Hali-Brite SPS Series, Installation And Maintenance Manual

Page 1: ...nd Maintenance Manual SPS Solar Power Supply Hali Brite Inc 1119 Madison St Brainerd MN 56401 Tel 800 553 6269 Fax 218 454 0972 www halibrite com Copyright 2020 Hali Brite Inc Brainerd MN U S A Printed in U S A Rev 6 ...

Page 2: ...2 SPS Installation and Maintenance Manual ...

Page 3: ...3 Specifications 9 3 1 Electrical Specifications 9 3 2 Physical Specifications 9 3 3 Environmental Specifications 9 4 Installation 10 4 1 Unpacking 10 4 2 Tools and Supplies Needed 10 4 3 Installation 11 5 Maintenance 19 5 1 Maintenance Schedule 19 6 Repair 20 6 1 Battery Replacement 20 6 2 Fuse Replacement 20 6 3 Solar Panel Replacement 21 6 4 Charge Controller Replacement 22 6 5 Frangible Coupli...

Page 4: ...nical electrical and physical defects excluding lamps for a period of one year from the date of installation or a maximum of two years from the date of shipment and are guaranteed to be merchantable and fit for the ordinary purposes for which such products are made Hali Brite will correct by repair or replacement at its option equipment or parts which fail because of mechanical electrical or physi...

Page 5: ...s will not infringe any third party s patents or rights The information given does not release the buyers from making their own experiments and tests 1 4 Disclaimers This manual is published for informational purposes only and the information provided should not be considered as all inclusive or covering all contingencies If further information is required Hali Brite Inc should be contacted Sale o...

Page 6: ...ards or unsafe practices that could result in severe personal injury or death DANGER Indicates immediate hazards that will result in severe personal injury or death 2 2 General Practices Read and become familiar with the general safety instructions provided in this section of the manual before installing operating maintaining or repairing this equipment Do not attempt to assemble or install this e...

Page 7: ...maintenance wiring accessibility and cover removal 2 3 Electrical Practices Do not attempt to make electrical connections with the power on Disconnect and lock out electrical power before touching any electrical connections Install all electrical connections to local code Use only electrical wire of sufficient gauge and insulation to handle the rated current demand All wiring must meet local codes...

Page 8: ... in mechanical or electrical equipment Attempt to maintain or install this equipment without the correct tools as specified in this manual 2 5 Proper Usage Always use this equipment as specified in this manual Improper usage may result in serious personal injury property damage or possible death Do not make any modifications that have not been recommended by Hali Brite Do not use any replacement p...

Page 9: ... ETL certified Photovoltaic Panel 50 or 135 watt Load 8 13 watts Autonomy 10 days typical 3 2 Physical Specifications Dimensions Height 37 55 inches 94 140 cm Width 59 or 33 inches 150 or 84 cm Mounting 2 frangible couplings and flanges to a 6 x 32 inch anchor assembly with 4 5 8 inch mounting bolts Product Weight 196 278 lb 87 126 kg Shipping Weight 276 398 lb 125 180 kg 3 3 Environmental Specifi...

Page 10: ...ad to detection of equipment damage If you note any damage to any equipment file a claim with the carrier immediately The carrier may need to inspect the equipment A typical shipping crate including an L 806 wind cone is shown below Figure 1 Note To prevent damage to the equipment transport the pallet to the installation site before removing the SPS components from the pallet The anchor assembly m...

Page 11: ...the southern hemisphere The front of the solar panel must face the equator The SPS shall be located 8 to 15 feet from an L806 or L807 Size 1 wind cone and 12 to 15 feet from an L807 Size 2 wind cone Electrical cable to connect the wind cone to the SPS is supplied with the wind cone additional cable may be required This cable is not suitable for direct burial The following instructions assume this ...

Page 12: ...ches square and at least 3 inches thick 5 Orient the SPS anchor assembly in the center of the base with the conduit entrance as shown Place blocks under anchor assembly as needed to ensure the anchor bolts will protrude about 4 inches above the top of the finished concrete surface Make sure the 2 mounting nuts and washer on each anchor bolt will be above the top surface of the concrete 6 Ensure th...

Page 13: ... the mounting leg of the SPS and into the battery enclosure 8 Remove the top nut and lock washer from each of the 4 anchor bolts One nut should remain on each of the 4 bolts 9 Caution The following step should be performed by 2 people Lift the SPS from the pallet and guide the mounting legs on to the 4 mounting bolts Install a lock washer and nut on to each of the 4 mounting bolts 10 The bottom nu...

Page 14: ...he fuses until instructed to do so 3 Unpack the batteries from their packing materials Locate the battery terminal bolts and washers shipped with each battery 4 Place the batteries in the battery enclosure with the battery connection posts towards the charge controller as shown in Figure 6 The batteries are installed as close as possible to the charge controller snugly against the battery stop in ...

