Designed by Ralph Hillman
Sun Tracker Installation Manual
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INSTALLATION INSTRUCTIONS FOR THE SUN TRACKER
Proper installation is the responsibility of the owner. Product failure due to improper installation is not covered under the Sun Tracker s warranty. See the owner s manual for warranty information. We recommend you seek a qualified RV service person for the installation. Caution: Before you begin, read these instructions carefully and completely:
IMPORTANT: Save these instructions for future reference. NOTE TO INSTALLER: Be sure to leave these instructions with the customer.
NEVER TRAVEL WITH YOUR SUN TRACKER IN THE RAISED POSITION.
NEVER TRAVEL FASTER THAN 75 MPH.
DOING THE ABOVE WILL VOID THE WARRANTY.
NEVER TRAVEL FASTER THAN 75 MPH.
DOING THE ABOVE WILL VOID THE WARRANTY.
(With a Complete System)
IMPORTANT SAFEGUARDS
To reduce the risk of fire, electric shock and/or injury to persons, basic safety precautions should always be followed when using electrical appliances, including the following:
1. READ ALL INSTRUCTIONS BEFORE USING THE Sun Tracker.
2. The Sun Tracker is NOT A TOY. It is to be used by Adults ONLY.
3. Turn the Sun Tracker OFF and lower the system when you plan to travel.
4. NEVER push more than ONE button on the transmitter at a time.
5. Do not operate more appliances than the inverter can handle.
6. Return this appliance only to the nearest Authorized Service Center for examination,
repair or adjustment.
1. READ ALL INSTRUCTIONS BEFORE USING THE Sun Tracker.
2. The Sun Tracker is NOT A TOY. It is to be used by Adults ONLY.
3. Turn the Sun Tracker OFF and lower the system when you plan to travel.
4. NEVER push more than ONE button on the transmitter at a time.
5. Do not operate more appliances than the inverter can handle.
6. Return this appliance only to the nearest Authorized Service Center for examination,
repair or adjustment.
ASSEMBLY
The Sun Tracker complete system will arrive in 6 boxes.
Box 1: Stainless steel frame and hardware.
Box 2: Rotating motor with wire harness & Strobe light and manual
Box 3: Solar panels
Box 4: 3000 watt modified sine wave inverter
Box 5: 25 amp solar booster controller
To assemble the Sun Tracker, remove the frame from box 1.
Next remove the rotating motor from box 2.
The base plate is attached to the rotating motor with the top plate attached. Do Not remove the top plate. Before you mount the frame to the top plate see (BASE PLATE LAYOUT) below. On the bottom of the frame there are 4- 12mm bolts. Remove the bolts, place the frame on top of the rotating motor and line up the holes in the bottom of the frame to the holes on the top plate of the rotating motor. Next take the 12mm bolts that you removed and screw them into the frame from underneath the top plate of the rotating motor.
Next open the small box of hardware and take out the 8- ¼" bolts and slide them into the adjustable mounting track of the riser arms on the frame. Now, take out the stand-offs and assemble them, see drawing below. There are 2 holes in the back of the frame, underneath the riser arms, to screw the stand-offs to. Lift the riser arms to install the stand-offs.
Box 1: Stainless steel frame and hardware.
Box 2: Rotating motor with wire harness & Strobe light and manual
Box 3: Solar panels
Box 4: 3000 watt modified sine wave inverter
Box 5: 25 amp solar booster controller
To assemble the Sun Tracker, remove the frame from box 1.
Next remove the rotating motor from box 2.
The base plate is attached to the rotating motor with the top plate attached. Do Not remove the top plate. Before you mount the frame to the top plate see (BASE PLATE LAYOUT) below. On the bottom of the frame there are 4- 12mm bolts. Remove the bolts, place the frame on top of the rotating motor and line up the holes in the bottom of the frame to the holes on the top plate of the rotating motor. Next take the 12mm bolts that you removed and screw them into the frame from underneath the top plate of the rotating motor.
