samlexsolar SRV-50-KIT Manuale utente
Owner's
Manual
Please read
this manu-
al before
operating
your kit
Solar
Charging Kit
SRV-50-KIT
SRV-85-KIT
SRV-120-KIT
Solar
Expansion Kit
SRV-EXP-50-KIT
SRV-EXP-85-KIT
SRV-EXP-120-KIT
2
INDEX
1. Introduction ........................................................ 3
2. Components List ................................................. 4
3. General Safety .................................................... 5
4. Required Tools & Materials ................................ 7
5. Charge Controller Installation ........................... 7
6. Connector System for Connecting Solar Panels 8
7. Wiring ................................................................. 12
8. Solar Panel Installation ...................................... 15
9. Connecting Solar Panels in Parallel ................... 17
10. Typical Battery Connections .............................. 18
11. Warranty ............................................................. 20
3
1
INTRODUCTION
Your new Samlex Solar Charging or Expansion Kit provides you with a clean,
green, silent and sustainable way to ensure your batteries are fully charged
and you have a continuous source of electricity while dry camping or in the
absence of a conventional electricity. Each kit comes with a high quality
solar panel, which produces DC electricity when illuminated by sunlight.
In a Solar Charging Kit, a state-of-the-art 30 Amp solar charge controller
is provided to be connected between the solar panel and the storage
batteries. The solar charge controller will make sure the battery is charged
with the harnessed solar electricity, as per the battery manufacturer’s
recommendations. The solar charge controller comes with eight selectable
charging proles to meet the charging requirements of most standard
lead acid batteries used in RVs and remote off-grid solar applications, as
well as Nickel Cadmium (NiCad) batteries. The LCD screen on the charge
controller provides detailed information about the system status including
battery voltage and charging current. The solar charge controller is ush
mountable, which is ideal for mounting within the RV interior. The Samlex
Solar Charging Kit also includes a mounting system: sturdy aluminum
Z-brackets with the nuts and bolts required to at mount the solar panel
on the roof of the RV or any other at surface. If you wish to optimize
the collection of solar energy by tilting the solar panel to an optimal
inclination, an adjustable tilt-mount may be purchased separately. The cable
management hardware incorporated in the kit will enable you to effectively
manage any external wiring. To expand your system further and harness
more energy from the sun, you may use one of our Solar Expansion Kits
which come with a solar panel and all the hardware you need to mount the
extra solar panel and link it to the existing system.
This manual provides instructions on how to put together the various
components of the Samlex Solar Charging and Expansion kits. Please refer
to the separate solar charge controller manual for detailed information
about the installation, operation and programming of the solar charge
controller.
Please read the manual carefully before installing or operating the solar
kits to prevent personal injury or damage to the components. If you have
any concerns about the suitability of the kits for your application or doubts
about any of the instructions in the manual contact your authorized Samlex
America Distributor or Samlex America Technical Support at 1-800-561-5885.
4
2
COMPONENTS
No Model SRV-50-KIT SRV-85-KIT SRV-120-KIT SRV-EXP-50-KIT SRV-EXP-85-KIT SRV-EXP-120-KIT
1 Samlex 50 W Solar panel 1 0 0 1 0 0
2 Samlex 85 W Solar panel 0 1 0 0 1 0
3 Samlex 120 W Solar panel 0 0 1 0 0 1
4Samlex 30 Amp Charge Controller
model SCC-30AB 1 1 1 0 0 0
5
Pre-assembled Positive (+) PV wire,
20 ft, AWG # 12 with male MC4
connector on one end
1 1 1 1 1 1
6
Pre-assembled Negative (-) PV
wire, 20 ft, AWG # 12 with female
MC4 connector on one end
1 1 1 1 1 1
7 MC4 Male Connector 0 0 0 1 1 1
8 MC4 Female Connector 0 0 0 1 1 1
9 Positive MC branch connector 0 0 0 1 1 1
10 Negative MC Branch Connector 0 0 0 1 1 1
11 5-hole mounting bracket 4 4 4 4 4 4
12 Stainless Steel Serrated Flange bolt
¼”-20 x ¾" 4 4 4 4 4 4
13 Stainless Steel Nylon
Insert Locknut, ¼” 4 4 4 4 4 4
14 Stainless Steel Flat washer, ¼”-20 8 8 8 8 8 8
15 Well Nut - Nut Thread: ¼”-20,
Length: 1”, Shank Dia.: ½” 4 4 4 4 4 4
16 Stainless Steel Serrated
Flange Bolt, ¼”-20x1¼” 4 4 4 4 4 4
17 Cable clamp 6 6 6 6 6 6
18 #8 Self Tapping Screws 6 6 6 6 6 6
19 Cable Ties 6 6 6 6 6 6
20 Battery Ring Terminals 2 2 2 2 2 2
21 Insulated Fork Terminals 4 4 4 0 0 0
22 7 x 19, 5/8" Flat Head Tapping
Screws 4 4 4 0 0 0
23 Samlex RV Kit
Installation Manual 1 1 1 1 1 1
5
3
GENERAL SAFETY
3.1. Warnings
Please read the instruction manual carefully before attempting to carry out
any installation and wiring. Contact your RV dealer or Technical support at
Samlex America (1-800-561-5885) for any questions concerning the installation.
Installation and wiring compliance
Installation and wiring must comply with the local and National Electrical Codes and must be done
by a certied electrician.
1. Disconnect all power sources before carrying out the installation.
2. Make sure the correct polarity is observed when making connections between the solar panel,
charge controller and the battery. Damage due to reverse polarity connection is not covered
by warranty.
3. Make sure all wire connections are secure as loose connections may cause sparks.
4. Wear appropriate clothing and safety gear including protective eyewear when performing
any electrical installation.
Preventing re and explosion hazards
Working with electronic/electrical equipment may produce arcs or sparks. Thus, such equipment should not
be used in areas where there are inammable materials or gases requiring ignition protected equipment.
These areas may include spaces containing gasoline powered machinery, fuel tanks, battery compartments.
Precautions when working with batteries
• Batteries contain very corrosive diluted sulphuric acid as electrolyte. Precautions should be taken
to prevent contact with skin, eyes or clothing.
• Batteries generate hydrogen and oxygen during charging resulting in evolution of explosive gas mixture.
Care should be taken to ventilate the battery area and follow the battery manufacturer’s
recommendations.
• Never smoke or allow a spark or ame near the batteries.
• Use caution to reduce the risk of dropping a metal tool on the battery. It could spark or short circuit
the battery or other electrical parts and could cause an explosion.
• Remove metal items like rings, bracelets and watches when working with batteries. The batteries can
produce a short circuit current high enough to weld a ring or the like to metal and thus cause a severe
burn.
• If you need to remove a battery, always remove the ground terminal from the battery rst. Make sure
that all the accessories are off so that you do not cause a spark.
• Use properly insulated tools only when making battery connections.
Precautions when working with solar panels
With the incidence of sunlight or other light sources on all solar panels, a voltage appears at the output
terminals of the solar panel turning it into a source of electricity. To avoid a shock hazard make sure the solar
panel is covered with an opaque (dark) material such as paper/cloth during the installation. Do not make
contact with the terminals when the panel is exposed to sunlight or any other light sources.
6
3
GENERAL SAFETY
Precautions when working with Charge Controller Model no. SCC-30AB
If two or more solar panels are connected in series/parallel make sure that the sum of the short circuit current
ratings of all panel strings does not exceed 80% of the charge controller’s current rating i.e. 24 Amps for the
30 Amp charge controller. The open circuit voltage of the solar array i.e. the maximum voltage across the array
should not exceed 26 V when the 12 V setting on the charge controller is used and not exceed 52 V when the
24 V setting on the charge controller is used.
3.2. Routine Maintenance
• Inspect the solar panels and make sure the surface is free from dust, dirt and other debris,
clean with a wet cloth or glass cleaner, if necessary.
• Check to make sure all structural components, mechanical fasteners and electrical connections are
secure, clean and corrosion-free.
• Check and maintain the battery electrolyte levels at regular intervals as per the battery manufacturer’s
recommendations if ooded wet cell lead acid batteries are used.
• Check and replace damaged components if necessary.
3.3. Installation Overview
1. Read the manual in detail and understand the installation procedure.
2. Open the packaging and check to make sure that all parts have been received as per the parts list
in the manual.
3. Arrange for the required tools to carry out the installation. A sample list of tools (not exhaustive)
is provided in Section 4.
4. Determine the mounting location of the solar panel(s) on the roof of the RV.
5. Mount the charge controller at the desired location (see Section 5).
6. Pass the cable from the solar panels to the interior of the RV (See section 6).
7. Wire the battery to the charge controller and then the solar panel to the charge controller ensuring
the correct polarity is observed (See Section 6).
8. Secure the solar panel to the RV roof (See Section 7).
solar
panel
battery
solar
charge
controller
Fig. 3.3. Installation Block Diagram
7
4
REQUIRED TOOLS & MATERIALS
5
CHARGE CONTROLLER INSTALLATION
4.2. Required Materials
1. Silicone or any suitable roof sealant. Contact your local RV
dealer or RV store for a recommendation on a sealant to
suit your specic RV roof material.
2. Anti-galling lubricant to prevent “thread galling” of
all stainless steel fasteners exposed to the outdoor
environment. This should be available at most hardware or
auto-parts stores. If anti-galling lubricant is not available
any standard lubricant will minimize the occurrence of
“thread galling”.
3. If wiring distances are longer than the lengths of wire
provided with the kit, extra stranded copper wire will
be required. Wires should be 12 AWG or thicker, single
conductor, Type UF (Underground Feeder - marked as
sunlight resistant), Type SE (Service Entrance) or Type USE/
USE-2 (Underground Service Entrance).
4.1. Required Tools
1. The Samlex Solar Charging Kit comes with a 30 Amp PWM charge controller Model no. SCC-30AB to
optimally charge your batteries from the solar panel.
2. The Solar charge controller comes with its own detailed manual. Read the manual in detail.
The instructions in this section are only a brief summary of information contained in the manual.
3. Make sure the solar panels and batteries are disconnected from the charge controller before
installing the charge controller.
4. The charge controller should ideally be located in an area relatively close to the battery.
5. The charge controller should be mounted indoors in a dry location.
6. The charge controller is designed to be ush mounted on a wall or cabinet so that the wiring
at the back can be accessed. Allow adequate spacing (2-3 inches) behind the unit to accommodate
the charge controller and the wiring.
7. Using the cut-out template provided in the charge controller manual, mark the cut-out on
the installation surface and the location of the mounting holes.
8. Using a hand drill and suitable drill bit, drill the mounting holes.
9. Using a jig saw or suitable cutting tool cut the material out from the installation surface.
10. After wiring the charge controller terminals (see Section 6 on wiring), x the mounting plate
to the installation surface using the screws provided with the charge controller (7 x 19, 5/8" Flat Head
Tapping Screws - Philips Drive).
1. Philips drive screw driver
2. 7/16” wrench
3. 3/8” wrench
4. Wire stripper
5. Wire crimping tool
6. Hand Drill
7. ½” drill bit
8. Jig-saw or suitable cutting tool
9. Pliers
10. Punch or Awl
88
6
CONNECTOR SYSTEM FOR CONNECTING SOLAR PANELS
The Positive and Negative outputs of a solar panel are fed through a water tight junction box. Appropriate
size of wires are wired to the junction box for further connections.The solar panels supplied with these kits are
provided with approximately 3 ft. each of Positive & Negative wires that are pre-connected to the junction box.
The free ends of the wires are terminated with special mating type of connectors for ease of extending these
wires for further connections. The special mating type of connectors used for the 3 ft. wires provided with the
solar panels and also for the separate extension wires are as follows:
• "SolarLine - MC4" Series manufactured by Multi Contact
• "Helios - H4" -Series manufactured by Amphenol
Both of above "MC4" & "H4" Series are interchangeable and any one of these may be used in these kits. In this
manual, MC-4 Series will be used for explanations.
6.1. General Information on MC4 Connector System
MC4 Connector System consists of male and female connectors. This type of connector system is easy to
install and uses “snap-in” type of safety locking clips to lock the two mating connectors, thereby, avoiding
unintentional disconnection. Also, the mating contacts are sealed against ingress of dust and water.
Specications are as follows:
• Contact diameter Ø 4 mm
• Maximum rated current - 30 A
• Maximum system voltage - 1000 V
• Degree of ingress protection when connected and properly locked - IP67
• Temperature range 40°C to +90°C
• TÜV Rheinland – type approved
6.2. MC4 Connectors (Fig. 6.2)
The MC4 Connectors mentioned in this manual have been designated “Male” and “Female” based on the
characteristics of the mating contact inserts inside the terminals.
In the MC4 Male Connector (1 of Fig. 6.2), the internal mating contact insert (2, Fig. 6.2) is a male pin. It has
two slots (3 of Fig. 6.2) for insertion of the two “snap-in” type of locking tabs (6 of Fig. 6.2) of the MC4 Female
Connector (4 of Fig. 6.2) for rm mating connection. This connector is marked "-".
In MC4 Female Connector (4, of Fig. 6.2), the internal mating contact insert (5 of Fig. 6.2) is a female cylindrical
socket. It has two “snap-in” type of locking tabs (6 of Fig. 6.2) that are inserted into the two slots (3 of Fig. 6.2)
in the MC4 Male Connector (1 of Fig. 6.2) for rm mating connection. Wire is crimped to the contact inserts (2
and 5 of Fig. 6.2) using a special purpose crimping tool designed for MC4 connectors. After the wire has been
crimped, the contact insert is required to be seated securely inside the housing and the strain relief / seal (7 of
Fig. 6.2) is to be tightened fully to provide a water-tight seal.
