2" long ) 1 ea.
1/4"-20 x SS Hex Flange Lock Nut 4 ea. 5/8" ZP Hex Nut 2 ea.
1/4" SS Flat Washer 4 ea. 5/8" ZP Flat Washer 2 ea.
5/8" ZP Lock Washer 2 ea.
5/8" ZP Jamb Nut 1 ea.
2 1/2lb Disk Weight 8 ea.
RECOMMENDED TOOLS:
•(2) 15/16” combination wrenches •(2) ¾” socket or combination wrenches
•(2) 9/16” combination wrenches •(1) flathead screwdriver
•(2) ½” combination wrenches •(1) 7/16” socket or combination wrench
NOTE TO INSTALLER: The installer MUST provide the schedule 40 steel pipe. Before assembling your
Track Rack™, use the list above to assure that you have all of your components. In the event that you may have
missing parts, contact Zomeworks Customer Service @1-800-279-6342.PLEASE have your SALES ORDER
NUMBER,SERIAL NUMBER,DATE OF PURCHASE, along with your DEALER NAME when calling.
UTR-SERIES POLE INSTALLATION
IMPORTANT NOTE: ZOMEWORKS CORP. ASSUMES NO LIABILITY FOR THE STRUCTURAL
INTEGRITY OF THE POLE AND ITS INSTALLATION. SOIL AND WIND CONDITIONS VARY. IF THERE
IS ANY DOUBT, CONSULT WITH A LOCAL STRUCTURAL ENGINEER.
LOCATION CONSIDERATIONS:
For installations in sandy or muddy areas, for tall mounting poles, or for any mounting different from the
situations described in these instructions, you will need to consult a local structural engineer. Large TRACK
RACKScan receive significant wind loads, so a strong mounting pole and foundation is very important. Also,
be aware of turbulence near buildings or sudden changes in terrain. The site should receive the maximum
possible sunlight from AM to PM, in the winter and summer. Avoid shade from buildings and trees, including
shade that may occur in other seasons. The height of the pole should result in adequate ground clearance for the
mounted modules.
CAUTION – BE CAREFUL WORKING AROUND THE RACK AFTER INSTALLATION ON THE
POLE. SOME OF THE STRUCTURAL MEMBERS MAY BE AT HEAD LEVEL.
•The customer provided pole is a 2 1/2” (nominal) schedule 40 steel pipe with a 3” OD. Pole can be black or
galvanized steel pipe.
•Note: Heavier schedule steel pipe schedule 80, schedule 160 can be used as long as OD is 3”.
•Using the chart below, find the MINIMUM acceptable pole height above your finished grade. It is strongly
recommended that the pole height be to our minimum specifications.
•The minimum recommended hole depth is 1/3 the pole length, 1/3 in the ground, 2/3 above the ground.
Example: 5’ below grade, 10’ above grade, total of a 15’ pole.
•Center the pipe in the hole, and using a level, make sure pole is vertical.
•Fill the hole with concrete (3000-psi minimum strength), and check level of the pole.

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•The pole may be filled with concrete for added strength (only to approximate ground level).
•Allow concrete and pole to set for a minimum of 36 hours BEFORE installing the Track Rack™.
MOUNTING POLE RECOMMENDATIONS:
40" 29"
6"
(6-5
8" OD)
6"
(6-5
8" OD)
SCHEDULE 40
STEEL PIPE
SLOPE AWAY FROM
POLE FOR DRAI AGE
F-Series
UTRF168
CO CRETE
EARTH
72"
144"
8"
(8-5
8" OD)
30" diameter
Pipe set in
concrete
169" EW
120" NS
168 Sq. Ft. of
Module Area POLE INSTALLATION DETAIL
18" to 30"
50"
F-Series
UTRF90
60"
120"
54"
108"
Description
Min. Pole Height
Min. Pole Depth
Minimum
Schedule 40
Steel Pipe
F-Series
UTRF64
6"
(6-5
8" OD)
96"
48"
24" diameter
Pipe set in
concrete
146" EW
120" NS
90 Sq. Ft. of
Module Area
Minimum
Recomended
hole diameter
Rack
Dimensions
(up to but NOT to
exceed Sq. Ft.)
124" EW
80" NS
64 Sq. Ft. of
Module Area
24" diameter
Pipe set in
concrete
Ground Clearance at
45° Tilt N/S & E/W
33"21"30"
F-Series
UTRF120
146" EW
120" NS
120 Sq. Ft. of
Module Area
24" diameter
Pipe set in
concrete
Universal
UTR-020
76"
2.5"
(2-7
8" OD)
18" diameter
Pipe set in
concrete
67" EW/
44" NS
20 Sq. Ft. of
Module Area
38"
K-Series
UTRK-040
84"
3"
(3-1
2" OD)
18" diameter
Pipe set in
concrete
124" EW/
48" NS
40 Sq. Ft. of
Module Area
42"
IMPORTANT NOTE: TO MINIMIZE CONFUSION DURING INSTALLATION MOST
OF THE HARDWARE MENTIONED IN THE FOLLOWING STEPS WILL COME
PARTIALLY ASSEMBLED ON THEIR RESPECTIVE PARTS. WHEN RE-
INSTALLING THE HARDWARE PLEASE MAKE SURE TO FOLLOW DIAGRAMS
EXACTLY TO MINIMIZE POSSIBILITY OF DAMAGE TO TRACKER.

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Step 1: Laying out the canister set:
SOUTH
ORTH
Diagram 1
•Remove Canister set from box and carefully unwind the copper transfer tube and place on the ground or
work surface as shown. Make sure canister tabs are on the bottom.
Step 2: Bottom Rail attachment:
Diagram 2a

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•Separate the top rail and bottom rail and slide the bottom rail in between the canister tabs and the crossover
tube.
ORTH
SOUTH
Diagram 2b
•Remove the 3/8” Bolts, Washers and Nylock Nuts from the Hardware bag and insert them through the
bottom rail and canister tabs as shown and tighten completely.
•Secure the 4-UV Cable Ties around both the bottom rail and the transfer tube, making sure not to pinch the
transfer tube between the cable tie and the bottom rail. This step can be completed at a later time if so
desired.

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Step 3: Attaching the Axle Assembly:
ORTH
SOUTH
Diagram 3
•Remove the Axle Assembly from the box. The axle assembly will have the shock and bumper bolt taped to
the bent rod. There is no need to remove them as it will make this step more difficult. The shock is also
already pre-attached to the bent rod and secured with a cotter-pin.
•Remove the shaft-collar and slide over the end of the axle and as far up as possible and lightly secure with
the provided 5/32” Allen Wrench.
•With the axle assembly in the position shown slide the axle through the bearing on the bottom rail until the
bearing comes in contact with the shaft collar. It may be necessary to wiggle the axle as you slide it through
the bearing.
•The Gimbal can also come pre-attached; it is not necessary to remove it.

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Step 4: Top Rail Attachment:
ORTH
SOUTH
Diagram 4a
•Remove the remaining rail from the box and position as shown in Diagram 4a & 4b.
•Slide the rail U-brackets over the canisters and slide the entire rail up against the axle assembly, making
sure to seat the axle into the bearing on the top rail.
ORTH
SOUTH
Diagram 4b