Next open the small box of hardware and take out the 8- ¼" bolts and slide them into the adjustable mounting track of the riser arms on the frame. Now, take out the stand-offs and assemble them, see drawing below. There are 2 holes in the back of the frame, underneath the riser arms, to screw the stand-offs to. Lift the riser arms to install the stand-offs.
The Solar Panels may need to be drilled for the mounting. If this needs to be done then you will need to drill ¼" holes, 8" on each side of the center hole. (be sure to place a piece of wood under the frame of the solar panel before you drill these hole to prevent damage to the solar panel.) This will give you a 16" center for mounting. Be sure not to drill the holes too close to the edge, leaving enough room for the nuts to spin freely. See diagram. Once this has been performed then you will be able to mount the solar panels to the frame. This is done by placing the ¼" bolt that are in the adjustable frame into the holes of the solar panels. Once the bolts have been placed into the holes of the solar panels you can reach around the frame of the solar panels and put on the lock washer and nuts to the ¼" bolts. Tighten them down firmly with a 10mm wrench. You should slide the panels on the frame so there is approximately. The same amount of free space on both the top and bottom of the riser arms.
You will want to mount the strobe light next. These is done by attaching the strobe light to the stainless steel mounting plate, then take the mounting plate and align it to the top solar panel frame. Drill at least 2 holes in the mounting plate and frame to mount the plate. Attach the frame to the solar panel and use one of the mounting screws to attach the black wire from the strobe light to one of the mounting bolts for a ground. Then attach the RED wire from the strobe light to the GRAY wire from the top plate on the rotating motor together. The GRAY wire from the bottom of the rotating motor will lead to the switch in the RV.
BASE PLATE LAYOUT
Next you will want to wire the solar panels together. This is done by putting the positive leads together and the negative leads together. Now, you will wire the bottom solar panel to the rotating motor. Attach the positive lead from the bottom solar panel to the RED wire from the top of the rotating motor's top plate. IMPORTANT: When you run the wire from the bottom solar panel to the top plate make sure that you run the wire behind and under the frame. See photos. This is important so when the Sun Tracker rises or lowers you will not pinch the wire and cause a short in the system.
PHOTO 1 PHOTO 2
1) Find an area on the roof that has a clearance of 34" from center. You will have a clearance of 2 ½" where the Sun Tracker will ride over sun roofs and vents. (See Photo 1)
2) Be sure to clean the surface thoroughly before attaching the mounting plate.
3) For best results try to find the studs on the roof. If you are unable to find the studs don't worry because the Butterfly anchors will lock up against the roof's plywood.
4) Place the base plate down and use it as a guide to drill the holes. Lay the base plate lengthwise (front to rear). (See Photo 2)
5) Mark All the holes in the base plate on the roof.
6) Remove the base plate and drill 3/8" holes where the marks are.
7) Place the Butterfly anchors through holes in the roof and slide the lock down tight against the roof.
1) Find an area on the roof that has a clearance of 34" from center. You will have a clearance of 2 ½" where the Sun Tracker will ride over sun roofs and vents. (See Photo 1)
2) Be sure to clean the surface thoroughly before attaching the mounting plate.
3) For best results try to find the studs on the roof. If you are unable to find the studs don't worry because the Butterfly anchors will lock up against the roof's plywood.
4) Place the base plate down and use it as a guide to drill the holes. Lay the base plate lengthwise (front to rear). (See Photo 2)
5) Mark All the holes in the base plate on the roof.
6) Remove the base plate and drill 3/8" holes where the marks are.
7) Place the Butterfly anchors through holes in the roof and slide the lock down tight against the roof.
8) Coat the bottom of the base plate with the Lap Sealant. (Make sure the base is clean and dry)
9) Place the base plate over the holes and bolt the base down to the Butterfly anchors attached to the roof.
10) Tighten the Butterfly bolts down tight.
11) Allow to dry. The lap sealant will remain soft.
12) Run the wires down the refrigerator or bathroom vent or drill a hole in the roof to put the wires down to the controller and battery box.
