BULLHORNR. 5 Watt Solar Panel with Regulator. Installation Guide REMOTE MONITORING AMERICAN INNOVATIONS. Field Data Division

Transcription

1 BULLHORNR REMOTE MONITORING 5 Watt Solar Panel with Regulator Installation Guide AMERICAN INNOVATIONS Field Data Division

2 Installing the 5 Watt Solar Panel with Regulator This document explains how to install the items included in the 5 watt solar panel installation kit. The information applies to the following Bullhorn satellite units that use the Orbcomm or SkyWave satellite network for communications: AMR6-SAT, AMR6-ORB APM4AM-SAT, APM4AM-ORB APM4AMCP-SAT, APM4AMCP-ORB If you need assistance with the installation, please call AI Technical Support at Required Tools The tools listed below are required to install the items included in the installation kit: Flathead screwdriver Phillips screwdriver Adjustable wrench Wire stripper Wire cutter Wire crimper Mounting hardware appropriate for the type of mounting surface (supplied by customer). Appropriate tools to prepare the mounting surface for the installation. Depending on the mounting surface, this may include a hand drill and metal, masonry, or wood drilling bit. Part No , Rev. 0 1

3 2 Part No , Rev. 0 December 13, 2007 To Install the Solar Panel Complete the following steps: 1. Prepare the mounting surface for the solar panel installation. Depending on the type of mounting surface, use a hand drill and a metal, masonry, or wood drilling bit. 2. Assemble the solar panel mounting bracket and solar panel in the following manner: a. Install the provided hardware in the mounting holes on the solar panel mounting bracket as shown in the next figure. Hardware includes (2) 5/16 hex head bolts with nuts and (4) washers and split-ring washers. Figure 1. Solar Panel Mounting Bracket b. Place the solar panel face down on a flat surface. c. Install the solar panel mounting bracket in the left and right channels of the multimount frame as shown in the next figure. Figure 2. Solar Panel Multi-Mount Frame

4 5 Watt Solar Panel Installation Guide 3 d. Position the solar panel mounting bracket in the center of each channel. Use an adjustable wrench to loosely tighten hardware to prevent the bracket from moving. e. Using four (4) end caps provided in the installation kit, insert an end cap in both ends of each channel as shown in the next figure. Figure 3. Installing End Caps 3. Install the solar panel on the mounting surface using the following guidelines: To prevent signal interference during data transmissions, install the solar panel at least two (2) feet above the Bullhorn unit. Install the solar panel using the solar panel mounting bracket and mounting hardware appropriate for the type of mounting surface. Mounting hardware is provided by the customer. Position the solar panel 10 degrees above horizontal and facing south for full sun exposure. If you plan to install the solar panel on a pipe, use the provided u-bolt and pipe bracket with the solar panel mounting bracket as shown in the next figure. Use an adjustable wrench to tighten mounting hardware. Figure 4. U-bolt and Pipe Bracket Option

5 4 Part No , Rev. 0 December 13, Install the battery bracket inside the enclosure as shown in the next figure. Use a Phillips screwdriver to loosely tighten the mounting hardware that secures the battery bracket to the inside of the enclosure. 5. Route the solar panel interface cable through the water-tight fitting on the bottom of the enclosure. Figure 5. Installing the Battery Bracket 6. Complete one of the following steps: a. If the solar controller is factory-installed on the door inside the enclosure, continue with the section entitled Connecting the Factory-Installed Solar Controller on the next page. -ORb. If the solar controller is not factory installed on the door inside the enclosure, continue with the section entitled Installing and Connecting the Solar Controller on page 7.

6 5 Watt Solar Panel Installation Guide 5 Connecting the Factory-Installed Solar Controller If the solar controller is factory-installed on the door inside the enclosure, complete the following steps: 1. Use a flathead screwdriver to loosen two (2) screw terminals on the terminal block attached to the door inside the enclosure. Refer to the next figure. 2. Connect the red, solar panel wire in the terminal labeled Solar Panel RED + located opposite the yellow solar controller wire. 3. Connect the black, solar panel wire in the terminal labeled Solar Panel BLK opposite the black solar controller wire. 4. Tighten screw terminals to secure the solar panel wires in place. Figure 6. Connecting the Solar Panel Interface Cable 5. Connect the terminal lug with the red, solar controller and solar panel wires to the red battery post. Refer to the next figure. 6. Connect the terminal lug with the black, solar controller and solar panel wires to the black battery post. 7. Place the battery on the battery bracket. 8. Secure the mounting bracket in place using a Phillips screwdriver to tighten mounting hardware.

