Renogy Off-Grid Kit General Manual
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Renogy Off-Grid Kit General Manual

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Off-Grid Kit
Renogy off-grid kit general Manual
1
2775 E. Philadelphia St., Ontario, CA 91761
1-800-330-8678

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  • Page 1 Off-Grid Kit Renogy off-grid kit general Manual 2775 E. Philadelphia St., Ontario, CA 91761 1-800-330-8678...
  • Page 2 Important Safety Instructions Please save these instructions. Please read the instruction manual carefully before attempting to carry out any installation or wiring. Contact Technical support for any questions concerning the installation. WARNING: Indicates a potentially dangerous condition. Use extreme caution when performing this task.
  • Page 3  Care should be taken to ventilate the battery area and follow the battery manufacturer’s recommendations. Never smoke or allow a spark or flame near the batteries.  Use caution to reduce the risk of dropping a metal tool on the battery. It could spark or short circuit the battery or other electrical parts and could cause an explosion.

  • Page 4: Table Of Contents

    Table of Contents General Information ......................... 5 Charge Controller Installation ....................6 Mounting Recommendations: ..................... 6 Wiring ............................ 8 Mounting Systems ........................11 Z-Bracket Mounting ......................12 Making Brackets to panel Frame ..................14 Install of Panel to General Mounting Surface ..............19 Install of Panel to RV Roofs ....................24 Rail Mount System ......................31 Roof Securements for Attachment Points ..............34 Rail System Construction ....................37...

  • Page 5: General Information

    This manual will provide you with instructions on how to assemble the various components of a RENOGY Off-Grid Solar Kit. Please refer to the separate Renogy Solar Charge Controller Manual for detailed information about the installation, operation, and programming of the solar charge controller.

  • Page 6: Charge Controller Installation

    Charge Controller Installation RENOGY Starter and RV Kits come with a PWM- type charge controller to optimally charge your batteries from solar power. Each charge controller comes with a separate detailed manual. It is recommended that you read the solar charge controller manual in detail. The instructions in this section are only a brief summary of the information contained in the manual.
  • Page 7 1. Choose Mounting Location—place the controller on a vertical surface protected from direct sunlight, high temperatures, and water. Make sure there is good ventilation. 2. Check for Clearance—verify that there is sufficient room to run wires, as well as clearance above and below the controller for ventilation. The clearance should be at least 6 inches (150mm).

  • Page 8: Wiring

    Wiring 1. Unscrew battery terminals and connect battery connections...
  • Page 9 2. Unscrew PV terminals and connect PV connections 3. Insert temperature sensor block terminal and connect wires (POLARITY SENSITIVITY DOES NOT MATTER)
  • Page 10 4. Insert battery remote sensor block terminal and connect wires (POLARITY SENSITIVE)

  • Page 11: Mounting Systems

    Mounting Systems In this section we are going to cover the basics for mounting 12V solar panels using the following:  RENOGY Z-Bracket Mount system  RENOGY Rail Mount System Rail mount vs. Z-Bracket  RENOGY Single Pole Mount System...

  • Page 12: Z-Bracket Mounting

    Z-Bracket Mounting RENOGY Z-Bracket Mounting The Renogy Z-Bracket Mount System is designed to support the installation of single panel units, generally in off-grid installations. These units are ideal for installation on RV roofs and non- inhabited dwellings such as sheds or garages. It is also suited as attachment to a user made structure such as a wooden frame.
  • Page 13 The following tools and equipment are highly recommended to have available to assist with installation but are in no way a comprehensive list of tools that can ease installation. Installers feel free to substitute comparable equipment where appropriate. Image Component Description Allows for tightening of fasteners.

  • Page 14: Making Brackets To Panel Frame

    May be useful in planning Z-Bracket configuration and positioning. Used direct sealant into penetrations to avoid leaking. Caulking Gun Sealant compatible with your specific installation. Compatible Sealant Used to ensure panel is level and/or plumb to the mounting surface and orientation.
  • Page 15 NOTE: Various solar modules will have different varieties of mounting hole locations. Please align brackets in a way that will evenly support the module.
  • Page 17 Repeat for each Z-Bracket in the set at each corner.

