SOLAR SYSTEM INSTALLATION AND OPERATION MANUAL

Electrotechnics Corporation
1310 Commerce St.
Marshall, TX 75672
Phone (03! 3"#101 or ("00! 227#173$
%a& (03! 3"#177
# 1 #




















































SCHOOL
Table of Contents
Topic Page Nube!
'ntro()ction 3
S*stem Con+i,)ration $
S*stem -peration 6
Solar Panel(s! 6
Controller 6
%lasher 6
.atter* 6
Time Cloc/ 7
.eacons 7
Terminal .loc/ 7
'n0erter 7
'nstallation "
%o)n(ation "
'nstallation o+ .ase 1ssem2l* "
Preparation o+ Pole "
'nstallin, the Pole 10
'nstallin, the Solar Panel(s! 10
'nstallin, the 3E4s 12
Connectin, the .atter*(s! 13
%inal Connection an( S*stem Chec/o)t 13
3imite( 5arrant* 15
Cop*ri,ht 15
Critical Parameters # 1ppen(i& 1 16
Pre#T)rn -n Chec/s # 1ppen(i& 1 16
Post#T)rn -n Chec/s # 1ppen(i& 1 16
Solar Panel(s! # 1ppen(i& . 17
Preparation o+ %o)n(ation # 1ppen(i& C 1"
Tro)2le Shootin, # 1ppen(i& 4 20
"igu!es
T*pical Solar 'nstallation # %i,)re 1 $
T*pical Control Panel # %i,)re 2 5
T*pical S*stem .loc/ 4ia,ram # %i,)re 3 5
Solar Panel Electrical Connections .P Solar %i, $ 11
Solar Panel Electrical Connections 6*ocera %i, 5 11
.ac/2one Circ)lar Connector Pin o)t # %i,)re 11 16
S7)are .ase Template # %i,)re C1 1"
T*pical %o)n(ation # %i,)re C2 1
T*pical S*stem Electrical 5irin, 4ia,ram # %i,)re E1 22
Solar Panel Parameter Ta2le # Ta2le .1 17
# 2 #
Int!o#uction
Solar po8er is a relia2le, e++icient, an( e++ecti0e metho( to po8er
either 1lternatin, C)rrent (1C! or 4irect C)rrent (4C! loa(s. Since
solar po8er s*stems pro0i(e 4C c)rrent, 4C o)tp)ts +or 4C loa(s
are more e++icient.
1 Solar s*stem consists o+ three (3! ma9or s)2s*stems, the solar
panels 8hich con0ert solar ener,* to electrical ener,*: the 2atteries
8hich store the electrical ener,* an( release it on (eman(: an( the
loa( ; the components that are 2ein, po8ere( 2* the 2atteries.
Each s*stem pro0i(e( 2* Electrotechnics Corporation (E3TEC! has
2een si<e( +or the speci+ic application speci+ie( 2* the en( )ser. 5e
ha0e consi(ere( the po8er cons)me( 2* the loa(, the po8er
,enerate( 2* the solar panels, an( the ,eo,raphic location o+ the
installation.
The a(0anta,es that *o)r solar po8er s*stem pro0i(es incl)(e=
Clean e++icient po8er that (oes not ,enerate poll)tants
>elia2ilit* o+ contin)o)s po8er 8itho)t 8orr* a2o)t
2ro8n?2lac/o)ts
Eas* installation since con()its an( po8er lines are not
re7)ire(
@o monthl* )tilit* 2ills +rom *o)r local po8er compan*
1ll e7)ipment pro0i(e( is stan(ar(, easil* replace( i+ re7)ire(. Ao)r
s*stem is pre#8ire( to the ma&im)m e&tent possi2le +or eas*
assem2l* an( installation.
5e ha0e pro0i(e( a pa,e (1ppen(i& 1! 8hich (escri2es critical
parameters that *o) sho)l( ens)re are met ()rin, the installation.
These parameters incl)(e solar panel tilt an,le, s*stem (esi,nation,
an( solar panel a<im)th.
'+ *o) e&perience (i++ic)lt* ()rin, the installation or ()rin, operation
o+ *o)r solar s*stem, call E3TEC ("00#227#173$ or 03#3"#101! +or
assistance. Ao) sho)l( ha0e *o)r s*stem (esi,nation (+o)n( on
1ppen(i& 1! a0aila2le to +acilitate assistance.
# 3 #
S$ste Configu!ation
Ao)r s*stem 8ill consist o+ a 2atter* ca2inet, 2atter*(s!, solar
controller, solar panel(s! 8ith mo)ntin, rac/, an( pole. '+ *o)r
application is a tra++ic 8arnin, s*stem *o) 8ill ha0e a soli( state 4C
+lasher an( 3E4 2eacons ()nless *o) ha0e speci+ie( Balo,en
2eacons!. '+ the application is +or a school <one 8arnin, 2eacon
s*stem, a time cloc/ or pa,in, )nit 8ill also 2e pro0i(e(.
>e+er to +i,)re 1 +or a t*pical tra++ic 8arnin, solar s*stem )sin, 2 3E4
+lashin, 2eacons. %i,)re 2 (epicts a t*pical control panel
con+i,)ration +or a school <one +lasher. %i,)re 3 (epicts a t*pical
electrical 2loc/ (ia,ram.
