Global Solar powerflex Installation Instructions Manual

Mobile solar power for your rv

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Global Solar Energy recommends having the

PowerFLEX™ MOBILE Solar Kit professionally installed.

Although the kit is relatively straightforward to install,

working with high current battery systems and working

on the roof of the RV can be dangerous.

Global Solar Energy will be happy to work directly with

your dealer or service center of choice to ensure a

proper, long lasting installation. Just send us their

contact information or have them contact us and we'll

take care of the rest.

GSE Document: 1000564 Rev. E

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Summary of Contents for Global Solar powerflex

Page 1 RV can be dangerous. Global Solar Energy will be happy to work directly with your dealer or service center of choice to ensure a proper, long lasting installation. Just send us their contact information or have them contact us and we’ll...
Page 2 Contact Global Solar Energy Technical Support if you have any questions, concerns or would like to discuss you special application.
Page 3: Installation Instructions
PowerFLEX MOBILE Installation Instructions Solar Power for Your RV Global Solar Energy, Inc. 8500 S. Rita Road Tucson, AZ 85747 www.GlobalSolar.com Technical Support www.GlobalSolar.com 520-546-6313 DOCUMENT NO. 1000564 REV. E...
Page 4: Table Of Contents
Technical Support ............................20 About The Solar Charge Controller ......................20 Charge Controller Speci cation s : ....................... 21 Solar Panel Speci cations: ......................... 21 Installation Summary Chart ........................22 Global Solar® PowerFLEX™ Mobile Limited Warranty................23 DOCUMENT NO. 1000564 REV. E...
Page 5: Introduction & Safety Information
READ THESE INSTRUCTIONS COMPLETELY BEFORE BEGINNING INSTALLATION FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN DAMAGED PRODUCT, DAMAGE TO THE RV, AND/OR PERSONAL INJURY GLOBAL SOLAR ENERGY HIGHLY RECOMMENDS HAVING THIS SYSTEM INSTALLED BY A PROFESSIONAL RV TECHNICIAN THE INSTALLER SHOULD BE FAMILIAR WITH:...
Page 6: Kit Contents
Your PowerFLEX MOBILE Solar Power Kit includes the following items: ITEM PFM-2K PFM-1K PFM-1E PowerFLEX Solar Panel Solar Charge Controller Kit 1. Charge Controller, 1ea. 2. Standoﬀ Blocks, 2ea. 3. Ring Terminals, 2ea. 4. #6 x 1” Screws, 2ea. 5. #6 x 2” Screws, 2ea.
Page 7: Storage & Handling Precautions
Failure to follow these Storage and Handling guidelines can lead to product damage and premature failure and violate the PowerFLEX MOBILE Limited Warranty. For the protection of PowerFLEX MOBILE kits, the kit contents and sealed boxes must always be stored between temperatures of 60°F (15°C) and 85°F (30°C).
Page 8: Solar Panel Locaton
SOLAR PANEL LOCATON The following recommendations for location of the PowerFLEX solar panels are important to ensure best performance and aesthetics. The PowerFLEX solar panels: Need to be placed close enough to each other so that the pre-fabricated cables will reach. The included “Y”...
Page 9 If such a yellow surface is visible, repeat the scrubbing step until the yellow disappears, leaving a clean white colored surface. E. Rinse the roof with water thoroughly to avoid any residue buildup. F. For EPDM roofs, wipe the area where the PowerFLEX panels will be adhered with Isopropyl Alcohol.
Page 10: Installing The Solar Panels
SHOULD BE COVERED WHENEVER WORKING ON THE SOLAR POWER SYSTEM IN ORDER TO AVOID ELECTRICAL SHOCK AND/OR ARCING. A. The PowerFLEX solar panels included a long piece of cardboard in the package. This piece of cardboard should be cut to the length of the solar panel and used to shade it during the installation.
Page 11: Installing The Edge Trim
3. Repeat above step for the remaining 3 panel edges, in the recommended sequence. 1. Ensure Proper Fit A. Lay the 7 rubber edge trim pieces around the perimeter of the PowerFLEX panel. Starting at the end opposite the cables [labeled “1” above], carefully place the trim piece so that the inner edge of edge trim piece is centered and butted against the edge of the panel.
Page 12 Trim at bottom of panel Trim at top of panel Trim at corners with 1/8” gap All edge trim in place 2. Procedure for mounting-edge attachment to edge of panel A. Prepare the tip of the adhesive tube by cutting the tip at a 45° angle. The opening should be approximately 3/16”...
