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GreenWay® SolarLEDPathandTrailLightingSystem
InstallationandOwner’sManual
2 MKTG-IM-GWY-03-EN-0513
InstallationManual|Greenway®SolarLEDPathandTrailLightingSystem
ImportantNotesandWarnings
Thisinstallationandinstructionmanualprovidesinstallation,operation,andmaintenanceinstructionsfortheSolGreenWaysolarLEDlightingsystem.Theentirecontentsofthismanualshouldbethoroughlyreviewedandunderstoodpriortoinstallingthisequipment.Donotdiscardthismanual,asitcontainscompletemaintenanceinstructions,atroubleshootingchart,andasparepartslist.Toinsureproperoperationofthisequipment,itisimportantthattheequipmentbeutilizedforitsintendeduse.Anyuseofthisequipmentforpurposesotherthanthoseintendedwillvoidallwarranties.
Installationand/ortroubleshootingshouldbeperformedonlybyqualifiedpersonnel.FollowlocalcodesatalltimesduringinstallationoftheGreenWaysystem.
Beverycarefulwhenworkingwithbatteries.
Donotallowbareendsofthewirestotoucheachotherorgroundedmetalpartswhileconnectedtothecontroller.Thiswilldamagethecontroller.
ThismanualcontainsimportantinstructionsfortheSolGreenWaySeriesthatshallbefollowedduringinstallationandmaintenanceofthechargecontroller.
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InstallationManual|Greenway®SolarLEDPathandTrailLightingSystem
1.0SystemOverview
FIGURE1: SolGreenwaySystemHardwareComponents
SolarPanelPan
ArmAssembly
Pole
FixtureAssembly
SolarPanelMount
BatteryBox(singleordual) Battery(1or2)
Controller
HolesforFixtureInstallationMust
FaceDown
DriveRivets(bottom-3)
SolarPanelAssembly
BatteryBoxChannel
FixtureMountingScrews
DriveRivets(top-3)
SolarPanelMountingScrews&Washers(4sets)
BatteryBoxMountingScrews(4)
BatteryBoxChannel-suppliedonlywhenusingadualbatterybox
BatteryCable(1perbattery)
BatteryHarness(SingleorDual)
FixtureHarness
PVHarnesss
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InstallationManual|Greenway®SolarLEDPathandTrailLightingSystem
1.0PositioningtheLight
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InstallationManual|Greenway®SolarLEDPathandTrailLightingSystem
2.2RoutingtheLoadCableThroughtheArmAssembly
LEDFixtureConnector
HolesforMountingLEDFixtureMustFaceDown
FixtureHarness
ConnectortoController
2.0Assembling
2.1 PolePreparationFourholesmustbedrilledatthetopofthepole.Thisshouldbedonebeforethepoleissetandanchored.
1. Drilltwoequally-spaced0.125-inch(3.2mm)pilotholes1inch(2.5cm)belowthetopofthepole,asshowninFigure3.
2. Drilltwoadditionalequally-spaced0.125-inch(3.2mm)pilotholes4inches(10.2cm)belowthetopofthepole,asshowninFigure3.Positiontheholes90degreesfromtheholesdrilledinStep1.
Itisimperativethatthepoleisproperlyanchored.Standardpoleanchoringmethodsmaybeused,providingtheymeettheengineeringrequirementsforEPAandweightofthesystemyouhavepurchased.
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InstallationManual|Greenway®SolarLEDPathandTrailLightingSystem
2.3DrillingHolesintheSolarPanelMount1. Drilltwoequally-spaced0.125-inch(3.2mm)pilotholes1inch(2.5cm)below
theendofthepipe,asshowninFigure5.
2. Drilltwoadditionalequally-spaced0.125-inch(3.2mm)pilotholes4inches(10.2cm)belowtheendofthepipe,asshowninFigure5.Positiontheholes90degreesfromtheholesdrilledinthepreviousStep.
