Installation Manual for Solar Lighting Kit

™
SLK
solar systems
SOLAR LIGHTING KIT
Installation Manual for Solar Lighting Kit
Lumina
Solar Module
SPCC10
Charge Controller
+ -
+ -
+ -
+ -
+ -
+ -
+ -
+ -
Fuse
Fuse
Solar Module
Lumina
+
Battery
Installation Manual for Solar Lighting Kit
Please unpack your kit carefully. Check and identify all the components as follows.
Kit Contents:
Description
Solar module SP20
Lumina light fitting
Fluorescent lamp 9W Solar charge controller, SPCC10, 12V
Cable 50m, c/w solar module connectors fitted Battery cable with fuse and croc clips, 2m
Cable tie
Solar module mounting bracket
Phillips screwdriver
Slotted screwdriver
Wire stripper
Cable clips
15A spare fuse
Coach screw (bracket to wall) Bolt M5 12mm (bracket to solar module)
Nut M5
Shake proof washer Qty
2
4
4
1
1
1
10
8
1
1
1
50
2
8
8
8
8
Stock Number
9SPS0020
96321200
68509807/01
94100000
63132609
9K000050
63910177
73230608
GSLK1610
GSLK2610
GSLK0610
63915609
61315291/01
79081712
79054310
79150659
79350676
Bolt M5
12mm
x8
Nut
M5
x8
Fluorescent
lamp 9W
Solar Charge
Controller
SPCC10
x1
x4
Lumina light
fitting
Shake
proof
washer
Cable
clip
x50
x8
Cable tie
x4
x10
Coach
screw
x8
Solar module
SP20
x2
Battery cable with fuse
and croc clips
x1
Slotted
screwdriver
x1
Phillips
screwdriver
x1
Spare
fuse
x2
Wire
stripper
x1
Solar module
mounting bracket
x8
Cable
50m
x1
SAFETY WARNING:
• Take great care when handling the battery.
• Do not short-circuit the battery terminals with any wire,
tool, necklace or watch strap etc.
• Avoid sparks near the battery as it may cause the battery
to explode.
• Beware of acid from the battery, which can burn skin and clothes.
• Wash your hands thoroughly after touching the battery.
• Do not eat, drink or smoke near the battery.
• Use the battery in a well-ventilated area and never use it
b) A ‘sealed’ valve regulated battery is a good option.
Gel and AGM types are also good. If, however, a
flooded type is used, then regular topping up with
de-ionised water (available from auto suppliers) will
be necessary.
c) Recommended Sollatek batteries are:
i) SFGM36-12, 12V, VRLA, 36Ahr
ii) SFGM48-12, 12V, VRLA, 48Ahr
iii) SFGM57-12, 12V, VRLA, 57Ahr
For more information on batteries log on to
www.sollatek.com
d) A larger 12V battery can be used to give longer
running time provided there is enough sunlight
available during the day to charge it.
in a sealed container.
Important Notes.
• Follow the correct sequence of the connection
procedure below so as to avoid damage to system
components and to avoid sparks while connections are
made.
• If a battery is used which requires you to add acid, follow
the battery manufacturers instructions carefully.
• The cable supplied has two special connectors already
fitted to it, one each end. Do not cut them off. These are
for connection to the solar modules. For this reason, run
the solar module cables to the charge controller as the
first cable run. However, do not connect them to the
charge controller until the battery and lights are
connected. It is suggested you run the cables to the
modules but leave the cables unplugged from the solar
modules until last.
1) Battery Selection.
a) The SKL4 is not supplied with a battery and so this
will need to be purchased separately. It must be a
12V, lead-acid type. It is recommended that you use
a good quality deep discharge solar battery of
between 36Ahr to 90Ahr (amp per hour).
If a solar battery is not available, then a recreation
battery could be used but you should choose one of
approximately twice the Ahr rating. If no better
alternatives are available, then a vehicle/truck battery
could be used but it should be 4 times the
recommended Ahr rating, ie a minimum of 150Ahr,
otherwise battery life and system
performance will be reduced.
2) Component Positioning.