  • Page 19: Install Of Panel To General Mounting Surface

    Install of Panel to General Mounting Surface NOTE: Ensure screw locations are backed by structural element such as a rafter, stud, etc.
  • Page 21 NOTE: Orient panel in level/plumb layout desired before fixing in position.
  • Page 22 NOTE: Begin new fastener at indicated location first to secure panel in level plumb/level layout. Repeat for all fastener locations.
  • Page 23 NOTE: Seal around all edges of bracket and screws. Repeat for all brackets.

  • Page 24: Install Of Panel To Rv Roofs

    Install of Panel to RV Roofs Installation on to the roofs of RV’s typically requires more specialized instruction due to the nature of construction of most commercially available RV roofs. Please note that this section includes the use of a fastener type included in the Z-Bracket kit.
  • Page 25 Used to drill clearance holes for well nuts in roof top. Cordless Drill Used with Cordless Drill to create clearance holes for the well nuts. Must be Drill Bit matched to the well nut’s outer diameter. Recommended variety requires 3/8” bit.
  • Page 26 NOTE: Mark all holes locations in this step as the panel must be removed for well nut insertion.
  • Page 28 NOTE: Use of sealant is optional with a well nut but sealing will add extra assurance. Seal under well nut head. Repeat for all holes.
  • Page 29 NOTE: Orient panel in level/plumb layout desired before fixing in position.
  • Page 30 NOTE: Screw has compressed expanded the well nut, binding into the roof material. Repeat for all fasteners.

  • Page 31: Rail Mount System

    The Renogy Rail Mount System is designed to support off-grid and grid-tied solar photovoltaic systems and is compatible with all Renogy panel sizes, 100 W and larger. The system contains multiple components which will vary depending on a particular installation’s needs. A typical system will be comprised on the rail units themselves coupled with Splice Kits, L-Feet, End Clamps, and Mid Clamps as well as all required fasteners to secure all components together.
  • Page 32 Recommended tools to have before installation: The following tools and equipment are highly recommended to have available to assist with installation but are in no way a comprehensive list of tools that can ease installation. Installers feel free to substitute comparable equipment where appropriate. Image Component Description...
  • Page 33 Sealant compatible with your specific roof installation. Consult with documentation/warranty paperwork for Compatible the roof. Sealant Used to drill pilot holes for the roof 7/32” Drill Bit attachment bolts. Recommended 3” in length. Fastener to be torqued down into roof 5/16”...

  • Page 34: Roof Securements For Attachment Points

    Roof Securements for Attachment Points CAUTION: If using an alternative base for the L-Foot such as the MTS-QMSC or a third party stand- off system to clear obstructions, please consult those product manuals for additional instruction before proceeding with this section. NOTE: Leave L-Foot fasteners attached to the unit as they come packaged.
  • Page 35 NOTES: • Rafters usually spaced 16” or 24” increments. Installer should verify. • Ensure attachment points (L-Feet) are spaced at maximum, 48” apart. •Rails should be spaced apart a maximum of 60% the length of the spanning panel edge. NOTES: •...
  • Page 36 NOTE: Start lag bolt threading by hand.

  • Page 37: Rail System Construction

    Rail System Construction...

  • Page 40: Rail Seating

    Repeat for all continuous rail sets. Rail Seating...

  • Page 43: Panel Securement

    Panel Securement End clamps must be installed a minimum of 1” (30 mm) from the rail edges. WARNING:...
  • Page 45 NOTE: Ensure that the End Clamp is spaced a minimum distance of 1.25” from rail end face.
  • Page 46 Continue mid-clamp procedure for each additional panel.
  • Page 47 NOTE: Ensure that the End Clamp is spaced a minimum distance of 1.25” from rail end face. End clamps must be installed a minimum of 1” (30 mm) from the rail edges. WARNING: Repeat procedure for each panel row.

  • Page 48: Pole Mount System

    RENOGY Pole Mount System The Renogy Pole Mount System is designed for off-grid applications, when mounting to a roof is not ideal. It will support off-grid systems, and panels up to 100W. The system comes complete with all fasteners to secure the system to the installation surface. This system makes the installation of small solar systems easy, affordable and quick.

  • Page 49: Fasten L-Channels To L-Brackets

    Fasten L-Channels to L-Brackets A. Place Washer (H) flush to top surface of L-Channel (B), and align the holes. B. Slide the Spring Washers (I)) onto the Cap Head Bolt’s (G) thread so that the bottom face of the Cap Head Bolt is touching the top surface of the spring washer. C.

  • Page 50: Slide U-Bolt Through Back Face Of L-Channel

    Slide U-Bolt through back face of L-Channel A. Hold the assembled system up to pole so that L-Channel (B) back face is flush to surface of the pole and slide the U-Bolt (E) through the holes. B. Fasten U-Bolt (E) with a large washer (L) and 1 or 2 nuts (M) (depending on how much thread is available.

  • Page 51: Attach Support Arm To Bottom L-Brackets

    Attach Support Arm to bottom L-Brackets A. Flush Support Arm (D) to L-Bracket (C) and align the holes. B. Place washer on Support Arm (D) surface and align holes. C. Feed a Cap Head Bolt (G) through Support Arm (D), and the L-Bracket (C). D.

  • Page 52: Fasten T-Slotted Brackets To Top L-Channel Using The L-Brackets

    Fasten T-Slotted Brackets to top L-Channel using the L-Brackets A. Slide T-Bolt (F) through the top of the T-Slotted Bracket (A) approximately 35mm (1.4in) down. There is no need to place a spring washer, or regular washer through the T-bolt. B.

  • Page 53: Fasten The Bottom Of The T-Slotted Brackets To Support Arm

    Fasten the bottom of the T-Slotted Brackets to Support Arm A. Slide T-Bolt (F) through same slot as previous step. The distance that the bolt should slide depends on the angle that the T-Slotted Bracket (A) was fastened to the top L-Channel (B).

  • Page 54: Slide Panel Onto Brackets And Fasten With End Lamps

    Slide panel onto brackets and fasten with end lamps A. Hold the panel up to the pole mount to determine approximate position that End Clamps (J) must be to hold panel. B. Start with the bottom clamps since they will hold most of the load. C.
  • Page 55 Figure 7 Figure 8...

  • Page 56: Mc4 Connectors

    Caution! General information about MC4 connectors Each RENOGY Solar Panel will have an MC4 Connector System that consists of male and female connectors. This type of connector system is easy to install and uses a “snap-in” type of safety locking clips to lock the two mating connectors. The “snap-in” feature avoids unintentional disconnection.
  • Page 57 − Figure 5.2 Back view of RNG-100D Figure 5.2 shows the MC4 Connectors that come preassembled with each RENOGY solar panel. When purchasing unassembled MC4 Connectors for custom cabling, it is recommended that the appropriate crimper is used; this will avoid loose connections and create a strong internal contact when mating the MC4 Connectors.

  • Page 58: 12V Wiring

    12V wiring In this section, we will show the basic 12V and 24V connections for off-grid systems that use a PWM- type controller. Please follow them thoroughly. The battery must first be wired to the charge controller before the solar panel is connected to the charge controller.
  • Page 59 Refer to Figure 6.1 for connections. 1. First, connect the negative cable to the negative (−) battery post. The best way to secure the battery cable to the battery post is by using a ring terminal. A bolt is sufficient to secure the ring terminal onto the battery post;...
  • Page 60 3. Once the fuse holder is in place, don’t attach a fuse just yet. Connect the bare stranded portion of the cable to the positive (+) battery terminal on the charge controller. 4. The fuse between controller and battery should be the current rating of the controller.
  • Page 61 Figure 6.2. Adapter kits can be found in Complete Solar Kits or sold as separate components at www.renogy-store.com. Fig. 6.2. MC4 Adapter Kit Adapter kits are sold in different lengths, and the basic gauge size is #12 AWG. Unassembled MC4 Connectors can also be purchased separately to make a custom adapter cable suitable for different length specifications.
  • Page 62 Figure 6.3 Solar panel and adapter kit 6.4 Solar Panel to charge controller Once the battery is connected to the charge controller and the panel(s) are positioned and mounted in the desired location, we are ready to connect the panel(s) to the charge controller. Panels should be mounted in a place that is free from shading by neighboring obstacles such as vents, air-conditioners, TV antennas, etc.