%i,)re 1 # T*pical Solar 'nstallation
# $ #
%i,)re 2 # T*pical Control Panel
C
%i,)re 3 # T*pical S*stem .loc/ 4ia,ram
# 5 #
Solar
1rra*
# D
Control
Panel
D # D # D
#
D #
.atter*
3oa(
(3E4!
# D
%lasher
@TC17E
Controller
S$ste Ope!ation
S)nli,ht is con0erte( 2* the solar panels to electrical ener,* 8hile the 2atteries
store the electrical ener,*. The solar panels are connecte( to the 2atteries
thro),h a controller 8hich controls the char,in, an( (ischar,in, rate o+ the
2atteries. The time cloc/ controls the time an( ()ration that po8er is applie( to
the loa(. '+ the s*stem is a 2$ ho)r +lashin, 2eacon s*stem, then no time cloc/
8ill 2e in the s*stem. The +lasher is a soli( state, 12?2$ 0olt 4C +lasher that
s8itches the po8er +rom one 2eacon to the other. '+ the loa( is not a +lashin,
2eacon s*stem, then no +lasher is pro0i(e( 8ith the s*stem.
The loa( is al8a*s po8ere( +rom the 2atteries 0ia the controller, ne0er +rom the
solar panels (irectl*. Each o+ these ma9or components is (escri2e( in more
(etail.
Sola! Panel%s&' The solar panel(s! are o++ the shel+ items, 8arrante( +or 20
*ears. 1s note( a2o0e, the panels con0ert s)nli,ht to electrical ener,* to char,e
the 2atteries. 1 sin,le panel 8ill )s)all* 2e +rom $0 # 130 8atts. 4epen(in, on
*o)r s*stem re7)irements *o) ma* ha0e m)ltiple panels. 1ppen(i& . (escri2es
the solar panel in more (etail.
Cont!olle!' The controller +)nctions to control the char,e on the 2atteries. The
ProStar controller is a soli( state (e0ice 8hich control the char,in, an(
(ischar,in, o+ the 2atteries. The controller pro0i(es temperat)re compensate(
char,in, so that the rate o+ char,e is controlle( +or 2oth temperat)re an( state o+
char,e. The controller 8ill sh)t o++ char,in, 8hen the 2atter* reaches a char,e o+
15.2 E4C. The controller 8ill (isconnect the loa( 8hen the 2atter* 0olta,e
reaches 11.$E4C. These set points ha0e 2een esta2lishe( to pre0ent (ama,e to
the 2atter* +rom an o0erchar,e con(ition or a lo8 0olta,e con(ition. The
controller also has a man)al (isconnect s8itch that allo8s *o) to electricall*
(isconnect the 2atteries +rom the s*stem.
The Prostar controller pro0i(es a 3C4 (ispla* that c*cle thro),h a (ispla* o+
2atter* 0olta,e, arra* c)rrent, an( loa( c)rrent.
"las(e!' The +lasher is a 12?2$E 4C, soli( state +lasher that cons)mes ne,li,i2le
po8er ()rin, operation. The +lasher is set at the +actor* to pro0i(e 50 +lashes per
min)te, +or 1 or 2 circ)it operation ((epen(in, on *o)r s*stem con+i,)ration!,
3E4 or Balo,en ((epen(in, on *o)r s*stem con+i,)ration!, an( a 50F ()t*
c*cle.
)atte!$' The 2atter* stores the electrical ener,* 8hich po8ers the loa(.
.atteries are maintenance +ree seale( ,el, a2sor2e( mat technolo,*. '+ *o)r
s*stem is G/noc/e( (o8nG 2* acci(ent an( *o)r 2atter* p)nct)re(, *o) 8ill
e&perience little to no aci( spille( ()e to the a2sor2e( mat technolo,*.
# 6 #
Tie Cloc*' The time cloc/ is a soli( state pro,ramma2le (e0ice 8hich 8ill
control the operation o+ *o)r loa( 2ase( on the pro,ram *o) enter in the time
cloc/. The time cloc/ a)tomaticall* compensates +or (a*li,ht sa0in,s time an(
leap *ear. The (a*li,ht sa0in,s time +eat)re can 2e (isa2le( at the )serGs
(iscretion. The time cloc/ is rate( at 15 amps per circ)it an( operates on 12E
4C. The time cloc/ )s)all* has one rela* 2)t ma* come 8ith 2 or $ rela*s i+ the
en( )ser has re7)este( a cloc/ 8ith 2 or $ rela*s. The time cloc/ 8ill 2e either an
E3TEC @TC#17E, an E3TEC TC#2000 2#8a* pa,in, time cloc/ or an E3TEC TC#
1500 1#8a* pa,in, time cloc/.
)eacons' '+ *o)r s*stem is +or +lashin, 2eacons, it 8ill come 8ith the appropriate
2eacons # either 1 or 2 "H (ei,ht inch! or 12H (t8el0e inch! am2er or re( 3E4 or
halo,en. Most solar po8ere( +lashin, 2eacon s*stems )se 3E4s.
Te!inal )loc*' @ormall* all components are pre#8ire( 8ith circ)lar connectors
+or ease o+ component replacement. Bo8e0er i+ *o)r s*stem is 2ein, )se( to
po8er loa(s other than 2eacons, a terminal 2loc/ 8ill 2e pro0i(e( to +acilitate
termination +or the loa(. The po8er terminals 8ill 2e clearl* i(enti+ie( as to
positi0e (D! or ne,ati0e (#!. 1ll Te&as appro0e( solar s*stems 8ill ha0e terminal
2loc/s.