Decide upon the position of each of the system
components around the building, taking into
consideration the following points:
a) The Solar module should be placed outside in direct
sunlight away from shade (e.g. tree, building etc…);
south facing in the northern hemisphere or north
facing in the southern hemisphere. Remember that
shade will move as the sun moves at different times
of the day. Position it so that it will not get damaged
by animals or vehicles and to reduce the chance of
theft. Refer to the centre section of this booklet for
the correct tilt angle.
b) Position the battery and charge controller around
the centre of the system so as to keep cable runs short and improve system performance.
c) The cable between the battery and charge
controller should be kept short, preferably less than
2 meters.
d) The cable between the solar modules and the
charge controller should also be kept fairly short if
possible, preferably less than 2meters.
e) Sollatek recommends that the Luminas are installed
just above eye level and easy to reach, in order to
operate the light switch on each Lumina. Keep the
cables as short as possible to achieve maximum
power.
3) Mounting Instructions.
iv)
Ensure there is free air movement behind the
modules to give good ventilation, so that they don’t
get too hot in the sun. This is especially important
when mounted on metal roofs.
v) Ensure the dark, patented surface faces the sun and
the face with the cable is behind.
Figure 1: Checking cable length between SPCC10 and the Solar Module
a) Mounting the solar module.
i) Ensure you can connect the cable to the back of each
module before finally fixing them (Figure 1).
vi) Tilt the modules directly north or south towards
the equator as described in section 2a. Tilt the
modules at an angle from the flat position, depending
where you are in the world. Appendix 1 is a useful
page you can tear out and use to check the angle. Generally speaking, countries on the same latitude
(distance from the equator) will use the same tilt
angle.
vii) Make sure the modules are secure to withstand high
winds.
Figure 2: Fixing the mounting bracket to the Solar module
ii) Mount the x8 brackets to the x2 solar modules by
using the Bolt M5, Nuts M5 and shake proof washer
(Figure 2).
Figure 4: Removing of Lumina screw cap
Figure 5: Disassembly of the Lumina light fitting
Figure 3: Fixing the solar module to the ceiling
using the supplied coach screw
iii) Mount the solar modules on the roof or wall (refer to
Appendix 1) using the coach screw (Figure 3).
b) Mounting the Lumina light fittings (load).
i) Remove both end covers, the diffuser and the lamp, if
fitted (Figure 4 & 5).
Figure 6: Stripping of cable for connection to the Lumina
Figure 8: Attaching Lumina to wall
iv) Using a further two screws (supplied), attach the
light to the wall or ceiling as required (Figure 8).
Figure 7: Fixing the cable to the Luminax
ii) Strip 5mm of insulation from the cable. Feed the cable
through the entry hole in the base and connect to the
terminal block marked + and - observing correct
polarity. (white/black to‘+’, white to ‘-’). Fit the cable
clamp with the two small screws provided with the
Lumina (Figure 6 &7)
Figure 9: Lamp insertion
v) Insert the lamp until it clicks into place (Figure 9).
Figure 10: Closing the Lumina cap
vi) Slide on the clear lens (diffuser) and attach the small
end cover to complete the installation (Figure 10).
Figure 8: Attaching Lumina to wall
iii) Replace the large end cover over the electronics and
secure to the base using two screws supplied.
vii) Safety
Although the standard Lumina light is designed to
operate from an input voltage of 12 VDC, much higher
AC voltages are present on the internal circuit board
and at the lamp socket during operation, and so due
care should be taken. The Lamps contain mercury
vapour, which could be harmful if the lamp is broken
and the gases inhaled. Due care and attention should
be taken when disposing of expired lamps.
80º
ON
70º
O
Y
EW
N
N
IC
E,
PO
R
R
K
TL
A
N
D
PA
RI
S
LO
ND
60º
M
A
D
RI
D
ST
LO
U
IS
KA
BU
SA
N
L
DI
EG
CA
O
I
M
UM
KHARTO
L
, BANGA
ORE
,
, ACCRA
,LAGOS
NAIROB
I, D
H O R I Z O
la
70º
So
45º
If in the northern hemisphere: face your panel directly south.
le
Solar modu
If in the southern hemisphere: face your panel directly north.
