CARTON INVENTORY WARNING SOLAR KIT INSTALLATION SOLKIT12V - (1 Panel) SOLKIT12V2P WARNING- (2 Panels) CAUTION with: Charger, Cable 15', Fuses (2), Battery Strap and Strain Relief (2) Model SOLBBOX 12V Battery Not Included Mounting Bracket (1 per panel) 12V 20W Model SOLPNL 20W 12V DC Power Adapter 12 Vdc to 32Vdc Model K76-33847 Hardware Bag (1 per panel) Wire Tie Strain Relief (2) WARNING To reduce the risk of fire and the risk of SEVERE INJURY or DEATH to persons: Disconnect electrical power to operator BEFORE proceeding. Disconnect battery power internal to operator. Do NOT dispose of the battery in fire. The cells may explode. Check with local codes for disposal instructions. Do NOT open or mutilate the battery. Released electrolytes are corrosive and may cause damage to the eyes or skin. It may be toxic if swallowed. Exercise care in handling batteries in order not to short the battery with conducting materials such as rings, bracelets and keys. Change the battery provided with one identified for use with this product ONLY in accordance with the instructions and limitations specified in the manual. Observe proper polarity orientation between the battery and charging circuit. Do NOT mix batteries of different sizes or from different manufactures in this product. COMPLETED OVERVIEW NOTE: Image is for reference only, your operator and control box may appear different. (Facing South) Cable From to Control Box Cable from to Control Box Cable Control Arm to Control Box 1
PREPARATION This solar kit is not intended to replace or eliminate the need for the primary batteries provided with the operator. Those batteries are designed to provide motor run currents that the additional battery kit cannot provide. Primary batteries are required to operate the gate. Do not remove the batteries from the control box. Both the primary and external batteries must be fully charged prior to installation. It is strongly recommended that new batteries are used for solar applications. Verify solar kit contents. You will need to purchase a UL recognized, sealed lead-acid (SLA) battery (not included) or a marine deep cycle battery. See Suggested Batteries. NOTE: Automotive batteries are not acceptable. Remove and retain fuse in fuse holder. Jolt XSA12800B 12V, 80AH Werker WKA12-80C/FR 12V, 80AH Universal UB12750 12V, 75AH PowerSonic PS-12750 12V, 75AH Genesis NP75-12 12V, 77.5AH Potential sources: www.batterygiant.com www.apexbattery.com www.batteriesplus.com SUGGESTED BATTERIES MFG PART NO. SPECIFICATIONS Select Site for (s) The solar panel(s) must be located in an open area clear of obstructions and shading. For the entire day. NOTE: The solar panel(s) comes with a 10' cable, so if a suitable site cannot be located close to the gate control box and battery box, additional cable will be required. Regional Installation Recommendations C C A B A Total solar panel power required 20 watts Region A SOLKIT12V (1 panel) Region B Region C Not SOLKIT12V2P Recommended (2 panels) NOTE: The (s) recommendation is based upon both the average solar radiation and the temperature effects on batteries in the given regions. Local geography and weather conditions may require additional solar panels for the installation or prevent the use of solar entirely. For example, valleys or areas near lakes may experience fog or lake effect rain and snow that other areas, only a few miles away, may not experience. Northern climates where temperatures reach -4 F (-20 C) and below are poor candidates for Battery Powered Gate Operator applications; therefore, they are also poor candidates for solar power. 2
POSITION SOLAR PANEL(S) NOTE: If the panel(s) is not casting a shadow, it is not charging the battery. The location of the panel(s) is critical to the success of the installation. In general the panel(s) should be mounted using the provided angle bracket facing DUE SOUTH and not be obstructed or shadowed throughout the day. The solar panel(s) should be mounted in an area clear of all obstructions and shading from buildings and trees. The area should be clear for a 180 arc from due east of the panel(s) location to due west of the panel(s) location. Keep in mind that tall trees or buildings that do not shade the solar panel(s) in the summer could shade the solar panel(s) during the winter months when the sun sits lower in the sky. Sun s Position INCORRECT Summer Sun Height Up to 15 Winter Sun Height South South NOTE: DO NOT install solar panel near potential shading or obstructions that will block the panel during any part of the day. CORRECT TIP: To optimize the system for winter operation the angle can be increased by up to an additional 15 (solar panel(s) sits more vertical). TIP: The area around the solar panel(s) should be clear of shadows or obstructions to the sun for a 180 arc east to west. South 180º Cable From to Control Box TIP: Wire runs should be kept as short as possible. The solar panel(s) can be located up to 200' from the operator using #14 AWG wire in any direction, including elevating it. If a suitable site cannot be found for the panel(s), please contact Chamberlain to determine if solar is right for this installation. (Facing South) 3