13) See "Wiring Diagram" for instructions for the wiring.
9) Place the base plate over the holes and bolt the base down to the Butterfly anchors attached to the roof.
10) Tighten the Butterfly bolts down tight.
11) Allow to dry. The lap sealant will remain soft.
12) Run the wires down the refrigerator or bathroom vent or drill a hole in the roof to put the wires down to the controller and battery box.
13) See "Wiring Diagram" for instructions for the wiring.
The Sun Tracker's riser motor comes prewired so there is no need to wire it. We have included these wiring instructions in case the wires are accidently cut or the motor needs replacement.
TOP PORTION OF THE COLLECTOR
Your Sun Tracker Comes with the motors Prewired
Connect the WHITE wire to the Riser Motor s BROWN wire
Connect the BLUE wire to the Riser Motor s BLUE wire.
Connect the GRAY wire to the Strobe Light s RED wire.
Connect the Strobe Light s BLACK wire to the Solar Panel Frame for Ground.
Connect the RED wire to the HOT + Output of the Solar Panel.
Connect the Solar Panels Ground wire to the Top plate Ground Screw.
Connect the WHITE wire to the Riser Motor s BROWN wire
Connect the BLUE wire to the Riser Motor s BLUE wire.
Connect the GRAY wire to the Strobe Light s RED wire.
Connect the Strobe Light s BLACK wire to the Solar Panel Frame for Ground.
Connect the RED wire to the HOT + Output of the Solar Panel.
Connect the Solar Panels Ground wire to the Top plate Ground Screw.
BOTTOM PORTION OF THE COLLECTOR
Connect the GRAY wire to the eluminated rocker switch. The other side of the switch goes to the battery Hot (+) for the strobe light.
Connect the BLACK wire to the Controller "In Battery" Ground (-)
Connect the RED wire to the Controller "In Battery" Hot (+)
BLUE wire connects to the BLUE wire in the electronics box.
WHITE wire connects to the WHITE wire in the electronics box.
BROWN wire goes to the BROWN wire in the electronics box.
YELLOW wire goes to the YELLOW wire in the electronics box.
ORANGE wire goes to the ORANGE wire in the electronics box.
(Refer to wiring diagram 1)
Connect the BLACK wire to the Controller "In Battery" Ground (-)
Connect the RED wire to the Controller "In Battery" Hot (+)
BLUE wire connects to the BLUE wire in the electronics box.
WHITE wire connects to the WHITE wire in the electronics box.
BROWN wire goes to the BROWN wire in the electronics box.
YELLOW wire goes to the YELLOW wire in the electronics box.
ORANGE wire goes to the ORANGE wire in the electronics box.
(Refer to wiring diagram 1)
SPRING ASSEMBLY
The Sun Tracker is equipped with a spring assist system. To assemble the spring assist system you will need to raise the Sun Tracker. When the Sun Tracker is in the raised position the springs will be close to the pad eye. Take the spring and place it into the eye hole of the pad eye. Next tighten the nut on the pad eye to make the spring tight. The spring only needs to be tight enough to prevent it from coming loose when the Sun Tracker is raised. After the spring assist system has been assembled and tightened lower the Sun Tracker and test the system. The spring will become stretched out in the down position to give the Sun Tracker assistance in raising it.
TRACKING ADJUSTMENT.
