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Purkeys SOLAR BOLT Installation Manual

Charging system
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SOLAR BOLT™ CHARGING SYSTEM
INSTALLATION GUIDE
Doc 1.00
INST052

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Summary of Contents for Purkeys SOLAR BOLT

  • Page 1 SOLAR BOLT™ CHARGING SYSTEM INSTALLATION GUIDE Doc 1.00 INST052...

  • Page 2: Table Of Contents

    INSTALLATION GUIDE CONTENTS General Information ........................... 2 Solar Panel Installation ........................3 Solar Bolt Main Harness and Indicate Installation ................4 Cable Routing ............................ 9 Solar Bolt Controller Installation ....................... 10 Solar Bolt Indicate Battery Connections ................... 13 Solar Panel Configurations ......................16 Parts List ............................

  • Page 3: General Information

    The Solar Bolt provides three-stage charging for the batteries when the vehicle’s primary charging system is not active. It senses when the primary charging system is active and matches the charge voltage.

  • Page 4: Solar Panel Installation

    3. Peel the adhesive lining off the back of the panel and press firmly on the panel to ensure it adheres to the trailer. Applying heat to the trailer top is recommended to help the adhesive stick. P: 479.419.4800 | F: 479.419.4801 | www.purkeys.net...

  • Page 5: Solar Bolt Main Harness And Indicate Installation

    SOLAR BOLT MAIN HARNESS AND INDICATE INSTALLATION 1. Connect the Solar Bolt main harness to the 90 watt solar panel. The solar connectors on the main harness are already installed and ready to attach to the solar panel positive and negative wires.
  • Page 6 #12 x ¾” hex tek screws. IMPORTANT: Place the supplied cable clamps along the 2 conductor jacketed main harness every 6 inches to ensure proper support for the cable. Avoid sharp edges and possible chaffing points. Figure 5 P: 479.419.4800 | F: 479.419.4801 | www.purkeys.net...
  • Page 7 SOLAR BOLT INSTALLATION GUIDE 5. Mount the Solar Bolt Indicate at the front of the trailer via the mounting holes on the plate that the controller is mounted to. Figure 6 6. Route the jacketed 2 conductor input harness of the Solar Bolt Indicate over to the dual pole receptacle on the opposite side of the trailer.
  • Page 8 2 dual pole bolts connecting the positive and negative cables to the receptacle. Route the 2 conductor Solar Bolt Indicate input harness into the dual pole nose and cut off any excess. Apply ⅜” black heat shrink to the area where the jacketing was cut off to prevent water intrusion.
  • Page 9 Figure 10 10. Secure the Solar Bolt Indicate battery harness to the front of the trailer using the supplied nylon clamps and #12 x ¾” hex tek screws. IMPORTANT: Place the supplied cable clamps along the 2 conductor jacketed battery harness every 6 inches to ensure proper support for the cable.

  • Page 10: Cable Routing

    Figure 12 2. Once the cable is routed to the battery box, feed both the Solar Bolt main harness and the Solar Indicate battery harness into the battery box through a dome nut or a grommet. DO NOT cut the two harnesses until the mounting location for the Solar Bolt controller is determined.

  • Page 11: Solar Bolt Controller Installation

    SOLAR BOLT INSTALLATION GUIDE SOLAR BOLT CONTROLLER INSTALLATION 1. Mount the Solar Bolt controller to the liftgate battery box by using the supplied #12 ¾” hex tek screws. Figure 14 2. Determine the appropriate amount of cable needed to make the connections to the Solar Bolt controller, then cut excess cable.
  • Page 12 SOLAR BOLT INSTALLATION GUIDE 3. Connect the blue wire from the Solar Bolt main harness to the wire on the Solar Bolt controller labeled SOLAR POSITIVE. Solder and heat shrink. Figure 16 4. Connect the white wire from the Solar Bolt main harness to the white wire located on the Solar Bolt controller.
  • Page 13 SOLAR BOLT INSTALLATION GUIDE 5. Connect the ground wire from the Solar Bolt controller to the liftgate battery negative terminal. Figure 18 6. Connect the positive wire from the Solar Bolt controller to the liftgate battery positive terminal. Figure 19...