7 6 Part No , Rev. 0 December 13, Depending on the type of Bullhorn unit you are working with, complete one of the following steps to connect the battery cable: a. If you are working with the AMR6-SAT, AMR6-ORB, APM4AM-SAT, or APM4AM-ORB, connect the battery cable in the 2-pin connector labeled Battery on the controller board of the Bullhorn unit. -ORb. If you are working with the APM4AMCP-SAT or APM4AMCP-ORB, connect the battery cable in the 4-pin battery connector as shown in the next figure. The solar panel installation is now complete Figure 7. Connecting the Battery and Solar Controller

8 5 Watt Solar Panel Installation Guide 7 Installing and Connecting the Solar Controller If the solar controller is not factory-installed on the door inside the enclosure, complete the following steps: 1. Assemble the solar controller wires, battery cable wires, and fast-on terminal connectors in the following manner. Refer to the next figure. a. Use a wire cutter to remove the terminal lug on the end of the red and black battery cable wires. Cut wires as close to the terminal lugs as possible. b. Use a wire stripper to remove ½ of the outer jacket on the red solar controller wire and red and black battery cable wires. c. Insert the red solar controller wire and red battery cable wire in the fast-on terminal connector. Use a wire crimper to crimp the fast-on terminal connector. d. Repeat steps b and c using the black solar controller wire and black battery cable wire. Figure 8. Solar Controller and Battery Cable Wires 2. Complete the following steps to install the ferrite filter included in the installation kit. Refer to the figure on the next page. a. Open the ferrite filter and place the red and black battery cable wires inside the housing. Wrap the red and black wires around the housing one time as shown in the next figure. IMPORTANT: If you are working with the APM4AMCP-SAT or APM4AMCP-ORB, the battery cable includes a fuse wrapped in heat shrink tubing as shown in the next figure. To prevent damaging the fuse, do not place the fuse inside the housing of the ferrite filter. b. Close and lock the ferrite filter until it locks into place. A clicking sound indicates the ferrite filter is locked.

9 8 Part No , Rev. 0 December 13, 2007 Figure 9. Installing the Ferrite Filter 3. Complete the following steps to attach an adhesive, 3M VHB strip and 2-position terminal block to the door inside the enclosure of the Bullhorn unit. Refer to Figure 6 on page 5. a. To ensure proper adhesion, clean the surface of the door inside the enclosure to remove any moisture or debris that may be present. b. Remove the protective paper on one side of the VHB strip. (Do not remove the protective paper on the other side of the VHB strip at this time.) c. Place the VHB strip in the center of the door inside the enclosure. Apply firm pressure to ensure sufficient adhesion. d. Remove the remaining protective paper on the VHB strip. e. Attach the 2-position terminal block on the VHB strip. Apply firm pressure to ensure sufficient adhesion. f. Remove the protective paper on the back of the adhesive ID label that includes the description Solar Panel RED +, Solar Panel BLK. g. Attach the adhesive ID label on the door below the 2-position terminal block as shown in Figure 6 on page Complete the following steps to attach three (3) VHB strips and the solar controller to the door inside the enclosure of the Bullhorn unit. See Figure 6 on page 5. a. Remove the protective paper on one side of three (3) adhesive VHB strips. (Do not remove the protective paper on the other side of the VHB strips at this time.) b. Place the three (3) VHB strips close together, near the top of the door inside the enclosure. Apply firm pressure to each VHB strip to ensure sufficient adhesion. c. Remove the remaining protective paper on each of the three (3) VHB strips. d. With the label side of the solar controller facing down, attach the solar controller on the VHB strips. Apply firm pressure to ensure sufficient adhesion.

10 5 Watt Solar Panel Installation Guide 9 e. Remove the protective paper on the back of the adhesive ID label that includes the description From Solar Panel + YEL, BLK / To Bullhorn BLK, + RED. f. Attach the adhesive ID label on the door below the solar controller as shown in Figure 6 on page Complete the following steps to connect the yellow and black solar controller wires in the 2-position terminal block located on the door inside the enclosure. Refer to Figure 6 on page 5. a. Use a flathead screwdriver to loosen each terminal screw on the 2-position terminal block. b. Connect the yellow solar controller wire in the connector labeled From Solar Panel + YEL. c. Connect the black solar controller wire in the connector labeled From Solar Panel BLK. d. Use a flathead screwdriver to tighten the screw terminals and secure the solar controller wires in place. 6. Complete the following steps to connect the red and black solar panel wires in the 2-position terminal block. Refer to Figure 6 on page 5. a. Use a wire stripper to remove one (1) inch of the outer jacket on the solar panel interface cable to expose the red and black wires. b. Use the wire stripper to remove ½ of the outer jacket on the red and black solar panel wires. c. Connect the red, solar panel wire in the terminal labeled Solar Panel RED + located opposite the yellow solar controller wire. d. Connect the black, solar panel wire in the terminal labeled Solar Panel BLK opposite the black solar controller wire. e. Use a flathead screwdriver to tighten the screw terminals and secure the solar panel wires in place. 7. Connect the terminal lug with the red, solar controller and solar panel wires to the red battery post. See Figure 7 on page Connect the terminal lug with the black, solar controller and solar panel wires to the black battery post. 9. Place the battery on the battery bracket. 10. Secure the battery mounting bracket in place using a Phillips screwdriver to tighten mounting hardware. 11. Depending on the type of Bullhorn unit you are working with, complete one of the following steps to connect the battery cable: a. If you are working with the AMR6-SAT, AMR6-ORB, APM4AM-SAT, or APM4AM-ORB, connect the battery cable in the 2-pin connector labeled Battery on the controller board. -OR-

11 10 Part No , Rev. 0 December 13, 2007 b. If you are working with the APM4AMCP-SAT or APM4AMCP-ORB, connect the battery cable in the 4-pin battery connector as shown Figure 7 on page 6. The solar panel installation is now complete