Powerflextm Mobile Installation Manual
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Global Solar Energy recommends having the PowerFLEX™ MOBILE Solar Kit professionally installed. Although the kit is relatively straightforward to install, working with high current battery systems and working on the roof of the RV can be dangerous. Global Solar Energy will be happy to work directly with your dealer or service center of choice to ensure a proper, long lasting installation. Just send us their contact information or have them contact us and we’ll take care of the rest. GSE Document: 1000564 Rev. E PowerFLEXTM MOBILE Solar Power for Your RV READ THIS PRIOR TO INSTALLING The PowerFLEXTM MOBILE Solar Charging Kit is intended for use on newer roofs that are in good condition when using only the adhesive to secure the solar panel to the roof. Cleaning the roof is critical in obtaining a safe, secure and long-lasting installation. Failure to follow the included instructions can result in loss of adhesion, damage or loss of the product, and shortened product life. Mechanical fasteners such as screws or rivets are recommended in any installation where the quality of the roof is questionable or if the vehicle is to be used in extreme environments. Contact Global Solar Energy Technical Support if you have any questions, concerns or would like to discuss you special application. GSE Document: 1000564 Rev. E TM PowerFLEX MOBILE Installation Instructions Solar Power for Your RV Global Solar Energy, Inc. 8500 S. Rita Road Tucson, AZ 85747 www.GlobalSolar.com Technical Support www.GlobalSolar.com 520-546-6313 1 DOCUMENT NO. 1000564 REV. E Contents: INTRODUCTION & SAFETY INFORMATION....................................................................................................... 3 KIT CONTENTS .................................................................................................................................................. 4 TOOLS REQUIRED FOR INSTALLATION ............................................................................................................. 4 OTHER ITEMS ................................................................................................................................................... 4 STORAGE & HANDLING PRECAUTIONS ............................................................................................................ 5 INSTALLATION OVERVIEW ............................................................................................................................... 5 SOLAR PANEL LOCATON ................................................................................................................................... 6 ROOF SURFACE PREPARATION ........................................................................................................................ 6 INSTALLING THE SOLAR PANELS ...................................................................................................................... 8 INSTALLING THE EDGE TRIM ............................................................................................................................ 9 SPECIAL ROOF TYPES ...................................................................................................................................... 12 LOCATING THE SOLAR CHARGE CONTROLLER ............................................................................................... 12 ROUTING THE CABLE ...................................................................................................................................... 13 CONNECTING THE WIRING ............................................................................................................................ 17 MAINTENANCE ............................................................................................................................................... 18 WARRANTY REGISTRATION ............................................................................................................................................... 19 APPENDIX ....................................................................................................................................................... 20 Technical Support ....................................................................................................................................... 20 About The Solar Charge Controller ............................................................................................................ 20 Charge Controller Specications: ............................................................................................................... 21 Solar Panel Specications: ......................................................................................................................... 