MOUNT THE SOLAR PANEL(S) Position Solar Bracket Position solar bracket on mounting surface, mark and drill holes. NOTE: Solar panel(s) MUST be installed facing due south, use a compass to determine direction. Angled Bracket Must Face DUE SOUTH Angled Bracket Must Face DUE SOUTH Mounting Surface Mounting Surface Insert Mounting Bolts Insert bolts (2) provided into the track located on the back of the solar panel(s). NOTE: Hardware provided is metric. Bolt Bolt Hole Track Slide bolts in track away from bolt hole and align both bolts Bolt Bolt Hole Track Secure (s) to Solar Bracket Secure solar panel(s) to solar bracket using washered nuts (2) provided. Washered Nut Solar Bracket Washered Nut Mount (s) Assembly Secure solar panel(s) assembly to mounting surface using appropriate hardware. Mounted Panel Must Face DUE SOUTH Mounting Surface 4
INSTALL BATTERY BOX Location The battery box must be located within 10' of the operator control box. The box must be located in a place where it cannot be damaged due to flooding, excessive contact or by being knocked over. Place battery box either on the ground or a stable platform (not provided). NOTE: Image is for reference only, your operator and control box may appear different. Solar Panel SOUTH Cable to Control Box Cable to Control Box Battery Box Cables Open battery box. Route output cable and solar panel(s) cable as shown. Reminder, as soon as sunlight hits the solar panel(s) there will be electrical power at the leads. Leave the leads covered until ready to connect them. Extend output cable though strain relief leaving slack in the battery box, and tighten top strain relief. Attach red wire from solar cable to terminal 4 on solar controller and black wire to terminal 3. Tighten bottom strain relief. Attach and tighten the provided wire tie to both cables on the inside of the box. NOTE: If using a marine (flooded) battery, metallic jumper must be removed for proper charging. If using a sealed lead-acid (SLA) battery, leave jumper in place. 1 Panel Wiring Terminal 3 Terminal 2 Terminal 4 Terminal 1 Load Disconnect LED Charging LED CHARGING LOAD DISCONNECT Terminal 6 Terminal 5 Output Cable (To Control Box) RED Metallic Jumper WHITE ORANGE + Wire Tie Cable To Battery 5
WIRING MULTIPLE PANELS When multiple panels are required, they must be wired in parallel to terminals 3 and 4 on the solar controller. (Facing South) Control Box Cable to (Up to 200') (Facing South) 2 Panel Wiring Load Disconnect LED Charging LED Terminal 3 Terminal 4 Terminal 5 Terminal 6 CHARGING LOAD DISCONNECT Metallic Jumper Output Cable (To Control Box) RED WHITE ORANGE + Wire Tie 1 Cable To Battery 2 Cable NOTE: 3/4" hole diameter drill bit is required for drilling additional hole. Remove the battery before drilling and use caution to not hit any wires. MAINTENANCE OF PANELS The solar panel(s) glass should be cleaned monthly to keep the system operating at peak performance. Debris or dirt on the panel(s) surface will diminish or completely obstruct the panels ability to charge the 12V battery. NOTE: If panel(s) gets damaged in any way, it must be replaced. 6
O N WIRE BATTERY BOX TO OPERATOR CONTROL BOX Install Power Adapter Open control box cover and disconnect primary operator batteries at the control board. Locate the 24Vac input on the control board. Attach the yellow and black wires to the 24Vac input terminal (polarity is not important). Insert the provided strain relief though one of the knockouts and thread the battery box output cable through strain relief in the control box. Attach black wire from the output cable to the black wire on the power adapter connector. Attach the white wire from the output cable to the red wire on the power adapter connector. Place power adapter inside of the control box. Power Adapter Red (+) Black (-) White J4 24 VAC/ SOLAR INPUT Control Board Black Black Output Cable (To Control Box) Yellow OFF OFF SINGLE NO NO S1 1 2 3 4 5 ON ON DUAL NC NC SAVE MAGLOCK MODE EDGE PHOTO LA400 NOTE: For the LA400 the SAVE switch (S1) must be in the ON position after all operator adjustments have been made. INSTALL BATTERY Wire Battery NOTE: Battery voltage must be above 12Vdc for proper operation. Install the 12V 75AH min. (fully charged) sealed lead-acid battery into the battery box. Connect the orange wire to the positive terminal on the battery. Insert the 5 amp fuse into the fuse holder. Connect the black wire to the negative terminal on the battery. Reminder, if using a deep cycle marine battery, the metallic jumper must be removed for proper charging. Battery Terminal 3 Terminal 2 Terminal 4 Terminal 1 CHARGING LOAD DISCONNECT Terminal 6 Terminal 5 + Output Cable ORANGE + BLACK Metallic Jumper Cable from To Battery COMPLETE INSTALLATION Reconnect internal batteries to the control board and ensure that all wires are secure. Close control box cover and battery box. Secure battery box with strap (provided) if desired. 7
