Photonic Universe 40W Folding Solar Charging Kit Instruction Manual

Photonic Universe 40W Folding Solar Charging Kit

Product Information

The Photonic Universe Folding Solar Charging Kit is available in models 40W, 60W, 80W, 100W, 120W, and 150W. This kit is designed for use in motorhomes, caravans, RVs, campervans, cars, boats, yachts, and other systems with 12V lead-acid batteries. The kit comes with two identical aluminium frame solar panels made with tempered glass. The fold-away aluminum stand can be erected to position the panels towards direct sunlight to maximize energy output. When not in use or during transit, the kit can be placed into the rigid storage case made with a layer of soft material for added protection. The charging of the battery is regulated by a waterproof automatic solar charge controller mounted on the back of the solar kit. This controller has various functions such as overcharge protection, reverse current protection, reverse polarity protection, and overheating protection.

Product Usage Instructions

1. Ensure that your battery is not fully discharged. The battery must generate at least 9V to start the solar charge controller. If your battery is fully discharged, the solar charge controller will not start, and the kit will not be able to charge the battery. In such case, charge the battery first by other means for a short period of time to allow the voltage to reach 9V.
2. Take out the solar panels from the storage case and unfold them into their open position.
3. Erect the fold-away aluminum stand to position the panels towards direct sunlight to maximize energy output.
4. Connect the wiring from the solar panels to the charge controller by following the instructions in the manual. Ensure that you connect the wiring correctly to avoid any damage.
5. Connect the charge controller to the battery. Ensure that you connect the wiring correctly to avoid any damage.
6. Turn on the solar charge controller. The controller will constantly measure the state of charge of your battery and adjust the charging parameters accordingly (voltage, current, and charging program).
7. During the charging process, ensure that the solar panels are facing towards the sun and are not obstructed by any objects such as trees or buildings.
8. When not in use, turn off the solar charge controller and store the kit in the storage case provided.

Product Overview

Thank you for purchasing the Photonic Universe folding solar charging kit. This manual offers important information and suggestions with regards to installation, use, troubleshooting and more. Please read this manual carefully before using the product. This kit is constructed from two identical aluminium frame solar panels; each made with tempered glass. Although the glass is strong enough to withstand severe weather conditions including hail, it is recommended that you handle the kit with care. The glass can break from strong impact, for example if the kit is accidentally dropped and comes into contact with a sharp object.

The kit comes with a fold-away aluminum stand which may be erected to position the panels towards direct sunlight to maximize the energy output. When not in use or in transit, the kit can be placed into the rigid storage case made with a layer of soft material for added protection.

For ease of initial installation, the solar kit comes with crocodile clips for fast connection to your battery. You can later replace these crocodile clips with the ring terminals included in the kit. For example, if you require a permanent installation or if your battery compartment does not have enough space for crocodile clips. The battery end of the cable supplied with the kit has a plug 0.5m from the crocodile clips (battery plug) and if you replace the crocodile clips with ring terminals, you will still be able to connect / disconnect the kit using this plug.

Charging of your battery will be regulated by a waterproof automatic solar charge controller mounted on the back of the solar kit. This controller constantly measures the state of charge of your battery and chooses the appropriate charging parameters accordingly (voltage, current and charging programme). The controller also provides important protection functions for your battery:

• Overcharge protection – one of the most important functions of the controller. When your battery is full, the controller will either switch to a trickle-charging mode where it will continue to gently top-up the battery, or it will stop the charging completely.
• Reverse current protection – stops the power flow from the battery into the solar panel at night.
• Reverse polarity protection – if you accidentally connect the kit to the battery using the wrong polarity, your system is safe.
• Overheating protection – switches off the charging when the controller or ambient temperature reaches a critical level.
• Load protection – if you have connected a 12V load to the controller (optional), the controller will be protected from short circuits and excessive current.

In addition, the charge controller has an external temperature sensor to measure the ambient temperature. To regulate the speed of chemical reaction inside the battery, the controller will choose a slightly higher charging voltage in low ambient temperatures, and a lower voltage in high temperatures.

Installation instructions

1. Ensure that your battery is not fully discharged. The battery must generate at least 9V to start the solar charge controller. If your battery is fully discharged, the solar charge controller will not start and the kit will not be able to charge the battery. In such case, charge the battery first by other means for a short period of time to allow the voltage to reach 9V.

2. At the initial connection stage, keep the solar charging kit indoors or in an area not exposed to direct sunlight. Unfold the solar panels, extend the battery leads and connect the crocodile clips to the + positive (red) and – negative (black) battery terminals on a 12V lead-acid battery.
   Note: If you require a permanent connection between the controller and the battery or if your battery compartment is too small for crocodile clips, please replace the crocodile clips with the ring terminals provided (or purchase an optional 0.5m lead with a battery plug and ring terminals from Photonic Universe – product code CRING40). To replace the crocodile clips, cut them off and attach the ring terminals using a crimping tool or pliers. When the ring terminals are permanently fixed to your battery, you can use the battery plug to connect and disconnect the kit.
   Note: It is recommended that the kit is always connected to the battery terminals directly. Unless you are certain, do not use any existing 12V inputs or sockets (e.g. a cigarette lighter socket) for connecting the kit because these inputs or sockets may not be rated / may not have their connecting cables rated to the required power. Moreover, such inputs or sockets may be connected via other electronic components (e.g. ignition or another controller) which would interfere with the operation of your solar kit.