In+e!te!' -n rare occasion, the en( )ser ma* nee( to po8er a 120?2$E 1C loa(.
'+ *o) ha0e speci+ie( a re7)irement +or 1C po8er, *o)r s*stem 8ill ha0e an
in0erter installe(.
# 7 #
Installation
CAUTION' THESE INSTRUCTIONS ARE "OR ,UIDANCE ONLY AND ARE
NOT TO )E CONSTRUED AS EN,INEERIN, APPRO-ED DOCUMENTS.
YOU SHOULD CONSULT A LICENSED PRO"ESSIONAL EN,INEER "OR
APPRO-AL O" YOUR SITE AND ERECTION PLANS.
"oun#ation' 't is important that a proper +o)n(ation 2e prepare(. 1ppen(i& C
ill)strates a t*pical +o)n(ation. Ao)r installation 8ill 2e s)29ect to 8in(s an( other
en0ironmental consi(erations, so a proper +o)n(ation is critical to the s)ccess+)l
an( correct installation o+ *o)r solar e7)ipment.
Installation of )ase Assebl$' Most installations 8ill )se a 2rea/a8a* 2ase.
The 2ase sho)l( 2e installe( on a le0el s)r+ace. '+ the s)r+ace is not le0el, )se
le0elin, processes s)ch as ,ro)t, shims, or similar tools to le0el the +o)n(ation
s)r+ace. Ao)r +o)n(ation sho)l( ha0e +o)r ($! anchor 2olts installe( 8hen the
+o)n(ation is prepare(. These anchor 2olts are )s)all* 3?$H X 10 I 2olts that
come 8ith *o)r 2rea/a8a* 2ase.
P!epa!ation of Pole' @ormall* the pole is prepare( 2e+ore it is erecte(. 5hen
*o) recei0e the pole, it t*picall* (oes not ha0e an* mo)ntin, holes. Ao) 8ill nee(
to (rill the mo)ntin, holes in the (esire( locations.
Tools re7)ire(=
4rill motor an( hole sa8s (sa8s ran,in, +rom JH to 1 KH!
%ish tape to +ish the lea(s thro),h the pole
4e#2)rrin, +ile
Pipe 8rench
Meas)rin, tape
Bammer
The )ser m)st (eci(e ho8 he (esires to mo)nt the ca2inet an( 2eacons.
T*picall* the ca2inet is on one si(e o+ the pole 8ith the 2eacons on the other si(e
o+ the pole. Lnless the )ser is concerne( a2o)t 0an(alism, 8e s),,est that the
ca2inet 2e mo)nte( so that the control panel in the ca2inet is e*e le0el. The
control panel shel+ is appro&imatel* 15H +rom the 2ottom o+ the ca2inet +or a 2
2atter* ca2inet an( is appro&imatel* 30H +rom the 2ottom o+ the ca2inet +or a $
2atter* ca2inet. The lea(s +rom the solar panel an( +rom the 3E4(s! (the
2ac/2one harness assem2l*! 8ill enter the ca2inet +rom insi(e the pole thro),h
the mo)ntin, 2rac/et on the 2ac/ o+ the 2atter* ca2inet. 5e s),,est that the
)ser (rill the ca2inet lea( entr* hole appro&imatel* $ ; $M +eet +rom the 2ottom
(threa(e( en(! o+ the pole. The 2ase is appro&imatel* 1$H hi,h: th)s a hole $1?2
+eet +rom the 2ottom 8ill place the control panel shel+ appro&imatel* 5?12H a2o0e
the +o)n(ation. This hole sho)l( 2e 1H in (iameter.
# " #
'+ 0an(alism is an iss)e, the )ser ma* 8ant to mo)nt the 2atter* ca2inet at a
hei,ht so that it is onl* reacha2le 8ith a li+t 2)c/et tr)c/. 'n this instance, the )ser
8ill 8ant to ens)re that the top o+ the 2atter* ca2inet (oes not inter+ere 8ith the
tilt o+ the solar panels. 5e s),,est that the )ser (rill the hole +or the lea(s +eet
+rom the 2ottom o+ the pole. This 8ill place the control panel shel+ at
appro&imatel* 10 +eet a2o0e the +o)n(ation an( the 2ase o+ a 2 2atter* ca2inet
appro&imatel* +eet a2o0e the +o)n(ation. The 2ase o+ a $ 2atter* ca2inet 8ill
2e appro&imatel* " +eet a2o0e the +o)n(ation.
The ne&t step is to (rill the holes +or the lea(s lea(in, to the 3E4(s!. >emem2er
that normall* the 3E4(s! are on the opposite si(e o+ the pole +rom the 2atter*
ca2inet. '+ onl* 1 3E4 is 2ein, )se(, it t*picall* ,oes a2o0e the si,n. Ao)r local
hi,h8a* or street co(es 8ill speci+* ho8 hi,h the 3E4(s! 8ill 2e a2o0e the
+o)n(ation. 5hen meas)rin, the pole to (rill the 3E4 lea( holes, remem2er that
the 2ase a((s appro&imatel* 1$H to the hei,ht o+ the hole a2o0e the +o)n(ation.
'+ an acorn cap is pro0i(e(, the )ser m)st (rill an e&it hole near the top o+ the
pole +or the solar panel lea(s. 5e s),,est a JH hole +or these lea(s. This hole
sho)l( 2e appro&imatel* H#12H 2elo8 the top o+ the pole.