21 Installation Summary Chart ....................................................................................................................... 22 Global Solar® PowerFLEX™ Mobile Limited Warranty................................................................................ 23 2 DOCUMENT NO. 1000564 REV. E INTRODUCTION & SAFETY INFORMATION The PowerFLEXTM MOBILE Kit product line, the premier solar solution for RV’s , has been specically developed for use on recreational vehicles and will provide years of reliable service when properly installed. IMPORTANT READ THESE INSTRUCTIONS COMPLETELY BEFORE BEGINNING INSTALLATION FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN DAMAGED PRODUCT, DAMAGE TO THE RV, AND/OR PERSONAL INJURY GLOBAL SOLAR ENERGY HIGHLY RECOMMENDS HAVING THIS SYSTEM INSTALLED BY A PROFESSIONAL RV TECHNICIAN THE INSTALLER SHOULD BE FAMILIAR WITH: DC electrical systems and wiring in RVs Working with high capacity battery systems ADDITIONAL PRECAUTIONS NEVER MIX SOLAR PANELS OF DIFFERING BRANDS, PART NUMBERS OR POWER RATINGS IN THE SAME SYSTEM. DOING SO WILL RESULT IN POOR PERFORMANCE AND MAY DAMAGE COMPONENTS WORKING WITH ELECTRICITY AND LEAD ACID BATTERIES CAN BE DANGEROUS INSTALLATION OF THE SOLAR PANELS REQUIRES WORKING ON THE ROOF OF THE RV WHERE THERE IS A RISK OF FALLING WARNING! SOLAR PANELS PRODUCE ELECTRICITY WHEN EXPOSED TO LIGHT EVEN WHEN NOT CONNECTED TO THE SYSTEM. THE SOLAR PANELS SHOULD BE COVERED WHENEVER WORKING ON THE SOLAR POWER SYSTEM IN ORDER TO AVOID ELECTRICAL SHOCK AND/OR ARCING. 3 DOCUMENT NO. 1000564 REV. E KIT CONTENTS Your PowerFLEXTM MOBILE Solar Power Kit includes the following items: ITEM PFM-2K PFM-1K PFM-1E PowerFLEX Solar Panel 2 1 1 Solar Charge Controller Kit 1 1 - 1. Charge Controller, 1ea. 2. Standoff Blocks, 2ea. 3. Ring Terminals, 2ea. 4. #6 x 1” Screws, 2ea. 5. #6 x 2” Screws, 2ea. Edge Trim Set (7 pieces) 2 1 1 Top right, top left, bottom, (4) sides Structural Adhesive Caulking 300 ml-310 ml 1 1 1 Cable with PV connector (1 Pos, 1 Neg) 20’ 20’ 0 Cable, 10 AWG/2-Conductor 20’ 20’ 0 Y-Connector Set (1 Pos, 1 Neg) 1 0 1 Inline ATC Fuse Holder w/20A Fuses 2 2 - Ring Terminal, 10 AWG (Large) 2 2 - Cable Tie Mounts 10 4 10 Cable Ties 14 6 14 TOOLS REQUIRED FOR INSTALLATION Safety glasses suitable for use around liquid chemicals Phillips screw driver Wire cutters and strippers Caulking gun Crimping tool for 10 AWG connectors (ratcheting type preferred) Utility knife OTHER ITEMS Roof cleaning supplies appropriate for roof type Medium Synthetic Bristle Brush (E.g. deck scrub brush) Mild Liquid Dish Soap or RV-dealer-recommended wash Warm Water Isopropyl Alcohol >70% 4 DOCUMENT NO. 1000564 REV. E Pressure Washer / Hose With Spray Nozzle Tape measure STORAGE & HANDLING PRECAUTIONS Failure to follow these Storage and Handling guidelines can lead to product damage and premature failure and violate the PowerFLEXTM MOBILE Limited Warranty. For the protection of PowerFLEXTM MOBILE kits, the kit contents and sealed boxes must always be stored between temperatures of 60°F (15°C) and 85°F (30°C). Do not use screws, nails, staples or otherwise puncture any part of the solar panel. The PowerFLEXTM solar panel must not be rolled to a diameter smaller than 20”. Doing so may result in permanent internal damage and lead to immediate or premature failure. Do not fold or crease the solar panel. Scratches on the panel surface can occur if walked on improperly. Guidelines to avoid such damage include: o Keep walking on the solar panel to an absolute minimum. o Do not walk on the solar panel with hard soled shoes. o Inspect shoe tread for rocks or debris before stepping on the panel. o Be careful not to drop objects on the solar panel. The solar panel surface is slippery. Use extreme caution. Do not attempt to open the solar panel’s junction box. The junction box contains no user serviceable parts. Do not attempt to open the solar charge controller. The controller contains no user serviceable parts. The solar panel can become very hot when left in direct Sun light. Gloves may be required in hotter climates. INSTALLATION OVERVIEW The installation of the PowerFLEXTM MOBILE solar kit is fairly simple and straight forward with a little planning. The key installation steps are: 1. Choose a suitable location for the solar panel(s). 2. Prepare roof surface. 3. Install the solar panels, edge adhesive, and edge trim. 4. Choose the internal RV location for the charge controller. 5. Route the cable from the solar panels to the charge controller and then to the batteries. 6. Connect the wiring. 5 DOCUMENT NO. 1000564 REV. E SOLAR PANEL LOCATON The following recommendations for location of the PowerFLEXTM solar panels are important to ensure best performance and aesthetics. The PowerFLEXTM solar panels: