Related Manuals for Sol GreenWay GRNWY-50
Summary of Contents for Sol GreenWay GRNWY-50
- Page 1 GreenWay™ Solar LED Path and Trail Lighting System Installation and Owner’s Manual...
- Page 2 IMPORTANT SAFETY INSTRUCTIONS - SAVE THESE INSTRUCTIONS This manual contains important instructions for the SOL GreenWay™ Series that shall be followed during installation and maintenance of the charge controller. The SOL GreenWay™ is a patented, off-grid, standalone, solar-powered lighting system. Years of engineering, development, and testing ensure that this system meets or exceeds all performance and reliability specifications. Every system that leaves our factory has been quality control tested and inspected to assure you of an easy installation and highly dependable performance. All mechanical fittings and electrical connections are designed for simple and reliable installation. The system is ready for use immediately after the components are mounted and the plug and play connectors are joined. IMPORTANT NOTES AND WARNINGS This installation and instruction manual provides installation, operation, and maintenance instructions for the SOL GreenWay™ solar LED lighting system. The entire contents of this manual should be thoroughly reviewed and understood prior to installing this equipment. Do not discard this manual. It contains complete maintenance instructions, a troubleshooting chart, and a spare parts list. To insure proper operation of this equipment, it is important that the equipment be utilized for its intended use. Any use of this equipment for purposes other than those intended will void all warranties. Installation and/or troubleshooting should be performed only by qualified personnel. Follow local codes at all times during installation of the GreenWay™. Be very careful when working with batteries. Do not allow bare ends of the wires to touch each other or grounded metal parts while connected to the controller. This will damage the controller. CONTENTS Section 1 Site Selection and System Overview Section 2 Parts List Section 3 Pole Preparation and Attaching PV Array Section 4 Assembling Components and Riveting Arm Assembly Section 5 Mounting Battery Box and Installing Battery Section 6 Installing Luminaire and System Wiring Section 7 Controller 9-11 Section 8 Operation, Maintenance and Troubleshooting 12-15 Section 9 Warranty Operational Principles The SOL GreenWay™ solar LED lighting system is designed to provide reliable operation and illumination all year. The solar array (the photovoltaic panel, or PV panels) re-charges the battery each day, replacing energy that was used during the previous evening so that illumination can again be provided during the following evening. The system is designed with a reserve, so that regular illumination will continue to be provided during periods of rainy or cloudy weather. The controller monitors battery condition and will shut off illumination if the battery charge drops below a specified level. This may occur if there is a prolonged rainy or cloudy weather or if the solar array is shaded during part of the day. The controller automatically restarts the...
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Page 3: Site Selection And Preparation
Site Selection and Preparation Locate and install the PV panels in an area where the PV panels can face the equator (due south in the Northern hemisphere) and not shaded by trees, poles, buildings, or other objects during the day (Figure 1). Do not locate in an area where there is excessive ambient or reflected light at night which may simulate daylight and cause the system controller to turn off the system. Installing in a location where the solar panels are shaded during part of the day will prevent the solar panel from fully charging the battery, reducing the hours of nighttime illumination and possibly damaging the battery. If installed near a tree, check the tree branches every three months and trim when needed. Installation of the solar light system and pole must comply structural engineering requirements for local and national codes. FIGURE 1 LOCATING AND POSITIONING THE PV PANELS System Overview PV Modules- Always facing EQUATOR (South in Northern Hemisphere) PV Assembly Controller Battery Battery Box Battery Enclosure (B.E.) Cover Arm Assembly Holes for Luminaire install must face DOWN Pole LED Luminaire FIGURE 2 SYSTEM OVERVIEW 3 GreenWay™ installation & operation manual 0410 MKTG-IM-GREEN-002... -
Page 4: Parts List
Parts List DESCRIPTION PART NUMBER GRNWY-50 GRNWY-80 GRNWY-125 Pole 302012-007DB Solar Panel Assembly 30040-001 Solar Panel Assembly 30080-003 Solar Panel Assembly 33172-010 Solar Panel Mount 15 Deg 302012-101* or 45 Degrees 302012-103* Arm Assembly 302012-201 Battery 86008-001 Battery Box 202721-200 Solar Panel Harness 855200-031 Battery Harness 855200-002 LED Harness 805000-004 aiSUN™ Controller 855101-200 aiSUN™ 56L Single Battery 855200-010 Harness Solar Panel Assembly Mounting GWHP-PV Hardware Battery Box Mounting Hardware GWHP-BB Drive Rivets DR375X.50GR 11... - Page 5 Pole Preparation and Installation Four holes must be drilled at the top of the pole. This should be done before the pole is set and anchored. Drill two equally-spaced 0.125-inch (3.2 mm) pilot holes 1 inch (2.5 cm) below the top of the pole, as shown in Figure 3. Drill two additional equally-spaced 0.125-inch (3.2 mm) pilot holes 4 inches (10.2 cm) below the top of the pole, as shown in Figure 3. Position the holes 90 degrees from the holes drilled in previous step. Pole Anchoring It is imperative that the pole is properly anchored. Standard pole anchoring methods may be used, providing they meet the engineering requirements for EPA and weight of the system you have purchased. FIGURE 3 DRILLING 4 HOLES AT TOP OF POLE Routing Luminaire Load Cable Through Arm Assembly Insert the male end of the luminaire load cable (with cord grip in plastic bag) into the fixture end of the arm. Slide the luminaire load cable through the arm assembly until the connector plug emerges from pipe end of the arm assembly, opposite side of luminaire install holes (Figure 4). Holes for Luminaire install must face DOWN FIGURE 4 ROUTING LUMINAIRE LOAD CABLE Attaching the PV Module to the PV Mount Lay the PV module upside down on a protected surface (cardboard shipping carton can be used) and position the PV mount over the PV module so that the hole and grommet on the side of the pipe face the PV module junction box. Route the PV cable in through the center hole and out through the side of the PV mount. Fasten the PV mount to the PV module using the 4x bolts and washers provided (Figure 5). PV Module Cable Hole & Grommet MC Connectors Junction Box to PV Module FIGURE 5 ATTACHING PV ASSEMBLY TO PV MODULE...
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Page 6: Assembling The Components
Assembling the Components After the pole has been set and anchored, slide the arm assembly into the top of the pole (Figure 6a). Route the PV load cable through bottom of the solar panel assembly pipe and out through the grommet and hole on the front of the pipe (Figure 6b). Place the solar panel assembly on the top of the arm assembly. Swing the arm assembly so that the light fixture (which will be attached to the end of the arm) is in the desired position (Figure 6c) PV Assembly Equator (Due South in Arm Assembly Northern Hemisphere) Luminaire Load Cable PV Module Cable Arm Assembly Pole Luminaire Load Cable FIGURE 6 ASSEMBLING ARM ASSEMBLY AND PV ASSEMBLY TO POLE Riveting the Arm Assembly to the Pole and Solar Panel Assembly to the Arm Assembly Verify that the arm is positioned so that the light fixture (which will be attached to the end of the arm) is in the desired orientation. Using one of the pilot holes at the upper end of the pole as a guide, drill one rivet hole using a U.S. “W” gauge (0.386-inch) drill bit (or use a 25/64-inch drill bit if “W” gauge not available). Drill through the pilot hole and then through the arm assembly stock beneath the pilot hole (drill & rivet one pilot hole at a time). Place a drive rivet in the rivet hole (Figure 7a). Pound the drive rivet into the hole (Figure 7b) until the head of the drive rivet is tight against the side of the pole (Figure 17c). Install the three remaining drive rivets in the arm assembly. Verify that the solar panel is positioned so that the solar panel is facing due south. Using one of the pilot holes at the lower end of the solar panel assembly as a guide, drill one rivet hole using a U.S. “W” gauge (0.386-inch) drill bit. Drill and rivot one pilot hole at a time following same instructions used for the arm assembly. Drill holes in pilot holes (4 places) FIGURE 7 RIVETING THE ARM ASSEMBLY AND SOLAR PANEL ASSEMBLY 6 GreenWay™ installation & operation manual 0410 MKTG-IM-GREEN-002... - Page 7 Mounting Battery Enclosure and Routing PV and Luminaire Cables Route the ends of the solar PV cable and the Luminaire cable through the hole and grommet at the back of the battery box, as shown in Figure 9. Loosely fasten the brackets at the back of the battery box to the pipe of the solar panel mounting, using four 1/4”–20 x 1/2” hex head bolts. Securely tighten each bolt. Position the cables so they extend inside the battery box at least 12 inches (30.5 cm). Hole and Grommet Bracket Luminaire cable from LED Luminaire PV Cable from PV Array FIGURE 9 MOUNTING BATTERY BOX FIGURE 10 ROUTING CABLES Installing the Battery/Batteries Loosely connect the battery harness to the battery terminals. When connecting the battery, connect the positive terminal first (Red +). Protect the free (unconnected) ends of the battery harness from touching other metal parts so they will not accidentally cause a short. Tighten the connection on both terminals. Place the battery in the battery box. Connect the battery harness to the single aiSUN™ harness as shown in Figure 11. Battery Harness - one for each battery Black ( Red ( Gel Cell 100 Ah NRGLife™ Battery FIGURE 11 BATTERY AND BATTERY HARNESS Installing Luminaire For Ascot Fixture: Connect the connector from the LED luminaire to the connector at the end of the luminiare load cable. Slide the LED fixture onto the arm. Adjust the LED fixture for the desired tilt. Secure the LED fixture to the arm using the socket head bolts (Figure 12). For Shoebox Fixture: Loosen the set screws that secure the slip fitter. Plug LED luminaire connectors together. Slip fixture over pipe (guide excess wires into pole). Secure set screws. To adjust angle remove circular cover using Phillips screwdriver. Using a socket wrench, loosen bolt to adjust angle to desired angle. Tighten bolt and replace cover (Figure 13). 7 GreenWay™ installation & operation manual 0410 MKTG-IM-GREEN-002...
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Page 8: System Wiring Diagram
Set screws FIGURE 12 MOUNTING ASCOT FIGURE 13 MOUNTING SHOEBOX This lamp (LED) is in excess of the Exempt Risk Group defined in IEC 62471:2006-07. This lamp (LED) has been found to be in the Risk Group 2 classification at an exposure distance of 20 cm or less from the glass surface of the lamp. Care should be taken to avoid exposure when operating and installing this lamp. - Page 9 aiSUN™ Solar Light CPU This guide describes how to complete the assembly of your light system when it is outfitted with an aiSUN™ CPU. aiSUN™ features & troubleshooting information is provided What does the aiSUN™ CPU do? aiSUN™ is a unique solar charging controller and LED luminaire controller packaged into one intelligent solar light CPU. aiSUN™ performs the following 2 tasks: 1. Charges batteries: Electricity generated by the PV module is modulated and controlled by the aiSUN™ to properly and safely charge the solar light’s NRGLife™ batteries. 2. Operates the LED Luminaire: Using a factory-installed configuration, aiSUN™ turns on the LED luminaire after sunset and turns off the luminaire before sunrise as configured per each location. This includes dimming and response to motion detection in some configurations. aiSUN™ is factory configured for your location. No adjustments are required. Lights are programmed to run in one several operating modes. Operating mode is shown on the unit label as: HH.LLL.LLL.HH.LLL (1) (2) (3) (1) light setting after sunset (2) light setting in the middle of the night (3) light setting before sunrise where: HH is the number of hours at full intensity and LLL is the light intensity in percentage Dusk to Dawn unit label reads: Programmed Run unit label reads: DD.100.000.00.000 06.100.000.00.000 Split Night w/ Dimming (4 hours Split Night (4 hours at full, turn off, at full, dim to 50%, 2 hours at full) 2 hours at full) code: unit label reads: 04.100.000.02.100 04.100.050.02.100 9 GreenWay™ installation & operation manual 0410 MKTG-IM-GREEN-002...