2.4AttachingtheSolarPanelAssemblytotheSolarPanelMount
PVHarness
BottomView
HoleandGrommet
JunctionBox
PanelPan
PVMountScrews,LockWasher&washers(4)
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InstallationManual|Greenway®SolarLEDPathandTrailLightingSystem
2.5AssemblingtheComponentsPlacingtheArmAssemblyandSolarPanelMountAssemblyonthePole
FixtureHarness
ArmAssembly
Pole
ArmAssembly
a
b c
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InstallationManual|Greenway®SolarLEDPathandTrailLightingSystem
2.6 PositioningtheArmAssemblyandPVMountAssembly
TowardsEquator(DueSouthinthe
NorthernHemisphere)
SolarPanelAssembly
ArmAssembly
Pathway Parking Lot
b
a
c
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InstallationManual|Greenway®SolarLEDPathandTrailLightingSystem
2.7 RivetingtheArmAssemblyandPVAssemblytothePole1. Verifythatthearmispositionedsothatthelightfixture(whichwillbeattachedto
theendofthearm)isinthedesiredorientation.
2. Usingoneofthepilotholesattheupperendofthepoleasaguide,drillonerivetholeusingaU.S.“W”gauge(0.386-inch)drillbit.
Whendrillingarivethole,drillthroughthepilotholeandthenthroughthearmassemblystockbeneaththepilothole.
Drillandrivetonepilotholeatatime.Donotdrillanotherholeuntilthepreviousrivetissecured.Ifa“W”gauge(0.386-inch)drillbitisnotavailable,usea25/64-inchdrillbit.
3. Placeadriverivetintherivetholeandpoundthedriverivetintotheholeuntiltheheadofthedriverivetistightagainstthesideofthepole.
4. Repeatforremainingdriverivets.
c
ba
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InstallationManual|Greenway®SolarLEDPathandTrailLightingSystem
2.8 AttachingBatteryBoxtotheSolarPanelMount
StandardBatteryBox:
1. RouteendsofFixtureandPVHarnessthroughholeinbackofthebatterybox.
2. Looselyfastenthebracketsofthebatteryboxtomount,usingfour1/4”–20x1/2”hexheadboltsandtighteneachbolttoatorqueof15ft-lbs(20N-m).
Avoidstrippingthethreadedholesonthesolarpanelassembly.Donotover-tightenthebolts.
DoubleBatteryBox:
1. UsingBatteryBoxChannelasguide,drillthreeholesandmountchannel.
2. Looselyfastenthebracketsofthebatteryboxtomount,usingfour1/4”–20x1/2”hexheadboltsandtighteneachbolttoatorqueof15ft-lbs(20N-m).
Battery Box Channel location when using Double Battery Box
(a) Routing the Cables Into the Battery Box
(b) Securing the Battery Box to the PV Mount
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InstallationManual|Greenway®SolarLEDPathandTrailLightingSystem
4x1/4”–20x1/2”hexheadbolts
b
BatteryEnclosureChannelMountSet
2x3/4-11x12”
4.25”below
[email protected]”Dia.
ChannelMountholes:[email protected]”Dia.
28”
a
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InstallationManual|Greenway®SolarLEDPathandTrailLightingSystem
2.9 AttachingtheControllertoBatteryBoxCover
StandardBatteryBox:
DoubleBatteryBox:
a
b
MountingStudsforController
MountingStudsforController
c
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InstallationManual|Greenway®SolarLEDPathandTrailLightingSystem
2.10 AttachingtheLEDFixturetotheArmAttachingtheAscotFixturetotheArm
1. PlugtheAscotfixtureconnectorintotheharnessconnector.
2. SlidetheAscotfixtureintothearm.FeedanyexcesscablebackintothearmwhileslidingtheLEDfixtureontothearm.
3. Adjustforthedesiredtiltandsecurefixturetothearmusingthesocketheadbolts.
AttachingtheShoeboxFixturetotheArm
1. LoosenthetwosetscrewsontheShoeboxfixture.
2. PlugtheShoeboxfixtureconnectorintotheharnessconnector.
3. SlidetheShoeboxfixtureoverthearm.Feedanyexcesscablebackintothearmwhileslidingthefixtureoverthearm.
4. Removethecircularcover(usingaPhillipsscrewdriver)andloosenthebolt(usingasocketwrench)tochangetheangleofthefixture.Tightentheboltandreplacethecoverwhencompleted.
SetScrews
ba
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InstallationManual|Greenway®SolarLEDPathandTrailLightingSystem
LEDFixturePrecautions
TheAscotandShoeboxfixturescontainthefollowingwarninglabel:
This lamp (LED) is in excess of the Exempt Risk Group defined in IEC 62471:2006-07. This lamp (LED) has been found to be in the Risk Group 2 classification at an exposure distance of 20 cm or less from the glass surface of the lamp. Care should be taken to avoid exposure when operating and installing this lamp.
CAUTION: Possible Hazardous LED Radiation Emitted From This Product. Do Not Stare Directly Into Beam. Disconnect Power Before Servicing.
2.11 InstalltheBatteryCablesandBattery(s)
a
IfusingDeka®BrandBatteries,seeenclosedAddendum.
b
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InstallationManual|Greenway®SolarLEDPathandTrailLightingSystem
2.12 ConnecttheCables
Batteries(1or2)
GreenWire(toGround)
BatteryHarness
SolarPanel
LEDLuminaire
EternO4Controller
BatteryCable(1perbattery)
PVHarness
LuminaireHarness
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InstallationManual|Greenway®SolarLEDPathandTrailLightingSystem
2.10 Test
2.11 CloseBatteryEnclosureCover
a
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InstallationManual|Greenway®SolarLEDPathandTrailLightingSystem
3.0 OperationandMaintenance
3.1 ExpectedPerformanceTheGreenway™lightingsystemisdesignedtoprovidereliableoperationandilluminationallyear.ThesolarpanelprovidesenoughenergyduringanormaldaytochargethebatteryforoperationoftheLEDfixtureforthefollowingnight.Thesystemisdesignedwithafive-dayreservecharge.Asaresult,extendedperiodsoflowsunmaydepletethefive-dayreserveandaffectperformanceofthesystem.ThefollowingconditionsmaycauseyourGreenway™lightingsystemtooperateoutofspecification:
1. Prolonged Bad Weather.Aseriesofdayswithlowlevelsofsunlightmaydepletethebatteryreserve.Dependingontheseverityofthecondition,thenightlyilluminationperiodcouldbereduceduntilasunnydayre-establishesthereservebatterycharge.Pleasenotethatthesystemmayneedanywherefromtwodays(insummer)totendays(inwinter)ofgoodsunnyweatherbeforethefullfive-daybatteryreserveiscompletelyachieved.
2. Shading.InstallationoftheGreenway™lightingsysteminalocationwherethesolarpanelisshadedduringpartofthedaywillinhibittheabilityofthesolarpaneltofullychargethebatteryandmayseverelydamagethebattery.Thehoursofnighttimeilluminationwillbereducedbythecontrollerifthesolarpanelcannotfullychargethebattery.
IfyoubelievethatyourGreenway™lightingsystemisnotperformingasexpectedandtheaboveconditionsdonotapply,pleasecontactSolCustomerServiceat1.772.286.9461.
3.2 PreventiveMaintenanceandServiceObstructions
Obstructions(includingtreebranches)mustnotshadethesolarpanel(s).Checkforandremoveanyobstructionsinthevicinityofthesolarpanel(s)onceeverythreemonths.
SolarPanelCleaning
Thesolarpanel(s)shouldbecleanedperiodicallytoinsureoptimumperformance.
Solarpanelscangetveryhotwhenthesunisout.Itisadvisabletocleansolarpanelsduringtheearlymorninghours.
1. Usinganon-streakingwindowcleanerandasoftcloth,thoroughlywipedownthesolarpanel(s)toremoveanydirtandgrimethatmayhaveaccumulate.Aplasticscrapermayalsobeneededforremovingbirddroppings.
2. Drythesolarpanel(s)withasoftcleancloth.
3. RepeatSteps1and2,ifnecessary,untilalldirtandgrimehavebeenremoved.
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InstallationManual|Greenway®SolarLEDPathandTrailLightingSystem
FuseReplacement
Ifthefuseneedstobereplaced,besuretoalsocheckoperationofthecontroller.
1. Openthebatteryboxandremovethefusecoveronthefuseholder.
2. Removetheexistingfuse,insertthenewfuse,andreplacethefusecover.
3. Testthesystemandclosethebatterybox.
LEDFixtureReplacement
1. RemovetheLEDfixturefromthearmanddisconnectplugs.
2. InstallthenewLEDfixture,followingtheinstallprocedure.
TheLEDinthefixtureisnotserviceable.TheentireLEDfixtureassemblymustbereplaced.
3. Testthesystem.
BatteryReplacement
1. Openbatteryboxcoveranddisconnectthesolarpanelharnessconnectorfromthecontroller,thendisconnectthebatterycablefromeachbattery.
2. Removethebattery(s)fromthebatterybox.
3. Placethenewbattery(s)andplugthebatterycableintoeachbattery,thenplugthesolarpanelintothecontrollerconnector.
4. Testthesystem,thenclosethebatteryboxcover.
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InstallationManual|Greenway®SolarLEDPathandTrailLightingSystem
3.3 TroubleshootingChart
Problem PossibleCause Solution
Lightdoesnotilluminate. 1.Thebatteryisdischarged.2.Thebatteryisbad.3.TheLEDfixtureisbad.4.Thefuseisblown.5.Thecontrollerisbad.
1.Chargethebattery.2.Replacethebattery.3.ReplacetheLEDfixture.4.Replacethefuse.5.Checkthecontroller.
1.Lightdoesnotstayonfortheexpectedperiodoftime.2.Lightturnsonatduskbutdoesnotturnonagainatdawn(splitruntime).3.Lightdoesnotoperateeveryday.
1.Lowbatteryvoltage,causedbyinclementweather.2.Lowbatteryvoltage,causedbyshadingofthesolarpanel.3.Thebatteryisbad.
1.Allowfortwotothreedaysofconsecutivesunnyweathertochargethebatterypack.2.Cleartreebranchesandotherobstructionsfromthevicinityofthesolarpanel.3.Replacethebattery.
Fuseblowsrepeatedly. 1.Thereisashortcircuitinthewiring.
1.Checkallsystemwiringforashortcircuit.
Batteryvoltageislessthan9.0volts.
1.Thecontrollerisbad.2.Thebatteryisbad.
1.Checkthecontroller.2.Replacethebattery.
In-WarrantyServiceInstructions
AReturnedMerchandiseAuthorization(RMA)numbermustbeobtainedfromSolInc.beforeequipmentcanbereturnedforrepairorreplacementunderwarranty.
WerequirethefollowinginformationbeforewecanissueanRMAnumber:
• ControllerNumberfortheproductbeingreturned • SerialNumberoftheproductbeingreturned • WorkOrderNumber(locatedinsidethebatterybox) • Adescriptionoftheproblem • Theaddresstowhichtherepairedorreplacedproductistobeshipped
Equipmentbeingreturnedmustbeproperlypackagedtoprotectitfromdamageduringshipment.ShippingcostsandinsurancetoSolInc.aretheresponsibilityofcustomer.
Uponverificationoffailureduetodefectsinmaterialsorworkmanship,wewilleitherrepairorreplacetheproductatourdiscretion.ThecustomerwillberesponsibleforallshippingandhandlingchargesforanyequipmentthatissenttoSolInc.inerror(nodefinableproblems).
SolInc.|3210SW42ndAvenue|PalmCity,Florida34990
www.solarlighting.com
E-mailsupport:[email protected]
Phone:+1.772.286.9461|Toll:800.959.1329(USA&Canada)
Fax:+1.772.286.9616
OfficeHours:Monday-Friday:8:30amto5:00pm(EST)
©2011SolInc.Allrightsreserved