Page 15: ...ire One end is connected to the charge controller 10 Connect this black wire to the negative terminal of the first battery 11 Connect another black wire to the negative terminal of the first battery 12 Connect the black wire from the first battery to the negative terminal of the second battery as shown in Figure 6 13 If a third battery is supplied with the product connect another black wire from t...

Page 16: ...tery If fuses are not installed for every battery the unit will operate but will not have full battery capacity 4 Snap the fuseholder cover over each fuse Proceed as follows to install the photocell 1 Refer to Figure 7b The photocell is installed in a receptacle Figure 7b Photocell 2 Position the photocell near the receptacle with the photocell window facing away from the solar panel 3 Insert the ...

Page 17: ...too dark to perform these tests Stop this test and repeat it in normal daylight 8 Remove the protective cover from the solar panel Assuming daylight is available the Charging Status LED will become steady green and flash off briefly every 5 seconds This indicates the charging system is in Day Mode and the solar panel is charging the batteries 9 Locate the green photocell mounted on the side of the...

Page 18: ...s in the cover with the holes in the enclosure 4 Install the 10 mounting screws in the cover but do not tighten 5 Tighten the screws evenly and equally around the cover until the weather seal is compressed to about half of its original height 6 Install the shade to the 4 mounting posts on the enclosure cover as shown in Figure 8b using the 4 bolts provided Tighten each bolt securely 7 Clean the gl...

Page 19: ...aintenance Schedule Interval Task Daily Inspect the wind cone for proper lamp operation As Needed Clean the solar panel glass Make sure vegetation is not obstructing the solar panel Annually Remove the battery enclosure cover and inspect all electrical connections ...

Page 20: ...nal to ensure adequate performance All batteries must be replaced at the same time 7 Install the fuses using the procedure described in Section 4 3 6 8 Remove the temporary cover from the solar panel 9 Perform the electrical checkout as described in Section 4 3 7 10 Install the battery enclosure cover using the procedure described in Section 4 3 8 6 2 Fuse Replacement The fuses are replaced as fol...

Page 21: ...he procedure described in Section 4 3 8 3 Remove the battery fuses by reversing the procedure described in Section 4 3 6 4 The solar panel is attached to its mount with 4 bolts Refer to Figures 9 and 10 to locate the bolts and remove them Carefully lower the solar panel on to a supporting surface Figure 9 Lower Solar Panel Mounting Bolts Figure 10 Upper Solar Panel Mounting Bolts Lower Bolt Upper ...

Page 22: ...l block as shown in Figure 11 11 Reinstall the cover on the solar panel junction box 12 Attach the solar panel to the mounting brackets with the 4 mounting bolts and tighten securely 13 Install the fuses using the procedure described in Section 4 3 6 14 Perform the electrical checkout as described in Section 4 3 7 15 Reinstall the battery enclosure cover 6 4 Charge Controller Replacement Perform t...

Page 23: ...cribed in Section 4 3 6 10 Remove the temporary cover from the solar panel 11 Perform the electrical checkout as described in Section 4 3 7 12 Reinstall the battery enclosure cover 6 5 Frangible Coupling Replacement To replace the frangible couplings perform the following steps 1 Note Always replace both frangible couplings at the same time The frangible couplings are unique for this product and m...

Page 24: ...14 Tighten each flange and frangible coupling to each mounting leg After tightening make sure the holes in each flange align with the bolts on the mounting base 15 Reinstall the wind cone power cable through the mounting leg and into the battery enclosure 16 Lift the SPS on to the mounting base while guiding the mounting legs on to the 4 mounting bolts Install a lock washer and nut on to each of t...

Page 25: ...above horizontal 2 Determine the geographic latitude of the installation location 3 The desired solar panel elevation angle is the latitude plus 15 degrees Figure 14 Solar Panel Angle Adjustment 4 Choose the mounting holes which will result in an elevation angle closest to the desired elevation angle 5 If it is necessary to change the angle remove the bolt from each side bracket reposition the sol...

Page 26: ...cell into the receptacle and turn it clockwise 1 8 turn 7 Replacement Parts Part Number Description 2300 0024 Fuse MINI 30 amp 32 volt 1300 0081 Battery PVX 840T 1800 0036 Frangible Coupling 7800 0006 Photocell 4500 0020 Charge Controller 1067 0002 Mounting Flange 7300 0022 Weatherstrip Battery Enclosure 1049 0015 Anchor Assembly 7800 0005 Solar Panel 130 or 135 Watt 7800 0004 Solar Panel 50 Watt ...