- Page 10 Solar Light System Test Once all of the wires have been clicked together and the batteries are installed, perform a diagnostic test. Press the “PUSH TO TEST” Button. This will indicate to the CPU to turn on the LED Luminaire(s) and operate the lights at full intensity for 5 minutes. Several diagnostic LEDs will turn on & remain on for several seconds. This is normal. FIGURE 15 aiSUN™ SYSTEM TEST Troubleshooting and Diagnostic LEDs If the LED Luminaire turns on to full brightness, system operates OK and will automatically turn on & off with sunset and sunrise. If the LED Luminaire does not turn on as described, follow the Diagnostic LED table (below) to troubleshoot the system. If LED Luminaire does not turn on AND no Diagnostic LEDs are on, aiSUN™ is not powered, check battery and fuse connections. FIGURE 16 aiSUN™ TROUBLESHOOTING 10 GreenWay™ installation & operation manual 0410 MKTG-IM-GREEN-002...
- Page 11 Diagnostic LEDs aiSUN™ has diagnostic LEDs to indicate of the status of the Solar Light it is controlling. See the table (Figure 17) below to understand the function of the LEDs. Indicator Name Status Meaning Luminaire ON (Luminaire Status) Luminaire OFF LED fixture is in Power Save mode - battery voltage is LOW. Contact SOL Inc Customer Support Dimming due to Power Save is NOT active - battery voltage level is OK Charge aiSUN™ is charging the battery aiSUN™ is not charging the battery Low Volt Disconn FLASH Battery is disconnected or too low to operate the LED fixture. Contact SOL Inc Customer Support Battery condition is OK Code 2 (future use) Code 1 If system is a dual LED fixtures system; one fixture is disconnected Fixtures are OK Fault LED fixture issue: short circuit or open circuit Fixtures are OK FIGURE 17 LED DIAGNOSTIC TABLE Frequently asked Questions about aiSUN ™ Q: Does aiSUN™ have a timeclock inside? A: No, aiSUN™ does not have a “timeclock”, instead it uses the regular sun rise and sun set it detects to determine when night is occurring and for how long. By averaging 10 nights of sunrise and sunset data the CPU accurately determines length of night and when sunrise and sunset occur. Q: What happens during daylight savings time? A: Since aiSUN™ performs all of its timing based on sunrise and sunset daylight savings time has no impact on the CPU. Daylight savings time is a clock change to accommodate having daylight hours align with certain times of the day, despite what the clock says, when the sun set aiSUN™ turns on the solar light.
- Page 12 After the SOL GREENWAY® Light is installed; the battery, LED fixture, and controller require a break-in period before reaching peak performance and efficiency: 1. New batteries achieve full charging capacity after they have been used for approximately 4-5 days. Before that, they achieve approximately 85% of their rated charging capacity. 2. The LED fixture must operate for several days before it reaches its peak output. This will not be noticeable. 3. The controller must operate for approximately one week before learning the system’s parameters and achieving maximum efficiency. 4. The system may need a full day of peak sun to reset all of its circuits. If the system is installed during a period of inclement weather or late in the day, the system may not operate the first night. The break-in period will not affect normal performance of the light unless the break-in period occurs at a time that the system is operating at its extreme limits. This may be the case if the system is installed during the winter months or during a period of successive bad weather days. Expected Performance The SOL GREENWAY® Light is designed to provide reliable operation and illumination all year. The solar panel provides enough energy during a normal day to charge the battery for operation of the LED fixture for the following night. The system is designed with a five-day reserve charge. As a result, extended periods of low sun may deplete the five-day reserve and affect performance of the system. The following conditions may cause your SOL GREENWAY® Light to operate out of specification: 1. Prolonged Bad Weather. A series of days with low levels of sunlight may deplete the battery reserve. Depending on the severity of the condition, the nightly illumination period could be reduced until a sunny day re-establishes the reserve battery charge. Please note that the system may need anywhere from two days (in summer) to ten days (in winter) of good sunny weather before the full five-day battery reserve is completely achieved. 2. Shading. Installation of the SOL GREENWAY® Light in a location where the solar panel is shaded during part of the day will inhibit the ability of the solar panel to fully charge the battery and may severely damage the battery. The hours of nighttime illumination will be reduced by the controller if the solar panel cannot fully charge the battery. If you believe that your SOL GREENWAY® Light is not performing as expected and the above conditions do not apply, please contact SOL technical support at 1.800.959.1329 option #3. 12 GreenWay™ installation & operation manual 0410 MKTG-IM-GREEN-002...