CHARGING The Chamberlain Gate operator uses 2-12 volt 7amp hour batteries (24 volts) in the gate control box to keep the control board alive and arms functioning (in operation). These are referred to as the primary batteries. This solar battery kit is designed as a secondary DC power source for charging the primary batteries, not replacing the primaries. If the primary batteries are below operational voltage, attaching this secondary solar panel(s) kit will not immediately operate the gate operator, only after the secondary battery charging devise charges the primary batteries to an acceptable 24 volt level for operation prior to install. Recharging depleted batteries is a challenge for solar systems requiring full sun for extended periods, therefore it is recommended charging both primary and secondary batteries using an AC trickle charger and beginning with a fully charged system. It is assumed that the actual operator has been installed correctly and that its operation was verified before the installation of the solar kit, so that if there are any problems we can confine them to the solar operation. Solar systems are 100% dependent upon the amount of sun and direction of the solar panel(s) to maximize the battery charge. The system should be evaluated several times during the first month of operation to see if the external battery is being replenished by the solar panel(s). Also note that December in the US typically has the lowest amount of solar energy reaching the earth with June the maximum. If the battery voltage should continue to decrease, the system should be checked to see if the solar panel(s) is pointed properly, and if so an additional panel(s) may be required for this location. Obviously the number of operation cycles per day is another factor to be considered. In addition to the first month of use, the battery should be measured several times during the first year to make sure the lack of sun does not discharge the battery below 11.5 Volts as an additional solar panel(s) may be required. To verify correct solar operation, review the following: With sun shining on the solar panel(s), the green charging LED on the solar controller in the battery box should be on, indicating that the panel(s) is supplying power to the battery. If the green LED is not illuminated check: 1. Solar panel(s) connection at terminals 3 and 4 and polarity (See wiring diagram), and that no part of the solar panel(s) is in the shade. 2. The battery connections are secure and their polarity is correct. 3. Fuse F1 is good and installed. Inside the gate control box, measure voltage across the yellow and black wires from the output of the power adapter. 1. If this voltage measures greater than 31volts (yellow positive), installation is complete. 2. If voltage is less than 31Vdc, see Troubleshooting Procedures. If the there is no voltage out of the power adapter 1. Verify 12-14VDC on terminals 5 and 6 at the solar controller, verify voltage at both sides of the power adapter connector block (white positive). 2. Reverify the fuse is good. If the voltage output of the power adapter is less than 31 volts, but greater than 20 1. Unplug connector on gate control board and reconnect. 2. If the voltage rises to 31VDC, installation is complete. If not, the batteries inside the gate control box may require charging or replacement with new batteries. IMPORTANT NOTE: For the LA400 to conserve battery voltage, the SAVE switch located inside the gate control box must be in the ON position so board goes to SLEEP mode (If SAVE switch is not turned to the on position, batteries will drain prematurely). 8
TROUBLESHOOTING PROCEDURES Required test equipment: Digital multimeter, to measure current (5 Amps max.) and DC voltage All solar measurements must be taken when the sun is out. If your unit is not working, due to a low battery condition, follow the following steps (gate will be open and red LED on the sunsaver will be on): 1. Start by measuring the voltage on the primary batteries. The combined battery voltage must be above 25V, if they are not, recharge or replace the internal batteries. 2. Remove the external battery box cover and check for load disconnect LED (red). If load disconnect is on, remove battery and charge to 12.5Vdc. 3. Verify that the battery is a 75 Amp Hour (min.) Sealed lead-acid battery (SLA). Other types of batteries will dramatically decrease the effectiveness of this kit (do not use a standard automotive battery). If using a flooded, marine-type battery, make sure that the jumper is removed (see page 5). 4. Check fuse and all other connections in battery box. 5. Remove the external battery from the battery box while wires are connected. 