I N S T A L L A T I O N M A N U A L

UNIGIZER

™

SOLAR SYSTEM / SOLAR KIT

with 1, 2 or 3 J Unigizer and 20, 30 or 40 W Solar panel

Before you start

These instructions are for two solar products, the Unigizer™ Solar System and the Solar Kit. Installation of the components will take around 15 minutes and requires only one person. Ensure you have all the equipment required before beginning the installation.

Components included in the system/kit

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Unigizer™ Solar System: a 1, 2 or 3 J Unigizer™ mains/battery energizer a 20, 30 or 40 W solar panel and mounting bracket an accessories and spares bag (mounting screws, spare fuses etc) a compass an inclinometer (angle finder) a battery a battery box

Solar Kit (does not contain an energizer):

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 a 20, 30 or 40 W solar panel and mounting bracket an accessories and spares bag (mounting screws, spare fuses etc) a compass an inclinometer (angle finder) a battery a battery box

Note:

If you have purchased the Solar Kit, you will need a battery energizer or Unigizer™ mains/battery energizer in order to complete the installation.

Tools you will need

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In addition to the components provided in the system/kit, you will also need: a small hammer a 13 mm spanner a 10 mm spanner or 10 mm nut driver a marker pen

821613 issue 1, 10/2012

© Tru-Test Limited, 2012 All rights reserved

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Selecting a location for the installation

The solar panel should be set to face north. It is critically important for the solar panel to be installed in a location where NO objects will cast a shadow on it. In winter the sun sits very low on the horizon and shadows cast by distant objects can become an issue. Even partial shading from tree branches etc will produce a significant reduction in available output current and the batteries may not receive sufficient charge.

Preparing the mounting post

The Unigizer™ solar panel bracket is best suited for mounting onto a wooden fence post. A standard 1.2 m high, 130 mm diameter (type 1) fence post with a flat top is ideal. If a new fence post is to be installed, it must be planted firmly in the ground so that it does not shift in a storm. Use concrete or a professional post rammer to ensure that the post is stable.

Marking the post with ‘true north’

The highest amount of energy can be extracted from the sun if the solar panel is set to face

‘true north’. A compass points to ‘magnetic north’. The difference between the two is called the ‘magnetic declination’.

The map opposite indicates the magnetic declination. For example, Auckland’s magnetic declination value is 19.4 °.

Place the compass provided on top of the mounting post and align the red needle pointer to match the correct declination value for your location. True north is now indicated by N on the compass. Use a marker pen to mark an arrow on top of the wooden post indicating north, as shown.

Tip:

Keep all metal objects and electronic devices away from the compass at all times or the compass may not function correctly.

Mounting the base on the post

Preparing the base

A metal base is used to secure the solar panel mounting bracket to the post. The base comes attached to the solar panel mounting bracket for safekeeping, so begin by removing it. Locate the two 6 mm stainless steel cap screws on the base and remove these using the 6 mm Allen key provided. Put the screws aside as these will be used later.

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Fixing the base to the post

1 Find the five 6 mm x 75 mm coach screws provided in the accessories bag. These are provided for fixing the base to the mounting post.

2 Place the base on the post. If the post is small, the base can be positioned in the centre, but if the post is large, position the base closer to the north edge to allow a greater angle adjustment.

3 Use the hammer to locate a coach screw in the centre hole.

4 Tighten the coach screw down using the 10 mm spanner or nut driver, but not fully.

5 Rotate the base so that the holes for the two 6 mm stainless steel cap screws lie in the East/West plane.

6 Use the hammer to locate the other four coach screws.

7 Drive all five screws down fully using the 10 mm spanner or nut driver.

Caution!

The base is made of aluminium and may crack if the screws are over-tightened.

Mounting the solar panel and bracket

1 Lift up the solar panel bracket assembly and lower it onto the base. Rotate the bracket until the holes for the two 6 mm stainless steel cap screws lie in the East/West plane, then carefully hand turn the screws until they locate into the base nuts.

2 Use the 6 mm Allen key provided to tighten the two set screws enough to hold the base down but still allowing the bracket to rotate freely on the base.

3 Rotate the panel on the base until the face of the solar panel is facing true north as shown by the arrow you marked earlier.