Page 13 B. Starting with the edge trim piece labeled in the sketch above as #1, i. Apply the liquid adhesive to the panel edge, leaving a bead approximately 3/16” wide. The trim piece must be placed within 10 minutes of dispensing the adhesive.
Page 14: Special Roof Types
C. Repeat above process for panel edge #3 and#4, being sure to i. Butt the edge of each piece against the already-placed pieces AND ii. Ensure that the outer edge of the new piece matches the outer edge of the existing piece [See above sketch].
Page 15: Routing The Cable
ROUTING THE CABLE The overall circuit is generally as follows Your PowerFLEX MOBILE kit came with 20’ lengths of 10 AWG solar cable with connectors to the panels and a 20’ length of 10 AWG / 2-conductor cable to link the controller to the battery.
Page 16 Wire Size (AWG) for <7% Voltage Drop Distance (FT) Current (A) (# PFM Panels) 6 (1) 12 (2) 18 (3) 24 (4) 30 (5) 36 (6) Note: 90°C, Copper Conductor When routing the cable, leave a foot or so extra at each end to make connections easier. In most cases, the refrigerator vent is the best place to route the cable from the roof into the RV.
Page 17 Cable tie mounts must be applied in the following manner to ensure proper adhesion: Insert the supplied cable tie into the cable tie mount. Apply the supplied adhesive to the bottom of the cable tie mount and aﬃx to the location where you will be routing the cabling.
Page 18 Continue routing the cable to the solar charge controller location and cut to the appropriate length. Mark the Positive (+) cable prior to cutting. Remember to leave some extra cable to make the ﬁnal connections easier. At the charge controller end of the PV cable, strip 3/8” of insulation to expose the copper wire. Next, cut the loop on one of the included ATC inline fuse holders and strip 3/8”...
Page 19: Connecting The Wiring
CONNECTING THE WIRING Prior to connecting any of the wires, be sure the fuses are removed from the fuse holders and the solar panels are covered. WARNING – RISK OF EXPLOSIVE GASES Working around lead-acid batteries can be dangerous. Batteries generate explosive gases du ing normal battery operation.
Page 20: Maintenance
“BATTERY REVERSE” lights are on, cover the solar panel(s) and check the wiring. MAINTENANCE Proper maintenance is important and will ensure years of reliable performance. If your PowerFLEX MOBILE system will be stored in shaded conditions for longer than one week, it is recommended that the PV system fuse nearest to the battery ﬁrst be removed at the beginning of this storage period and only...
Page 21: Warranty Registration
Use only water or water with mild liquid dish soap to clean the panels. A clean, soft brush may be gently used to remove stubborn deposits. Never use high pressure sprayers to clean the solar panels. Avoid long periods of standing water on the solar panels. Make sure the water channels are clear and free of obstructions.
Page 22: Appendix
APPENDIX Technical Support For technical assistance, please contact Global Solar Energy at: www.globalsolar.com 520-546-6313 About The Solar Charge Controller For further controller information, see Manufacturer’s literature. The solar charge controller is designed to protect your 12 volt GEL or LEAD ACID battery from being overcharged by the solar panels and against connecting in reverse polarity.
Page 23: Charge Controller Speci Cations
Do not exceed the maximum input ratings. Do not reverse the BATTERY and ARRAY connections to the controller. If your PowerFLEX MOBILE system will be stored in shaded conditions for longer than one week, it is recommended that the BATTERY be disconnected from both the load and also the ARRAY.
Page 24: Installation Summary Chart
Installation Summary Chart REMEMBER SAFETY AT ALL STEPS Step # Description Key Requirements Ensure that the roof is No undue discoloration or chalking. Must clean up properly suitably new for good with the recommended methods. See the Roof Surface adhesion Preparation Section of the Installation instructions for details Choose a suitable location for See the Solar Panel Location Section of the Installation...
Page 25: Global Solar® Powerflex™ Mobile Limited Warranty
Global Solar® PowerFLEX™ Mobile Limited Warranty Global Solar Energy, Inc. is proud to oﬀer the PowerFLEX™ Mobile product with a FIVE-YEAR Limited Warranty. Global Solar warrants the product will be free from defects in materials and workmanship under normal use conditions during the warranty period. This limited warranty applies only if the product was (a) purchased from an authorized Global Solar dealer or distributor and (b) stored, installed and maintained according to Global Solar’s instructions.