- Page 13 Note: Solar panels can get very hot when the sun is out. It is advisable to clean solar panels during the early morning hours. Fuse Replacement If the SOL GREENWAY® Light does not operate, check the fuse. Note: If the fuse needs to be replaced, be sure to also check operation of the controller. 1. Open the battery box.
- Page 14 Battery Replacement 1. Remove the battery box cover. 2. At the controller, disconnect the solar array harness connector, then disconnect the single aiSUN™ harness from the battery harness. Caution: When disconnecting the cables, be sure to disconnect the solar array harness first. 3. Remove the battery from the battery box. 4. Disconnect the battery harness from the old battery and attach to the new battery. 5. Place the new battery in the battery box. 6. At the controller, connect the aiSUN™ single harness to the battery harness, then connect the solar array harness. Caution: When reconnecting the cables, be sure to connect the aiSUN™ single harness from the battery first.
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Page 15: Troubleshooting
SOLUTION The light does not turn on The battery is discharged. Charge the battery. at all. The battery is bad. Replace the battery. The LED fixture is bad. Replace the LED fixture. The fuse is blown. Replace the fuse. The controller is bad. Check the controller. The light does not stay on The run time is incorrectly set. Check and reset the run time. for the expected period of time. The light turns on at dusk The run time exceeds the maximum run Contact SOL for assistance. but does not turn on again time for your model and location. at dawn (split run time). Low battery voltage caused by Allow for two to three days of inclement weather. consecutive sunny weather to charge the battery pack. Low battery voltage caused by shading Clear tree branches and other of the solar panel. obstructions from the vicinity of the solar panel. The battery is bad. Replace the battery. The red LED on the Low battery voltage caused by Allow for two to three days of controller remains inclement weather. - Page 16 1990. SOL Inc warrants the Owner (defined as the entity that has final title to the goods) of each new SOL lighting system to be free from defects in materials and workmanship and to perform under normal use and service. SOL will, at its option, repair or replace any system or system component that is defective in materials or manufacture within a minimum of five (5) years after purchase.
- Page 17 Contact us for Help If troubleshooting does not work and further help is required, please call our 24/7 telephone technical support number: (772) 286-9461, option #3. In-Warranty Service Instructions A Returned Merchandise Authorization (RMA) number must be obtained from SOL Inc. before equipment can be returned for repair or replacement under warranty. We require the following information before we can issue an RMA number: • Controller Number for the product being returned • Serial Number of the product being returned • A description of the problem • The address to which the repaired or replaced product is to be shipped Equipment being returned must be properly packaged to protect it from damage during shipment. Shipping costs and insurance to SOL Inc. are the responsibility of customer. Upon verification of failure due to defects in materials or workmanship, we will either repair or replace the product at our discretion. The customer will be responsible for all shipping and handling charges for any equipment that is sent to SOL Inc. in error (no definable problems). SOL Inc. | 3210 SW 42nd Avenue | Palm City, Florida 34990 www.solarlighting.com E-mail support: support@solarlighting.com Phone: +1.772.286.9461 | Toll: 800.959.1329 (USA & Canada) Fax: +1.772.286.9616 Office Hours: Monday - Friday: 8:30am to 5:00pm (EST) © 2010 SOL Inc. All rights reserved...
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