Installation Instructions - Solar Panel

Transcription

1 Installation Instructions - Solar Panel P/N Rev. K. Solar Panel. 0 Back Bracket. 0 Solar Panel Bracket - Standoff. Rubber Grommet - / x /. 0 Spacer Washer - HDPE - / x. 000 Self-Tapping Screw - / x. 0 Lock Washer - /. 00 Hex Nut - /. Electrical Wire - Ga. - Lead -. Dome Nut - /. Lock Nut - /. Ring Terminal - - Ga. x # Stud WIRE CLIPS. 00 Wire Clip - Nylon. 0 Self-Drilling Screw - # x / PASSENGER SIDE OF TRAILER Determine solar panel location on trailer. Locate panel toward passenger side of trailer, with electrical box on panel toward center of trailer. Hold panel and back brackets against trailer, aligning slots in back brackets with horizontal and vertical rivet lines on trailer. Mark rivets that need to be removed. If slots cannot be aligned with rivets, drill / holes in trailer and fasten with / x self-tapping screw, lock washers and nuts. REMOVE RIVETS STEP : SOLAR PANEL Mark and drill / holes and fasten back brackets to panel with / x self-tapping screws, lock washers and nuts. LOCK SLOT IN BACK BACK DRILL HOLES SOLAR PANEL / X SELF-

2 Installation Instructions - Solar Panel - continued P/N Rev. K STEP : Mark hole location near solar panel electrical box for electric wire to pass through trailer wall. Drill / hole and install grommet. STEP : Loosely fasten remaining two standoff brackets to installed standoff brackets. Fasten with / x selftapping screws, lock washers and nuts. SOLAR PANEL RUBBER GROMMET DRILL / HOLE INSTALLED / X SELF- NOTE: Install backer plate if trailer wall is less than / thick. STEP : Align two standoff brackets with slots in back brackets. Loosely fasten standoff brackets to back bracket with / x self-tapping screws, lock washers and nuts. STEP : LOCK Mount solar panel to trailer through rivet holes where possible using / x self-tapping screws, spacer washers, lock washers and nuts. Fasten back brackets to horizontal rivet line, then loosely fasten standoff brackets to trailer. BACK S BACK / X SELF- / X SELF- LOCK LOCK SPACER NOTE: Mount brackets with fl anges facing either direction as needed to align holes in brackets with rivet lines on trailer. STEP : Tighten all fasteners on trailer fi rst, then tighten standoffs to back brackets. Tighten fasteners holding standoffs together last. Run electrical wire through trailer wall to inside of trailer. Secure with wire clips (included).

3 Installation Instructions - Battery Box P/N Rev. K. Battery Box Bottom. Battery Box Top. 0 Battery Box Hold-Down Bracket. Battery Box Front Bracket. Battery Clip. Solar Controller. Solar Gel Battery. 0 Cap Screw - / x. 00 Hex Nut - /. 0 Flat Washer - /. 0 Lock Washer - /. Dome Nut - /. Lock Nut - /. Modifi ed-reset Circuit Breaker - 0 Amp. Button Hd. Cap Screw - / x /. Machine Screw - Rnd. Hd. - # x. Nut/Machine Screw w/washer - #. 000 Self-Tapping Screw - / x. 0 Lock Washer - / Hex Nut - /. End Plug TERMINALS & CONNECTORS. 0 Ring Terminal - Ga. x / Stud. Ring Terminal - - Ga. x / Stud. Ring Terminal - - Ga. x # Stud. Ring Terminal - Ga. x # Stud. Wire Nut Connector. Parallel Connector - - Ga. 0 SUPPLIED W/CIRCUIT WIRE CLIPS. Self-Tapping Screw - / x. Wire Clip - / - / Hole BOTTOM Using either holes in bottom or in back of battery box bottom as guide, mark hole locations on trailer. Drill / holes and fasten battery box bottom to trailer with / x self-tapping screws, lock washers and nuts. / NUT BOTTOM CLIP & CIRCUIT STEP : CIRCUIT Fasten battery clip and circuit breaker to battery with / cap screws, fl at washers, lock washers and nuts as shown. Fasten circuit breaker with nut provided. / NUT CLIP / LOCK / FLAT / LOCK / X SELF- SUPPLIED W/CIRCUIT / X CAP SCREW NOTE: Install backer plate if trailer wall is less than / thick.