  • Page 14: Solar Bolt Indicate Battery Connections

    1. Determine the appropriate amount of cable needed to reach the liftgate batteries, and cut off the excess cable. Strip the outer jacket of the Solar Bolt Indicate battery harness to the appropriate length so each wire can reach the liftgate batteries.
  • Page 15 3. Crimp supplied ⅜” ring terminal to the black wire on the Indicate harness. Solder and heat shrink. Figure 22 4. Connect the black wire to the liftgate battery negative terminal. Figure 23 P: 479.419.4800 | F: 479.419.4801 | www.purkeys.net...
  • Page 16 Crimp supplied fuse holder to the red wire of the Indicate harness. Solder and heat shrink. Figure 24 6. Connect the fuse holder to the positive terminal of one of the liftgate batteries. Figure 25 P: 479.419.4800 | F: 479.419.4801 | www.purkeys.net...

  • Page 17: Solar Panel Configurations

    180 Watt (2 Solar Panels) 1. Place the second solar panel no more than four inches away from the first solar panel. 2. Connect the supplied Solar Bolt Y Splitter input side to the Solar Bolt main harness (Positive- Positive, Negative-Negative).
  • Page 18 270 Watt (3 Solar Panels) 1. Place the third panel no more than four inches away from the second solar panel. 2. Connect the second Solar Bolt Y Splitter input side to the longest output from the first Solar Bolt Y Splitter (Positive-Positive, Negative-Negative).
  • Page 19 360 Watt (4 Solar Panels) 1. Place the fourth panel no more than four inches away from the third solar panel. 2. Connect the third Solar Bolt Y Splitter input side to the longest output of the second splitter (Positive-Positive, Negative-Negative).

  • Page 20: Parts List

    SOLAR BOLT INSTALLATION GUIDE PARTS LIST PART# MOD00083-K SOLAR BOLT CONTROLLER ASSEMBLY PART# CHRG-006 90 WATT SOLAR PANEL PART# H-00383 SOLAR MAIN HARNESS 50FT P: 479.419.4800 | F: 479.419.4801 | www.purkeys.net...
  • Page 21 SOLAR BOLT INSTALLATION GUIDE PART# MOD00076-K SOLAR BOLT INDICATE PART# BK-1061 SOLAR BOLT INDICATE BAG KIT PART# SLR90W 90 WATT SOLAR BOLT PANEL UPGRADE P: 479.419.4800 | F: 479.419.4801 | www.purkeys.net...
  • Page 22 SOLAR BOLT INSTALLATION GUIDE PART# H-00382 SOLAR BOLT Y SPLITTER PART# BK-1062 SOLAR BOLT HARDWARE BAG KIT PART# INST052 SOLAR BOLT INSTALLATION GUIDE P: 479.419.4800 | F: 479.419.4801 | www.purkeys.net...

  • Page 23: Limited Commercial Warranty Policy

    Product or failure of a part not manufactured by Purkeys. This warranty shall not apply if any Purkeys product is used for a purpose for which it is not designed or is in any way altered without the specific prior written consent of Purkeys. ANY Product alleged by a Customer to be defective must be inspected by Purkeys as a part of the warranty claims process in order to confirm that the part has failed as a result of a defect in material or workmanship.
  • Page 24 INCONVENIENCE, OR OTHER INCIDENTAL OR CONSEQUENTIAL DAMAGES. PURKEYS SPECIFICALLY DISCLAIMS AND SHALL NOT BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES arising out of or from the use of Purkeys products by the Customer. THIS LIMITED WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, INCLUDING COMMON LAW WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE, MERCHANTABILITY, AND ANY OTHER EXPRESS OR IMPLIED WARRANTIES.

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