1ll holes sho)l( 2e (e#2)rre( to ens)re that cha++in, or c)ttin, o+ harness
ins)lation (oes not occ)r. EltecNs harnesses come 8ith a lar,e circ)lar connector
+or eas* matin, to the 2ac/ o+ the control panel. 't 8ill 2e necessar* to +ish the
harness thro),h the pole 2e+ore erectin, it.
Mo)nt the ca2inet on the pole )sin, the L#2olts pro0i(e( (the* 8ill 2e on the
2ac/ o+ the ca2inet 8ith the mo)ntin, 2rac/et. '+ instea( o+ mo)ntin, 2rac/ets
8ith L#2olts, *o) are pro0i(e( 2rac/ets +or 2an(in,, 2an( the ca2inet to the pole.
>emem2er the hole in the 2rac/et sho)l( 2e (irectl* o0er the hole that *o) ha0e
(rille( in the ca2inet.
Threa( the lea(s o+ the 2ac/2one harness into the pole +rom insi(e the ca2inet.
The lea(s o+ the 2ac/2one harness 8ill ,o thro),h the hole in the 2ac/ o+ the
ca2inet, thro),h the mo)ntin, 2rac/et, an( thro),h the hole (rille( in the pole.
Lsin, the +ish tape, p)ll the 3E4(s! lea(s to the hole(s! +or the 3E4(s! an( p)ll
the solar panel lea(s (the 9ac/ete( ,re* ca2le! o)t the top o+ the pole ; either
thro),h the en( o+ the pole or thro),h the hole i+ one 8as (rille(. '+ *o)r s*stem
is a 2 3E4 s*stem *o) sho)l( also threa( a O9)mperN +rom one 3E4 hole to the
other 3E4 hole. The en(s o+ this 9)mper sho)l( e&ten( thro),h each hole.
'+ an acorn cap 8as pro0i(e(, install the cap.
1t this point *o) sho)l( ha0e the 2ac/2one harness circ)lar connector e&ten(e(
+rom the hole +or the 2atter* ca2inet (insi(e the 2atter* ca2inet!, the 3E4 lea(s
# #
thro),h the 3E4(s! (as 8ell as the 9)mper i+ it is a 2 3E4 assem2l*! an( the solar
lea(s +rom the top o+ the pole.
Ao) ma* 8ant to install the solar panel(s! an( mo)ntin, rac/ prior to installin, the
pole in the 2ase. '+ so s/ip to the section G'nstallin, the solar panel(s! an(
mo)ntin, rac/G. 1+ter completin, the installation o+ the solar panel(s! an(
mo)ntin, rac/, then ret)rn to section G'nstallin, the PoleG. .e care+)l that *o) (o
not (ama,e the solar panel(s!.
Installing t(e Pole' >aise the pole o0er the 2ase an( threa( the pole into the
2ase. Ti,hten the pole so that it is sec)re. 6eep in min( that the +inal position o+
the pole m)st 2e 8ith the holes +or the 3E4s are +acin, the on#comin, tra++ic.
Most )nits 8ill 2e pro0i(e( 8itho)t the 2ase collar. Bo8e0er, i+ *o) are pro0i(e( a
2ase collar, install the collar aro)n( the pole an( 2ase. Ti,hten the collar on the
2ase.
Installing t(e Sola! Panel%s& an# Mounting Rac*'
/a!ning' To a+oi# elect!ical s(oc* 0(ile installing an# connecting t(e sola!
panels1 !eo+e t(e P- fuses in t(e cont!ol cabinet.
Ipo!tant' You! sola! panel is #esigne# to con+e!t sunlig(t into elect!ical
ene!g$. You! panel s(oul# be locate# so t(at it is e2pose# to t(e sun at all
ties an# is not s(a#e# b$ t!ees1 buil#ings1 o! siila! t(ings.
'nstr)ction sheets +or assem2lin, an( installin, the mo)ntin, rac/ 8ill 2e
containe( in the 2o& 8ith the mo)ntin, rac/. '+ +or some reason the instr)ctions
are not in the 2o&, sample instr)ctions ma* 2e o2taine( +rom Eltec. Please call
"00#227#173$ an( a set o+ instr)ctions 8ill 2e +a&e( to *o).
Tools *o) 8ill nee( are=
%lat hea( scre8(ri0er
Compass
Protractor
.all peen hammer
1ttach the solar panel(s! to the mo)ntin, rac/. 'nstr)ctions sho)l( 2e in the
carton 8ith *o)r solar panels. '+ the* are not, an( *o) nee( instr)ctions, please
call E3TEC at "00#227#173$ or 03#3"#101.
Ao) are no8 rea(* to install the mo)ntin, rac/ 8ith solar panels on the pole. '+
the mo)ntin, rac/ has L#2olts, it ,oes near the top o+ the pole, 9)st )n(er the
pole cap. '+ the mo)ntin, rac/ has a top o+ pole cap, *o) slip the mo)ntin, rac/
# 10 #
o0er the top o+ the pole. '+ it is a si(e o+ pole mo)ntin, rac/, +ollo8in, the
instr)ctions 8ith the rac/. The orientation o+ the solar panels sho)l( 2e so)th.
To optimi<e the ,eneration o+ electricit*, *o)r s*stem has 2een optimi<e( +or *o)r
location. Ao) m)st rotate the panels +rom the hori<ontal to the optimal an,le. Ao)
8ill +in( this an,le on the (ata pa,e, 1ppen(i& 1. Lsin, *o)r protractor: tilt the
solar panels )ntil the* are at this an,le. Ti,hten the n)ts on the 2olt to loc/ the
panels at this an,le.
3ocate the 9)nction 2o& )n(er the panel(s!. >emo0e the co0er(s! an( locate the
terminal 2loc/. '+ *o) ha0e more than one panel install the 9)mper +rom panel to
panel as sho8n in +i,)re $ +or a .P Solar panel an( +i,)re 5 +or a 6*ocera solar
panel. The re( 9)mpers 8ill connect the terminals in(icate( ODN on the terminal
2loc/ an( the 2lac/ 9)mpers 8ill connect the terminals in(icate( O#O. The solar
panels are 2ein, connecte( in parallel.
%i,)re $ ; Solar Panel Electrical Connections +or .P Solar Panel
@ote= i+ more than
-ne panel is 2ein,
)se(, then *o) 8ill
install a re( 9)mper
2et8een the positi0e
terminals an(
a 2lac/
9)mper 2et8een
the ne,ati0e
terminals.
%i,)re 5 # Solar Panel Electrical Connections +or 6*ocera Panel
# 11 #
D
1
D
#
1
6
5hite
>e(
.lac/ .lac/
@e,ati0e
Positi0e
D
1
D
#
1
6
.lac/
@e,ati0e
5hite
Positi0e
Earlier *o) installe( the 2atter* ca2inet an( inserte( the solar panel lea(
(9ac/ete( ,re* ca2le into the pole! an( +ishe( it o)t the top o+ the pole. @o8 insert
the t8o ca2les in this 9ac/ete( ca2le thro),h the /noc/e( o)t hole in the solar
panel 9)nction 2o&. The 8hite lea( ,oes to the positi0e connection an( the 2lac/
lea( ,oes to the ne,ati0e connection.
1+ter ma/in, this connection, *o) ha0e no8 complete( the 8irin, connections
+rom the solar panel to the solar controller. 5e 8ill install the +)ses 9)st prior to
s*stem chec/o)t. '+ *o) (i( not install the pole into the 2ase earlier, no8 is the
time to install the pole into the 2ase. >et)rn to the section G'nstallin, the PoleG.
Installing t(e LEDs'
%Note' T(is section a$ be s*ippe# if LEDs a!e not being installe#&
/a!ning' Reo+e t(e fuse a!*e# loa# insi#e t(e batte!$ cabinet p!io! to
connecting t(e LED%s&.
'+ *o) ha0e alrea(* (rille( the pole +or the 3E4Ns then s/ip the ne&t para,raph. '+
*o) ha0e not (rille( the holes +or the 3E4, *o) 8ill nee( to (o so at this time.
Eltec pro0i(es mo)ntin, har(8are pre#selecte( +or the 3E4Ns that 8e pro0i(e.
@ormall* this mo)ntin, har(8are incl)(es a h)2 8hich mo)nts to the pole either
thro),h L#2olts or 2an(in,. 'n man* instances, o)r (ealers pro0i(e the si,nal
hea(s an( mo)ntin, har(8are. Sho)l( the mo)ntin, har(8are (i++er +rom 8hat is
(escri2e( in this section, please contact the (ealer 8ho sol( *o) the s*stem +or
installation (etails.
P)ll the lea(s pre0io)sl* +ishe( +rom the 2atter* ca2inet to the 3E4 holes in the
pole thro),h the mo)ntin, h)2. 'nsert the L#2olts aro)n( the pole an( thro),h
the h)2 pro0i(e(. 'nstall the n)ts an( ti,hten.
-pen the 3E4 assem2l* (oor so that *o) ha0e access to the insi(e o+ the si,nal
hea(. 4eci(e i+ *o) are ,oin, to install the si,nal hea( 8ith the s)pport on the
2ottom o+ the hea( or on top o+ the hea(. 'nstall the si,nal hea( clos)re /it
(plastic stopper! in the top?2ottom o+ the hea( 8hich 8ill not 2e )se( +or s)pport.
%ee( the lea(s thro),h the mo)ntin, har(8are into the si,nal hea(. 'nstall the
loc/in, rin, onto the threa(s o+ the mo)ntin, har(8are an( ti,hten. The si,nal
hea( sho)l( 2e positione( in the (esire( (irection 2e+ore ti,htenin,.
@ormall* the 3E4 lens 8ill 2e mo)nte( in the si,nal hea( 8hen *o) recei0e the
assem2l*. The si,nal hea( sho)l( 2e mo)nte( so that the OtopN o+ the 3E4 lens is
in the O)pN position.
# 12 #
Connect the 3E4 lea(s to the terminal 2loc/ in the si,nal hea(. The positi0e (re(!
lea( 8ill ,o to the positi0e terminal an( the ne,ati0e (2lac/! lea( 8ill ,o to the
ne,ati0e terminal.
Close the hea( an( sec)re the si,nal hea( (oor.
Connecting )atte!$%s&'
/a!ning' Reo+e t(e batte!$ fuse in t(e batte!$ cabinet p!io! to connecting
t(e batte!$%s&.
'+ *o) ha0e 2een pro0i(e( 8ith more than 1 2atter*, *o) 8ill also ha0e re( an(
2lac/ 9)mpers 8ith rin, terminals to connect the 2atteries in parallel. Lnscre8 the
8in, n)ts +rom the 2atter* terminals an( attach the rin,s to the 2atter*
connection. The re( 9)mper ,oes to the positi0e terminal an( the 2lac/ 9)mper
,oes to the ne,ati0e terminal.
Threa( the 2lac/ an( re( 10 15P Ore( an( 2lac/ 8ires o+ the O2ac/2oneN harness
thro),h the hole in 2ac/ le+t corner o+ the control compartment in the 2atter*
ca2inet. These 8ires sho)l( ha0e rin,s on the en(s o+ them. Lnscre8 the 8in,
n)ts o++ the 2atter* terminals an( attach the re( 8ire to the positi0e terminal o+
the 2atter* an( the 2lac/ 8ire to the ne,ati0e terminal o+ the 2atter*.
"inal Connections an# S$ste C(ec*out'
Ao) sho)l( per+orm se0eral 7)ic/ chec/s to ens)re that *o)r 8ires an(
connections ha0e 2een ma(e correctl*. These chec/s are (e+ine( in 1ppen(i& 1.
1+ter *o) ha0e ma(e *o)r 8ire an( connections chec/s, connect the G2ac/2oneG
harness assem2l* +rom the solar panels an( 2atter* to the lar,e circ)lar
connector on the 2ac/ o+ the control panel. >e#install all +)ses. There are 3 +)ses,
the loa( +)se, the 2atter* +)se, an( the solar panel +)se.
The ProStar 15 controller sho)l( ha0e at least 1 3E4 lit, in(icatin, that 2atter*
0olta,e is present at the controller. '+ all 8irin, has 2een ma(e correctl*, 3E4s
8ill li,ht on the Prostar 15 controller. >e+er to the (escription o+ Prostar 15
controller 3E4s in 1ppen(i& E to ascertain 2atter* char,e state.
Ao) 8ill see the 3C4 (ispla* c*clin, thro),h the parameters it (ispla*s. Ao)
sho)l( see 2atter* 0olta,e 8ith a rea(in, ,reater than 11.$ 0olts, arra* c)rrent,
an( loa( c)rrent. Ao) 8ill ha0e to 8ait 2 min)tes a+ter s*stem initiali<ation 2e+ore
the loa( c)rrent is (ispla*e(. '+ the loa( is not t)rne( on, the rea(in, 8ill 2e 0.0
amps.
'+ *o) s*stem has a time cloc/, *o) sho)l( also see the (ispla* on the time cloc/
li,hte(. The cloc/ sho)l( 2e c*clin, thro),h se0eral (ispla*s 8hich sho8 (ate,
# 13 #
time, rela*s on (or o++!, an( pro,ram r)nnin,. '+ *o) ha0e Gpo8er +ailG sho8in, on
*o)r time cloc/, simpl* p)sh the 2)tton on the /e* pa( mar/e( GCG. This sho)l(
reset the time cloc/.
'+ *o) s*stem is +or a school <one an( has a time cloc/, *o) ma* test the 3E4s
2* t)rnin, the time cloc/ rela* on man)all*. To accomplish this p)sh G131G, the
p)sh G1G, an( then p)sh G.G. Ao)r 3E4s sho)l( no8 2e +lashin,. To t)rn the rela*s
o++, repeat the se7)ence G131G, G1G, an( G.G.
>e+er to 1ppen(i& 4 +or tro)2leshootin, *o)r s*stem. '+ *o) still ha0e pro2lems
8ith s*stem operation, *o) ma* call Electrotechnics Corporation (Eltec! +or
assistance. -)r n)m2er is "00#227#173$ or 03#3"#101.
Electrotechnics Corporation
1310 Commerce St.
Marshall, TX 75672
Phone (03! 3"#101 or ("00! 227#173$
%a& (03! 3"#177
# 1$ #
LIMITED /ARRANTY
Electrotechnics Corporation (E3TEC! 8arrants *o)r solar (e0ice to 2e +ree o+
(e+ects in material an( 8or/manship +or a perio( o+ 12 months +rom (ate o+
receipt 2* en( c)stomer.
This 8arrant* is 0ali( +or s*stems that are )se( 8ithin the (esi,n speci+ications
ori,inall* s)2mitte( 2* the en( c)stomer. S*stems )se( +or perio(s lon,er than
speci+ie( or 8ith loa(s ,reater than speci+ie(, in0ali(ate the 8arrant*. S*stems
not installe( properl* also in0ali(ate the 8arrant*. Some e&amples o+ improper
installation incl)(e sha(in,, incorrect a<im)th, an( incorrect tilt an,les. These
e&amples are not incl)si0e. Mis)se, a2)se, ph*sical (ama,e an(?or acts o+ Po(
to the e7)ipment in0ali(ate the 8arrant*.
Electrotechnics Corporation 8ill, at its (iscretion, repair s*stems ret)rne( 8ith
prior a)thori<ation or re+)n( the c)stomerGs mone*. 'n no e0ent 8ill
Electrotechnics Corporation or its emplo*ees 2e lia2le +or an* (irect, in(irect,
special, inci(ental, or conse7)ential (ama,es.
Some components )se( 2* Electrotechnics Corporation ha0e 8arrant* lon,er
than the 12 month perio( speci+ie( 2* Electrotechnics Corporation. %ollo8in, this
12 month perio(, Electrotechnics Corporation 8ill, 8hen practical, assist the
c)stomer in o2tainin, repair an(?or ser0ice +or these 8arrante( components.