1. MC4 Male connector (marked “-”)
2. Male contact insert
3. Slots for accepting “snap-in” type of locking tabs of the mating MC4 female connector
4. MC4 Female connector (marked “+”)
5. Female contact insert
3. “Snap-in” type of locking tabs of the mating with the slots on the MC4 female connector
7. Strain relief and seal
1
2
6
4
5
3
7
7
6
3
Fig. 6.2. MC4 Male and Female Connectors
Note: Additional pairs of male/female MC4 connectors are also sold separately (Model No. "MC4-2 Kit")
99
6
CONNECTOR SYSTEM FOR CONNECTING SOLAR PANELS
6.3. Output wires and connections on the solar panel
Fig. 6.4 shows the output wires and connections on a solar panel. The output wires from the junction box of
the solar panel are terminated with the help of MC4 connectors. The Positive (+) wire is terminated with a MC4
Female Connector (marked "+") and the Negative wire is terminated with a MC4 Male Connector (marked "-").
Warning!
When the surface of the solar panel / array is exposed to sunlight, a DC voltage appears
at the output terminals turning it into a live voltage source. For example, a 24 V nominal solar panel
my put out an open circuit voltage of around 45 VDC that may produce electrical shock. Multiple
solar panels connected in series (to increase the output voltage) will put out higher lethal voltages
To avoid any electrical shock hazard during installation, make sure that the solar panel / array is cov-
ered with an opaque (dark) material to block solar irradiation.
6.4. Extending to the output wires of the solar panel (Fig. 6.4)
Male MC4 mating
connector marked (-)
Male MC4 mating connector
marked (-) for Positive (+)
PV Extension wire
Female MC4 mating connector
marked (+) for Negative (-)
PV Extension wire
Female MC4 mating
connector marked (+)
To external
PV circuit
Caution!
*1. Note that the Positive (+) extension wire has
a male MC4 mating connector marked (-) that
mates with the female MC4 mating connector
marked (+) on the Positive (+) wire of the panel.
*2. Similarly, the Negative (-) extension wire has
a female MC4 mating connector marked (+) that
mates with the male MC4 mating connector
marked (-) on the Negative (-) wire of the panel.
*2
*1
Fig 6.4. Connecting extension wires to the output wires of solar panel
1. The Positive (+) wire of the solar panel is terminated with a MC4 Female Connector (marked +). Connect
this to the MC4 Male Connector (marked -) that is attached to the Positive extension wire. Make sure
that the locking tabs “snap in” for a rm connection. The bare end of the Positive extension wire will
now be of Positive polarity. Use a piece of red sleeve or red tape near the bare end for identication as
the Positive (+) wire.
2. The Negative (-) wire of the solar panel is terminated with a MC4 Male Connector (marked -). Connect
this to the MC4 Female Connector (marked +) that is attached to the Negative extension wire. Make sure
that the locking tabs “snap in” for a rm connection. The bare end of the Negative extension wire will
now be of Negative polarity.
3. Connect the two wires to the external PV circuit.
Warning!
Ensure that the polarity (+ or -) of the wires is identied correctly before connecting to a circuit or a
device. Damage due to wrong polarity may not be covered under warranty.
1010
6
CONNECTOR SYSTEM FOR CONNECTING SOLAR PANELS
6.5. Connecting two adjacent solar panels in parallel (Fig. 6.5)
To external
PV circuit
SCW-20-2 Kit
SBC-2 Kit
MC4 male
branch connector (+)
MC4 female
branch connector (-)
Fig. 6.5. Connecting two adjacent solar panels in parallel
Two or more solar panels can be connected in parallel to increase the current output at the same output
voltage. Fig. 6.5 above shows the arrangement for connecting two solar panels in parallel using the SCW-20-2
Connecting Wire Kit and the MC4 Branch Connector Kit (SBC-2) sold separately. This arrangement is applicable
if the two solar panels are to be mounted adjacent to each other.
The output wires of the two solar panels are rst connected in parallel using the MC4 Male and Female Branch
Connectors. The outputs of the Branch Connectors are then connected to the SCW-20-2 wires for connecting to
the external PV circuit.
6.6. Connecting two solar panels in parallel when separated by a distance (Fig. 6.6)
To external
PV circuit
Female MC4
connector
Male MC4
connector SCW-20-2 Kit
SBC-2 Kit
SCW-20-2 Kit
MC4 male
branch connector (+)
MC4 female
branch connector (-)
Fig. 6.6. Connecting two solar panels in parallel that are separated by an extended distance
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