See below "Testing the Sun Tracker" for hints on adjusting the Sun Tracker. The Sun Tracker only needs to be adjusted initially once. This is done at the time of installation. After the Sun Tracker has been properly adjusted you will not need to adjust it again. Using the remote transmitter, push the "Rotate" button. 1st hold the button down until the Sun Tracker has rotated a full 360 degrees. 2nd push the "Rotate" button for just a second and release. This will make the Sun Tracker move 15 degrees, or about 1 ½". Repeat this process 24 times. If the Sun Tracker is adjusted correctly the Sun Tracker will end up at the same point that you started. If the Sun Tracker skips or does not fully goes the 15 degrees, then it will need to be adjusted. The Sun Tracker is aligned by adjusting the micro switch located under the top plate. Using an alan wrench, dial the micro switch either in or out. If when you test the Sun Tracker, it skips past the 15 degrees, the micro switch needs to be dialed "Out". If the Sun Tracker does not travel the full 15 degrees, then the micro switch need to be dialed "In". Whenever adjusting the micro switch you only need to dial it in or out just a slight bit. After you have adjusted the micro switch you will want to test the Sun Tracker again. Repeat step 4 to confirm that the Sun Tracker is adjusted properly. Once the Sun Tracker is adjusted, it will not need to be adjusted again.
Wiring Diagram 1
SYSTEM WIRING DIAGRAM
SYSTEM WIRING DIAGRAM
BATTERY WIRING DIAGRAM
SOLAR PANEL WIRING DIAGRAM
Wire the panels together in Parallel, Positive to Positive and Negative to Negative. Connect the wires to the Junction box as show in the picture. Wire the Sun Tracker Red wire (+) from the top mounting plate to the bottom Junction Box, + to + and run a Negative wire from the bottom Junction Box to the Sun Tracker Top mounting plate on the side to the Ground Screw.
TESTING THE SUN TRACKER
Once the Sun Tracker has been fully installed it needs to be tested. To do this:
1. Turn the electronics box on.
2. Using the remote transmitter, push the "Up" button and raise the Sun Tracker.
3. It is best to test the Sun Tracker when you are on the roof of the RV.
4. Using the remote transmitter, push the "Rotate" button. 1st hold the button down until the Sun Tracker has rotated a full 360 degrees. 2nd push the "Rotate" button for just a second and release. This will make the Sun Tracker move 15 degrees, or about 1 ½". Repeat this process 24 times. If the Sun Tracker is adjusted correctly the Sun Tracker will end up at the same point that you started. If the Sun Tracker skips or does not fully goes the 15 degrees, then it will need to be adjusted. The Sun Tracker is aligned by adjusting the micro switch located under the top plate. Using an alan wrench, dial the micro switch either in or out. If when you test the Sun Tracker, it skips past the 15 degrees, the micro switch needs to be dialed "Out". If the Sun Tracker does not travel the full 15 degrees, then the micro switch need to be dialed "In". When ever adjusting the micro switch you only need to dial it in or out just a slight bit.
5. After you have adjusted the micro switch you will want to test the Sun Tracker again. Repeat step 4 to confirm that the Sun Tracker is adjusted properly. Once the Sun Tracker is adjusted, it will not need to be adjusted again.
6. See photo below for the location of the micro switch
1. Turn the electronics box on.
2. Using the remote transmitter, push the "Up" button and raise the Sun Tracker.
3. It is best to test the Sun Tracker when you are on the roof of the RV.
4. Using the remote transmitter, push the "Rotate" button. 1st hold the button down until the Sun Tracker has rotated a full 360 degrees. 2nd push the "Rotate" button for just a second and release. This will make the Sun Tracker move 15 degrees, or about 1 ½". Repeat this process 24 times. If the Sun Tracker is adjusted correctly the Sun Tracker will end up at the same point that you started. If the Sun Tracker skips or does not fully goes the 15 degrees, then it will need to be adjusted. The Sun Tracker is aligned by adjusting the micro switch located under the top plate. Using an alan wrench, dial the micro switch either in or out. If when you test the Sun Tracker, it skips past the 15 degrees, the micro switch needs to be dialed "Out". If the Sun Tracker does not travel the full 15 degrees, then the micro switch need to be dialed "In". When ever adjusting the micro switch you only need to dial it in or out just a slight bit.
5. After you have adjusted the micro switch you will want to test the Sun Tracker again. Repeat step 4 to confirm that the Sun Tracker is adjusted properly. Once the Sun Tracker is adjusted, it will not need to be adjusted again.
6. See photo below for the location of the micro switch
Home of the Sun Tracker "Patent Pending"