70º
So
40º
Ground
Ground
Wall
ule
od
m
lar
15º
45º
le
Solar modu
Ground
15º
Ground
O
30º
RO
So
round
DAR
HARARE
AM
ES SALA
O N T A L
20º
45º
ule
od
m
lar
G R O U N D
le
Solar modu
15º
Ground
MINIMUM
T ILT
0º
15º
Ground
Wall
du
mo
70º
Wall
Wall
MI
le
MIA
Wall
Angle of solar module from the ground
Ground
Wall
So
lar
mo
du
le
Ground
50º
le
du
Wall
o
rm
Wall
Wall
le
du
mo
So
lar
Appendix 1. solar module tilt angle.
c) Mounting the SPCC10 charge controller.
i) The controller should be as close to the battery as
possible in a well-ventilated area and away from
direct sunlight.However, do not mount it directly above the battery as acid fumes can damage a charge
controller.
ii) Leave space (10 cm minimum) to the right of the
controller for air to circulate round the black heat sink.
iii) Remove the lower plastic cover from the SPCC10 by
removing the screw caps and the two screws. Mount
the SPCC10 onto a flat, vertical surface with the cable
glands facing the floor.
4) System connection.
a) Observe correct polarity throughout
the system - connect negative to
negative and positive to positive.
b)
The cable supplied with the lighting
kit is coloured white and white/black. Use the white for the negative connections and the
white/black for the positive connection. Do this
throughout the system.
c) The cable supplied has two special connectors
already fitted to it, one each end. Do not cut them
off. These are for connection to the solar modules.
For this reason, run the solar module cables to the
charge controller as the first cable run. However,
do not connect them to the charge controller until
the battery and lights are connected. It is suggested
you run the cables to the modules but leave the
cables unplugged from the solar modules until last,
to avoid sparks and damage.
d) When running cables, make sure they will not
get damaged by sharp edges, doors closing, people
stepping on them, animals, etc. Try to keep them up
high where possible. Also be careful they will not trip
people up.
Figure 11: Fixing the SPCC10 to the wall
iv) Insert one screw into the wall upon which to hang the
controller (on the upper hole). After this, insert
mounting screws into the two lower holes in the
bottom section of the SPCC10 (Figure 11).
d) Mounting the battery.
i) The battery should be kept off the ground, preferably
on wood.
ii) Avoid short circuits from contact with metal objects/
tools.
iii) The battery should be positioned in a cool, dry place.
iv) Allow good ventilation and never place in a sealed
container.
v) Avoid sparks and naked flames near the battery as it
may explode.
vi) Keep the battery terminals clean. A small amount
of petroleum jelly smeared over the terminals will
help reduce corrosion.
Figure 12: SPCC10 connectivity
e) Connect the Lumina lights (load) by cable to the
SPCC10 through the left hand cable gland. The cables
should have been stripped of 8mm of insulation and
inserted into the terminals, observing the correct
polarity. (white / black is positive “+”, white is negative
“-“) (Figure 12).
i) Power up the system by fitting the fuse in the battery
cable (Figure 14).
j) Check the SPCC10 charge controller, one of the LEDs
should be lit.
k) Turn on each of the Lumina lights and check they all
work.
l) Figure 13: Removing of battery cable fuse before connectivity
f) Remove the fuse from the ready-assembled battery
cable before connection. Connect the battery cable
to the charge controller, then to the battery. The red
clip goes on the red/positive terminal of the battery,
the black clip on the negative (Figure 13).
g) Connect the solar module’s cable into the charge
controller but do not connect the plugs on the rear
of the solar modules yet. (Alternatively, cover the
solar modules with a blanket to prevent them
generating power).
h) Ensure all the wiring is secure using the cable clips and cable ties provided.
Turn off all the Luminas. Plug in the cables at the back
of the solar modules (or remove the blanket covering
them). This will now charge the battery during the
day.
m) It is highly recommended that you leave the system
with the lights off and charging the battery from the
solar modules until the battery is fully charged. The
state of charge is indicated by the LEDs on the SPCC10
charge controller. Once the ‘Full’ LED lights, the
system can then be used by turning on the lights.
n) The charge controller will protect the battery from
over-charging by automatically disconnecting
the solar modules when the battery is full. It will
automatically reconnect them as the charge gets
used again.
o) The charge controller will automatically protect the
battery from over-discharge by disconnecting the
lights if the battery gets too low. If this happens, you
can as an emergency, turn off all the lights, wait a
short while and press the reset button on the SPCC10.