4 Tighten the two set screws firmly to lock the panel in position.

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Setting the solar panel tilt angle

The solar panel must be tilted to maximise the solar energy that can be collected during the difficult winter months. The ideal tilt angle will vary depending on the location of the installation site.

As a general rule, the solar panel tilt angle in winter should be set at ‘the angle of latitude for the site’

PLUS 15 °.

The table opposite shows the latitude and tilt angle for the main centres:

To set the solar panel tilt angle:

1 Place the inclinometer (angle finder) on the face of the solar panel as shown.

2 Using the table opposite, note the main centre closest to your location and tilt the solar panel to the appropriate angle. For example, tilt the solar panel 52 ° if you are near Auckland.

3 Use the 13 mm spanner to lightly tighten the tilt angle setting nut. Double-check the angle setting and then firmly tighten the setting nut. Check that the solar panel cannot move at all. If there is any movement then readjust and tighten.

Tilt angles for main centres

Location

Whangarei

Auckland

Latitude Tilt angle

36 ° 51 °

37 ° 52 °

Wellington 41 °

Christchurch 42 °

56 °

57 °

Dunedin

Invercargill

45 °

46 °

60 °

61 °

Preparing the energizer

Familiarising yourself with the Unigizer™ mains/battery energizer (supplied with Unigizer™ Solar Systems only)

Open the box and check the contents. There should be:

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 a 1, 2 or 3 J Unigizer™ mains/battery energizer a user manual a battery connection lead set a fence connection lead set a mains power supply.

Note:

When using the Unigizer™ mains/battery energizer provided as part of this solar system or with the solar kit that you have purchased, you will not require the mains power adaptor provided. Retain it for possible use in the future.

Preparing the battery connection lead set

1 For a permanent solar installation, the standard battery lead set must have the crocodile clips removed before it can be connected to the battery.

2 Carefully pull the leads in order to separate them from the crocodile clips.

Caution!

Be careful not to damage the wires.

Connecting the solar panel and battery

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Connect the solar panel’s battery leads and the energizer’s battery leads to the battery:

Positive solar panel and battery leads ( + Red) connect to the positive battery terminal (+ Red)

Negative solar panel and battery leads (- Black) connect to the negative battery terminal (- Black)

Warning!

If the solar panel is connected incorrectly, the solar panel’s safety fuse will blow and will need to be replaced. The replacement fuse must be a 2 A, 5 x 20 mm, glass quick blow fuse. The safety fuse is located in the terminal box which is on the back of the solar panel.

Preparing the energizer

1 Mount the energizer and connect it to the fence as described in the energizer’s user manual.

2 Connect the other end of the energizer’s battery leads to the energizer.

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Using the solar system/solar kit

Solar panel charging and trouble shooting

The solar panel features a built-in electronic battery charging module designed to maximise the battery charge power by using "maximum power point tracking" technology. The module also maintains full control over the charging of the battery, with automatic switching between "boost" and "float" charging rates to ensure the battery is maintained in peak condition at all times.

The solar charging system is completely automatic and requires no maintenance, however it is important to be aware of the following details:

Charging control

In good sunlight the solar panel will "boost" charge the battery. If the battery voltage rises to 14.5 V, the battery is fully charged and the charging module will reduce the charge voltage to a maintenance "float" voltage of 13.5 V. If the battery voltage drops down below 13.2 V, the "boost" cycle will restart.

Over-current protection

The charging module is fully protected against over-current when the output leads are connected together or if a flat battery is connected.

Bad battery protection

If the charging module detects that a totally discharged battery (below 10 V) has been connected, it will only be charged at a low trickle charge rate

(0.15 A). This will continue until the battery voltage rises to within normal limits and then it will automatically switch over to a boost charge rate.

Important! -

The solar panel output voltage should only be measured when a 12 V battery is connected.

Reverse battery protection

In the rare situation that the 12 V battery is connected in reverse, the safety protection fuse on the charging module will blow to prevent damage. This 2 A glass fuse must be replaced before the Solar System can be used.

Protection fuse replacement

Remove the four No.1 Philips screws. Remove the lid of the solar panel terminal box. Locate, remove and then replace the 2 A fuse. A spare fuse is provided with the kit, however 2 A glass fuses (20 mm x 5 mm) are readily available from any good electronics store. Refit the lid and tighten the screws sufficiently to ensure the lid is secure. Over-tightening the screws will over-stress the plastic lid, but will not improve the water seal.

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