Electrotechnics Corporation 8ishes to pro0i(e e&ceptional ser0ice to o)r
c)stomers. E0er* e++ort 8ill 2e ma(e to ens)re that *o)r pro()cts are 8ithin
speci+ication an( +ree +rom man)+act)rin, (e+ect.
COPYRI,HT
This p)2lication ma* not 2e copie( or repro()ce( in an* manner or 2* an*
means 8itho)t the e&press 8ritten consent o+ Electrotechnics Corporation. 1ll
ri,hts reser0e(. Cop*ri,ht 2003, Electrotechnics Corporation.
# 15 #
APPENDI3 A
CIRTICAL PARAMETERS
S*stem 4esi,nation= QQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQ
Solar Panel Tilt 1n,le (%rom the Bori<on!= QQQQQQQQQQQQQQQ
Solar Panel 1<im)th= QQQQQQQQQQQ1"0
o
QQQQQQQQQQQQQQQQQ
P!e4Tu!n On C(ec*s
1. -n the solar panel lea(s, chec/ the 0olta,e 2et8een the t8o lea(s. This
0olta,e sho)l( rea( appro&imatel* 16#20 0olts. Ao)r rea(in, is
QQQQQQQQQQQQQQQQQQ.
2. -n the terminal 2loc/ mar/e( G.1TDG an( G.1T#G chec/ the 0olta,e
2et8een the 2 terminal 2loc/s. This 0olta,e sho)l( rea( 2et8een D11.$
0olts an( D13.$ 0olts. Ao)r rea(in, is QQQQQQQQQQQQQQQQQQQQQQ.
Post4Tu!n On C(ec*s
1. Eeri+* the 3E4 that is lit on the solar controller (ProStar 15!. >ecor( the
color o+ the 3E4 that is lit QQQQQQQQQQQQQQQQQQQQQQQQQQQQQ.
2. >ecor( the solar 0olta,e 2ein, (ispla*e( on the controller QQQQQQQQQQE.
3. >ecor( the arra* c)rrent 2ein, (ispla* on the controller QQQQQQQQQQamps
an( the time o+ (a* QQQQQQQQQQQQ an( 8eather stat)s (s)nn*, clo)(*,
rainin,! QQQQQQQQQQQQQQQQQQQQ.
$. T)rn on the loa( an( recor( the loa( c)rrent 2ein, (ispla*e( on the
controller QQQQQQQQQQQQQQQQQamps.
>e0ise( 2#
0
# 16 #
APPENDI3 )
Sola! Panel%s&
The c)rrent an( po8er o)tp)t o+ *o)r solar panel is proportional to s)nli,ht
intensit*. 't is important to install *o)r solar panel so that it is not sha(e( ()rin,
(a*li,ht ho)rs. The season o+ the *ear as 8ell as the a<im)th o+ *o)r panel 8ill
a++ect the o)tp)t o+ *o)r solar panel. 'n the @orthern Bemisphere *o)r panel
sho)l( 2e pointe( 1"0
0
or So)th. 1s the seasons e0ol0e, the an,le o+ the s)n to
the hori<on 8ill chan,e. To optimi<e the s)nli,ht on *o)r panel thro),ho)t the
*ear, *o)r panel sho)l( 2e set at the in(icate( an,le +rom the hori<on. This an,le
is +o)n( in 1ppen(i& 1.
Ao)r panel is compose( o+ cr*stalline cells interconnecte( to e++ect the 8atta,e
ratin, o+ the panel. %)rther the connection is s)ch that (ama,e to one cell(s! onl*
re()ces the o)tp)t o+ the panel 2* the po8er lost +rom the cell(s!. Th)s i+ onl*
one cell is (ama,e( *o)r panel 8ill still contin)e to pro()ce po8er close to the
rate( o)tp)t o+ the panel. The cr*stalline cells are encaps)late( 2et8een
tempere( ,lass an( an EE1 pottant 8ith PE% 2ac/ sheet to pro0i(e the
ma&im)m protection to *o)r cells +rom en0ironmental +actors. The panel is
ho)se( in an ano(i<e( al)min)m +rame to pro0i(e str)ct)ral stren,th an( ease o+
han(lin,.
T*pical o)tp)t ratin,s o+ panels are sho8 in Ta2le .1.
Panel >atin, ' T*pical E T*pical ' Short Circ)it E -pen Circ)it
30 5att 1.7" 16." 1.$ 21.0
$0 5att 2.37 16." 2.5" 21.0
50 5att 2.7 16." 3.23 21.0
55 5att 3.33 16." 3.6 21.0
60 5att 3.56 16." 3."7 21.0
65 5att 3.77 16." $.06 21.0
70 5att $.1$ 16." $.35 21.0
755att $.5$ 16." $.7 21.0
"0 5att $.75 16." 5.17 21.0
"5 5att $.7 16." 5.3 21.0
Ta2le .1
'+ *o) ha0e m)ltiple panels the* 8ill 2e connecte( in parallel. The total t*pical
c)rrent o)t 8ill 2e m)ltiplie( 2* the n)m2er o+ panels in *o)r arra*.
# 17 #
APPENDI3 C
P!epa!ation of t(e "oun#ation
Caution' T(is appen#i2 if p!o+i#e# fo! !efe!ence onl$. Elect!otec(nics
Co!po!ation is not license# to p!o+i#e enginee!ing se!+ices in $ou! state.
You s(oul# consult a license# p!ofessional enginee! fo! app!o+al of $ou!
plans an# $ou! site.