  • Page 63: 24V Wiring

    Figure 6.4 Completed 12V off-grid system Figure 6.4 shows the complete wiring of a typical off-grid system. It includes fuses for safety and protection. This configuration shows only one panel and one battery connected to the controller. In Sections 8 and 9, more panel and battery configurations (respectively) will be described.
  • Page 64 Please note the following about PWM controllers running in 24V configuration:  24V panels or 12V panels configured in series to make 24V should be used with 24V battery system only  It is not recommended that you charge a 12V battery system with a 24V solar array. Doing so will result in a performance loss of 50%.

  • Page 65: Multiple Panels/Strings In Parallel

    Multiple panels/strings in parallel A parallel connection is achieved by joining all of the positive (+) and negative (-) nodes together. When placing panels in parallel, it is recommended that the voltage levels are within specification. In other words, the V (maximum power voltage) of the panels must all be within 10% of each other.
  • Page 66 8.2 Three adjacent panels in parallel (12V systems) Figure 8.3 Three RNG-100D Panels in parallel Three solar panels is the maximum amount of panels that can be connected in parallel if they are adjacent to one another, without using extra cabling. Fig. 8.3 above shows the arrangement for connecting three solar panels in parallel.
  • Page 67 Fig. 8.4 shows the arrangement for connecting four solar panels in parallel. This arrangement is applicable if the solar panels are to be mounted in a 2x2 configuration as shown above. Please note that the positioning of the junction boxes must be followed for the cables to reach the MC4 Branch Connectors.
  • Page 68 8.4 Four panels in series-parallel (24V systems, 2x2 configuration) Figure 8.6 Four RNG-100D Panels in series-parallel configuration For 24V systems, Fig. 8.6. Shows two strings of panels in parallel. Each string consists of two panels in series. No additional cabling is required if the solar panels are to be mounted in a 2x2 configuration as shown above.

  • Page 69: Battery Configurations

    Battery Configurations The battery system can also be configured to create a “bank” of batteries. In this section, we cover the most basic configurations. When wiring batteries, extreme attention should be given. Never short a battery, as high currents can cause severe burns or even death. It is recommended that insulated/non-conducting tools be used when working with batteries.
  • Page 70 9.2 Parallel connection of batteries (12V) Figure 9.2 Two 12V batteries connected in parallel When two or more batteries are connected in parallel, their voltage remains the same but the Amp-hour ratings add up. Fig. 9.2 shows two 12V batteries in parallel forming a “bank”. For example, say each battery has 100 Ah.
  • Page 71 9.3 Series – Parallel connection of batteries (12V) Figure 9.3 Four 6V batteries connected in series – parallel Fig. 9.3 shows two strings in parallel; each string consists of two 6V batteries in series. For example, say each battery has 225 Ah. Each string would have a voltage of 12V with a capacity of 225 Ah.
  • Page 72 9.4 Series connection of batteries (24V) Figure 9.4 Two 12V batteries connected in series Wiring two 12V batteries in series as shown in Fig 9.4 will result in a 24V system. The same idea applies if you place four 6V batteries in series (Fig 9.5). Remember that when batteries are in series, the voltages add, but the total capacity of a string of batteries stays the same.
  • Page 73 9.5 Series-Parallel connection of batteries (24V) Figure 9.6 Four 12V batteries connected in series – parallel Multiple strings of batteries can be wired in parallel to increase the capacity. Figure 9.6 shows a battery bank with two strings of batteries. Each string consists of two 12V batteries in series. For example, if wiring four 12V/150Ah batteries like as shown in Figure 9.6, then each string will have a total capacity of 24V/150Ah.

  • Page 74: Inverter Wiring

    Inverter Wiring 10.1 General information about power inverters A power inverter, or inverter, is an electrical device that changes direct current (DC) to alternating current (AC); the converted AC can be at any required voltage and frequency with the use of appropriate transformers, switching, and control circuits.
  • Page 75 Please refer to Fig. 3. Each end of the battery tray cables should have a “ring terminal” type of connector. These connectors make it easy to achieve a secure and strong connection. Once the cables are connected and bolted down to the inverter, connect the black cable to the negative post of the battery (-).

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