You may then be able to turn on one light for a few
minutes longer.
p) If you find the lights go off sooner than you want, you
should consider saving power by only turning them
on when needed. If you still have a problem, consult
the troubleshooting guide overleaf.
Figure 14: Battery connectivity
5) Troubleshooting
Symptom
Cause
Solution
Lamp not operating
Incorrect input voltage Blown fuse Dead or broken lamp Reverse polarity connection
Switch not turned on
Charge controller off (Red LED)
Damaged cable from charge controller
Output fuse blown
Check input voltage
Establish cause and replace fuse
Replace lamp
Rewire, noting + and –
Turn on Lumina switch
Allow battery to charge next day
Check and repair cable
Check fuse inside SPCC10
Dim lamp
Incorrect voltage input
Incorrect lamp wattage
Lamp not securely fitted
Bad electrical connection
Old lamp
Check voltage
Replace with correct lamp
Fit correctly
Check wiring for faults
Replace lamp
Flickering tube
Bad electrical connection
Lamp not securely fitted
Lamp at end of life
Check wiring for faults
Fit correctly
Replace lamp
Battery doesn’t charge
Solar modules not properly connected
Wrong polarity on solar modules
Solar modules shaded from the sun
Check module connections.
Ensure that polarities are correct
Re-position solar modules
Battery status LEDs do not illuminate
Battery incorrectly installed.
Battery fuse blown
Battery wiring fault
Battery acid is very low (wet batteries only)
Battery is dead
Check battery cables and polarit.
Check battery fuse
Check battery wiring for problems
Fill the battery cells with distilled water
Replace
Internal load fuse blows (15Amp)
Short circuit in the load Load is drawing too much current
Find and repair short circuit
Reduce load size
Rapid on/off operation of relays (chattering) Voltage thresholds have been set incorrectly
Battery is significantly undersized
Solar modules working but battery fuse blown
Adjust thresholds to limits indicated in
these instructions
Increase number or capacity of battery
Replace battery fuse
Incorrect system operation
System needs re setting.
Press reset button on SPCC10
System shuts down too soon
Too much load
Poor connection
Solar module dirty/damaged
Don’t turn lights on so much
Clean/check connections esp on battery
Clean/replace solar module
6-9
hours
9-15
hours
18-29
hours
East
Africa
6-8
hours
8-10
hours
12-16
hours
25-30
hours
West
Africa
6-8
hours
8-10
hours
12-16
hours
25-30
hours
North
Africa
7-8
hours
9-10
hours
13-16
hours
27-30
hours
South
Africa
2-6
hours
3-8
hours
4-11
hours
8-22
hours
Central
Europe
3-5
hours
5-7
hours
7-11
hours
13-22
hours
Southern
Europe
Number of hours the Lamps will run in various locations around the world using a standard 36Ahr 12V solar flat plate gel battery
and 2 x 20WATT modules
Number of Luminas
5-7
hours
These figures show a range from worst month in year for sunshine and best month. For example in West Africa you can expect to run 4 Luminas
for up to 8 hours in summer and 6 hours in winter months.
These figures assume the battery is in good condition and the installation has been carried out correctly.
It also assumes the Solar module installation and tilt angle is correct and is exposed to sunshine most of the day without any obstacles.
PRO
VI
WOR
LD
E
G
ER
CLEA
W
N
RE
LIA B LE P
O
Internet:
www.sollatek.com
ID
ISO9001: 2000 accredited company
Fax:
International: +44 1753 685306
National: 01753 685306
E-mail:
sales@sollatek.com
W
IN
Tel:
International: +44 1753 688300
National: 01753 688300
Sollatek provides you with full back up support
and a two year worldwide warranty on all
products, with local support in
over
t went y
countries
worldwide.
D
Sollatek (UK) Ltd
Unit 10 Poyle 14 Newlands drive,
Poyle, Slough SL3 0DX, U K.
™
solar systems
www.sollatek.com
All weights and dimensions are approximate.
Specifications are subject to change without prior
notice. ©Sollatek (UK) Limited 2007. All Rights
Reserved. SOLLATEK and the SOLLATEK device are the
trade marks of the Sollatek group of companies.
TWO YEAR WORLDWIDE WARRANTY
(subject to terms and conditions).
SLK4 user manual Nov 08
Artwork ID: 10910037
Stock code: 74137830
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