The concrete +o)n(ation sho)l( 2e s)++icientl* si<e( to allo8 the installation o+
the anchor 2olts an( 2ase. The 2ase 8ill t*picall* 2e 13 3?$R s7)are i+ s)pplie( 2*
Eltec.
The 2ase template 8ill 2e as sho8n in +i,)re C1.
%i,)re C1
%i,)re C2 on the ne&t pa,e (epicts a t*pical pole +o)n(ation. Ls)all* the
+o)n(ation is s7)are altho),h it can also 2e circ)lar. >emem2er that the
+o)n(ation 8ill ho)se the anchor 2olts to 8hich the 2rea/a8a* 2ase mo)nts. The
+o)n(ation m)st ha0e a si<e that 8ill accommo(ate the 2rea/a8a* 2ase or it
m)st 2e at least 2G s7)are or i+ circ)lar it sho)l( ha0e a (iameter o+ at least 2G.
# 1" #
12.0R Min
1$.5R Ma&
13 # 3?$R
S7)are .ase Template
%i,)re C2
# 1 #
1nchor 2olts ($!
S $ Ties
300 PS'
Concrete
2G T*pical
5G
T*pical
S 6
Eertical
>e2ar
.rea/a8a* .ase
APPENDI3 D
T!oubles(ooting
If t(e t!oubles(ooting gui#e #oes enable $ou to !esol+e $ou! p!oble1
please call Eltec at 5664778498:;.
No LEDs a!e lit on Sola! Cont!olle! %P!osta! 9<&'
Eeri+* 8ith a m)ltimeter that *o) ha0e 0olta,e at the 2atter* connection to the
controller. '+ *o) ha0e 0olta,e o+ at least 11.5 0olts 4C, press the Gon?o++G (lar,e
2)tton in )pper ri,ht corner o+ controller!.
Lig(ts #o not flas( 4 Sc(ool =one S$ste'
Eeri+* that the re( 3E4 on the controller is not lit 8ith a soli( (ispla*. '+ it is
+lashin,, *o)r li,hts sho)l( 2e +lashin, i+ 8ire( correctl*, 2)t the +lashin, means
that *o)r 2atter* 0olta,e is lo8.
Eeri+* that *o)r time cloc/ has an acti0e (ispla* an( is scrollin, messa,es on its
(ispla*. Eali(ate that *o)r 8irin, is correct m* t)rnin, on the 2eacons man)all* at
the cloc/. -n the /e*pa( on the @TC 17E, press G131G, then press G1G, an( +inall*
press G.G. This se7)ence sho)l( t)rn *o)r li,hts on. '+ the* still (o not come on,
then *o) ha0e a pro2lem 8ith the 8irin,. '+ the* (o come on, 0eri+* that *o)r
pro,ram in *o)r time cloc/ is correct.
Chec/ that the 8irin, in the 3E4 hea( is positi0e to positi0e. The lea(s in the
G2ac/2oneG harness sho)l( 2e mar/e( GDG an( G#R. '+ *o) ha0e a t8o 2eacon
s*stem, then *o) sho)l( also ha0e a re( 9)mper that ,oes +rom the positi0e
terminal in one hea( to the positi0e terminal in the other hea(.
'+ the 8irin, is correct, 0eri+* that *o) ha0e 12D 0olts across the terminals in the
hea(.
Lig(ts #o not flas( 4 7; Hou! S$ste'
Eeri+* that the re( 3E4 on the controller is not lit 8ith a soli( (ispla*. '+ it is
+lashin,, *o)r li,hts sho)l( 2e +lashin, i+ 8ire( correctl*, 2)t the +lashin, means
that *o)r 2atter* 0olta,e is lo8.
'+ *o)r s*stem has a to,,le or /e* s8itch, ens)re that the to,,le?/e* s8itch is in
the GonG position.
Chec/ that the 8irin, in the 3E4 hea( is positi0e to positi0e. The lea(s in the
G2ac/2oneG harness sho)l( 2e mar/e( GDG an( G#R. '+ *o) ha0e a t8o 2eacon
s*stem, then *o) sho)l( also ha0e a re( 9)mper that ,oes +rom the positi0e
terminal in one hea( to the positi0e terminal in the other hea(.
# 20 #
'+ the 8irin, is correct, 0eri+* that *o) ha0e 12D 0olts across the terminals in the
hea(.
)atte!$ -oltage is Lo0 o! Lo0 -oltage Disconnect is >On>'
'+ the lo8 0olta,e (isconnect is not GonG, 0eri+* that the solar panels are char,in,
the 2atteries. >ea( the 3C4 (ispla* on the controller. The arra* c)rrent 8ill 2e
(ispla*e( as the (ispla* c*cles thro),h its (ispla*s. Lse the ta2le in 1ppen(i& .
to appro&imate 8hat the arra* c)rrent sho)l( 2e on a s)nn* (a*. '+ the arra*
c)rrent is not appro&imate to e&pecte( 0al)e, then *o) most li/el* ha0e a
pro2lem 8ith *o)r solar panel(s!. Chec/ *o)r 8irin, at the panels (in the 9)nction
2o&es! to ens)re that the 8irin, to the 2atter* ca2inet an( the 9)mpers +rom
panel to panel are correct. '+ the* are correct, then meas)re the 0olta,e at the
controller (at the PE D an( #! to ens)re that *o) ha0e at least 16 0olts present. '+
*o) (o, then the controller ma* 2e 2a(.
>e0 2#1#0
# 21 #