4 Installation Instructions - Battery Box - continued P/N Rev. K DOME NUTS & HOLD-DOWN S STEP : Secure dome nut strain reliefs to battery box bottom with / lock nuts. & S STEP : Place battery in battery box bottom. Install hold-down bracket and front bracket with / x cap screws, fl at washers, lock washers and nuts. HOLD-DOWN / ASSEMBLY / X CAP SCREW / FLAT / LOCK BOTTOM / NUT / FLAT DOME NUT / LOCK NUT BOTTOM FRONT TOP / X CAP SCREW STEP : # NUT/ Fasten solar controller to hold-down bracket with # x machine screws and nut/washers. NOTE: Before installing box top, connect wire as shown in solar panel instructions on next page. STEP : Secure battery box top to battery box bottom with / x / cap screws and lock washers. BOX TOP / LOCK / X / BUTTON HD. CAP SCREW # X MACHINE SCREW BOTTOM ASSEMBLY FULLY ASSEMBLED

5 Installation Instructions - Solar Panel Wiring P/N Rev. K SOLAR PANEL This unit replaces battery power from the vehicle. Disconnect vehicle power source before installing this unit. NOTE: Refer to wiring details on front of solar controller to wire. NEGATIVE WIRE (BLACK) OR (GREEN WIRE IS NOT USED) POSITIVE WIRE (WHITE) SOLAR WIRE - POSITIVE SOLAR WIRE - NEGATIVE WIRE - NEGATIVE NEGATIVE -GA. WIRE (BLACK) WIRE - POSITIVE POSITIVE -GA. WIRE (RED STRIPE) NOTE: On SMARTwire kits, a socket is on the end of the wire. Otherwise, terminate wire ends with ring terminals. DISCONNECT. 0 Ring Terminal - Ga. x / Stud. Ring Terminal - - Ga. x / Stud. Ring Terminal - - Ga. x # Stud. Ring Terminal - Ga. x # Stud. Wire Nut Connector. Parallel Connector - - Ga. CIRCUIT SMARTWIRE SOCKET TO JUNCTION BLOCK, JUNCTION BOX OR MOTOR CONTROLS SOLAR PANEL WIRING STEP : Insert solar panel cable through / dome nut on right side of battery box. Connect solar panel leads to solar controller leads with parallel connectors or wire nuts. Connect positive (white) solar panel lead to positive solar wire on controller. Connect negative solar panel lead (black) to negative solar wire on controller. Connect solar controller to battery with ring terminals. Connect negative solar controller wire to negative battery terminal with - to -ga. x / ring terminal. Connect positive solar controller wire to circuit breaker with - to -ga. x # ring terminal. NOTE: Circuit breaker is needed to protect solar panel. Mount circuit breaker next to positive (red) battery terminal. WIRING LOADS TO STEP : Two / dome nuts (fi t up to -ga. wire) are provided for -ga. load wire. For outgoing load wire, crimp -ga. x # ring terminal to positive wire and connect to circuit breaker. Crimp -ga. x / ring terminal on negative wire and connect to negative battery post. Route -ga. wire as desired, but do not fasten down yet. Locate desired mounting position for master disconnect switch and install prior to securing wire.

6 Installation Instructions - Master Disconnect Switch P/N Rev. K SCREWS SUPPLIED W/SWITCH WIRE CLIPS. Self-Tapping Screw - / x. Wire Clip - / - / Hole. 0 Self-Drilling Screw - # x /. Master Battery Disconnect Switch. Ring Terminal - Ga. x / Stud. 0 Rubber Boot. Solar Master Disconnect Box. Lock Nut - /. Dome Nut - /. 0 -Ga. Dual Conductor Wire - (not shown) SMARTwire - Ga. Socket - (not shown). Face Plate - Rotary Switch Route wire (P/N 0 or ) along planned route. Determine desired location of master disconnect switch along wire route. Cut positive half of this wire at mounting location. Do not cut negative wire. Carefully peel positive side of wire away from negative side about on either side of cut. STEP : Connect wires to master disconnect switch. Coat with dielectric grease and install rubber boots over ring terminals. DISCONNECT SWITCH STEP : Unfasten screws and remove cover/ switch assembly from master disconnect box. # X / SCREWS (SUPPLIED) COVER/SWITCH ASSEMBLY DISCONNECT BOX STEP : Run positive -ga. wire ends through dome nuts on master disconnect box. Run wire ends through rubber boots and crimp / ring terminals to ends of wire. STEP : # X / SCREWS (SUPPLIED) RING TERMINALS RUBBER BOOTS WIRE Re-install cover/switch assembly to master disconnect box. Fasten with supplied (# x / ) screws. DISCONNECT BOX DOME NUT DISCON- NECT BOX RUBBER BOOT RING TERMINAL WIRE COVER/SWITCH ASSEMBLY STEP : Fasten master disconnect switch box to trailer with four # x / self-drilling screws. # X / SELF-DRILLING SCREWS NOTE: Cut wires to length and strip only enough wire insulation to install ring terminals. Insert bare wire into ring terminals and crimp securely. RING TERMINAL STRIP WIRE INSULATION CRIMP SECURELY DISCONNECT SWITCH