6. Open the main control box and disconnect the white wire, from the battery box to the power adapter. 7. Inside the battery box, remove red wire from the solar panel(s) to sunsaver and place a DC amp meter between the red wire from the solar panel(s) and terminal 4 on the sunsaver (Figure 1). The current should read 0.8 amps with the panel(s) pointed properly in direct sunlight unless the battery is fully charged. If less than 0.8 amps, clean and/or redirect the panel(s) due south. An additional panel(s) may be required. 8. Reconnect the red wire from the solar panel(s) to terminal 4. Disconnect the black lead of the battery and measure the current between the black wire and the negative battery terminal (Figure 2). Readings should be slightly less than the reading in step 7 (a current reading much less than step 7 indicates a problem with sunsaver or battery is fully charged). If battery checks OK, replace the sunsaver. 9. Reconnect the external battery and measure voltage across 5 & 6 on the sunsaver (black and white). Now measure the voltage across the black and white wires at the adapter located in the electrical box (Figure 3). Voltage should be the same. If not, check connection. Reconnect the white lead. 10. Measure the voltage coming out of the power adapter (black and yellow wires) (Figure 4). This should be greater than 30 volts. If not, replace the power adapter. 11. If there are still problems with the installation, please contact Technical Support at 1-800-528-2806. FIGURE 1 FIGURE 2 FIGURE 3 FIGURE 4 9
TROUBLESHOOTING NOTE: Take these steps if any of the components of the battery kit or the gate operator fail to operate properly. PROBLEM Battery charger LED (green) fails to light. Operator control board does not power up once power adapter is connected. SOLUTION 1. Solar panel(s) may not be mounted properly or the day may be too cloudy to provide enough sunlight. Check mounting, orientation, and possible shading of the solar panel(s) or wait for a brighter day to verify. Check the panel(s) for damage or pinched wires. 2. Wire polarity connections. Verify that the red and black wires go to the correct locations on the battery charger module (see wiring diagram). 1. This battery kit will only work with operators that have local batteries that are used to provide motor current. Make sure these batteries are good and properly connected to operator control board. NOTE: This battery kit does not replace the operator batteries nor will it prevent the replacement of those batteries during normal maintenance for the operator. 2. Blown fuse. It is possible that a fuse, either in the battery cable harness or on the operator control board, may have been blown during the installation. If a blown fuse is found, first check all wiring to make sure it is correct, and then replace the fuse with the same size and type. 3. Battery is not charged. It is possible that the 12V 75AH min. battery (not provided) was not fully charged when installed. Use a voltmeter to make sure this battery is good and has at least 12V across the open circuit terminals. Operator powers up but does not run properly. 1. Debris or other obstructions are affecting gate travel. Make sure that the battery box, solar panel(s), and all connecting wires are clear of the gate. Clear the gate of all obstructions and verify all protection devices are operating properly. See gate operator owner s manual for additional troubleshooting. Operator works fine for several weeks or months but then batteries die. 1. Obstructed solar panel(s). Verify the correct installation and orientation of the solar panel(s). Make sure that the solar panel(s) is unobstructed from the sun throughout the entire day and the glass is clean. 2. Too many accessories will eventually drain the battery despite its larger size and capacity. Contact technical support at 1-800-528-2806 if accessories are required for the installation. Mag-locks must NOT be used with solar applications. 3. Inadequate solar panel(s). Many locations are not suitable for solar installations because of local geography or locations that simply do not receive enough sunlight. Contact technical support to determine if an additional solar panel(s) will help with your installation or if solar is entirely unsuitable. 4. Make sure SAVE switch is on after adjustments have been made for the LA400. Red LED load disconnect on. At 11.5V, the light comes on. Refer to Troubleshooting Procedures. 10
WIRING DIAGRAM MorningStar SS-6-12V SOLAR PANEL BATTERY BOX OPERATOR RED 4 + SOLAR 3 - F1 BATTERY 2 1 + - 6 + LOAD 5 - SEALED OR FLOODED REMOVE METALLIC JUMPER FOR MARINE BATTERY WHITE RED YELLOW 24Vac Input CONTROL BOARD POS (RED) 5A ATC 12VDC SEALED LEAD ACID BATTERY MINIMUM 75 AH NEG () POWER ADAPTER NOTE: Automotive batteries are not acceptable. 11
2007, The Chamberlain Group, Inc. 01-33644B All Rights Reserved