3. Check and confirm that the solar charge controller has started and detected the battery. If the battery has been detected, the Battery LED on the controller should turn on. If there is enough light falling on the solar panels, the Charging Status LED will also switch on (flashing), indicating that the kit has started charging the battery.
   Note: The Battery Status and Charging Status LED lights may not be easily visible in bright, direct sunlight. If you have any doubts, try checking the LED status indoors or in an area without the interference of bright sunlight.
   Note: The battery type will be automatically set by the controller to sealed type. The default charging voltage of 14.4V (at 25°C) should be suitable for most 12V lead acid batteries. If you require a different level of voltage for your lead acid battery, it can be set in the controller using one of the advanced system monitoring & programming methods listed in the Appendix.

4. Place the kit outside in a sunlit area, with no obstructions or shading on the solar panels. To maximize the output, adjust the position of the kit periodically to track the movement of the sun in the sky.
   Note: Placing the kit indoors next to a window will reduce the output considerably and is not recommended.

5. If your area has a high risk of theft, you can chain the kit down using the holes in the aluminium frame on the back.

Solar charge controller operation

1. Charging Status LED indicator
   Shows whether charging is on or off and also indicates when the solar energy/voltage is low.

2. Battery Status LED indicator
   Shows state of charge of the battery.

3. Temperature sensor
   Measures ambient temperature and automatically adjusts charging voltage depending on the temperature.

4. Solar panel connection
   For connecting the solar panel cables.

5. Battery connection
   For connecting the battery or battery bank.

6. Load connection (optional)
   For connecting optional 12V loads (not used in your kit).

7. RS485 communication port
   For connecting optional monitoring accessories.

Troubleshooting

holder at the end of the battery cables of your kit and replace if required.
Reverse polarity| Battery has been connected with a

reversed polarity. Please check and amend your connections.

Battery voltage under 9V| Measure battery voltage with a digital multimeter. Min 9V is required for start-up of the kit. If your battery is too low or completely discharged, charge it first by

other means.

Battery power not supplied to controller| Battery power is not reaching the solar charge controller for any other reason. Please check the battery cables of your kit for signs of damage. Pull-test any cable joints (strongly) between the controller and your battery:

–  connections straight under the controller;

–  attachment of cables to the battery plug;

–  fuse holder connection;

–  attachment of cables to the crocodile clips.

Charging LED is off during daytime| Solar panels disconnected| Confirm that solar and battery wire connections are correct and tight.
Battery LED green, flashing fast (4 times / second)| Battery over voltage| Using a digital multimeter check if the battery voltage is higher than the over- voltage disconnect point (16V), and if confirmed, disconnect the solar kit.

Contact your supplier or manufacturer for advice.

Battery LED is orange or red, constant| Battery is too low / battery is over- discharged| Remove any loads or power drain on the battery. Allow the solar charging kit sufficient time to recharge the battery.
Battery LED red, flashing fast| Battery overheating| The system will automatically switch off. Operation will resume when temperature is less than 50ºC.

Frequently asked questions (FAQ)

• Q. What type of batteries can be used with this kit?
  A. Any 12V lead acid battery: sealed, AGM, gel or flooded (typically used in cars, caravans, motorhomes, boats etc). The battery cannot be too small; you need to ensure that it can safely accept the maximum current provided by your solar kit. We recommend the following as a guide:

You may be able to use a smaller battery if it can accept high current and faster charging. Please check the battery specifications with the supplier or manufacturer of the battery.

• Q. Can this kit charge a Lithium battery?
  A. No. This folding kit is not suitable for charging Lithium batteries. If you have a lithium battery, please consider our folding kits which come without solar charge controllers –perfect for fitting with one of our Lithium- battery-compatible controllers.

• Q. What is the pair of unconnected “+” and “-“ cables on the right side of the controller?
  A. These cables are the optional 12V load output of the controller. It is not necessary to connect anything to them as the charging function of the solar kit / controller will operate regardless of whether these cables are connected or not. If needed, this 12V output can be used to power small 12V devices (with current up to 10A) such as LED lights, 12V-to-USB converters etc. This load output can be programmed to turn on and off at certain times, e.g. dusk to dawn, or by timer (see Appendix for programming methods and available working modes). The output also has over-discharge battery protection i.e. it turns itself off automatically when the battery becomes critically low.

• Q. What is the cable with an end plug on the right side of the controller under the “COM” sign?
  A. This is a communication cable for connecting an optional remote LCD meter MT50 or any other monitoring or programming accessories (see Appendix). Connection of any of these monitoring or communication devices is optional. If you plan to connect the remote meter MT50, it is recommended that the original RS485 to RJ45 cable (product code BW2MT50) is used to keep the connection point splash-proof.

• Q. Can this kit charge a 24V battery?
  A. No, this kit is designed to charge a 12V battery. Technically it is possible to re-wire the solar panels to work in 24V and the solar charge controller can also support charging of a 24V battery. However, such modification of the solar charging kit should only be undertaken by an appropriately qualified and experienced person approved by the manufacturer.
  Note: unauthorised modification to 24V will void the warranty.

• Q. Can the kit charge two or more 12V batteries connected in parallel (“+” to “+”, “–” to “–”)?
  A. Yes, it’s possible if the batteries are the same type, capacity and are always used together – wired in parallel as a single 12V battery bank.

• Q. Is there any risk that the solar kit will over charge my battery?
  A. No. One of the main protection functions of the charge controller is to ensure that your battery is not overcharged.

• Q. Can I extend the battery leads?
  A. Yes, it’s possible – please choose a cable with the same cross section for extension.
  www.photonicuniverse.com

• Q. Can the kit be connected to my battery through a cigarette lighter or another connector?
  A. You can use another connector between the kit and the battery with care. You must ensure that the connector is wired directly to your battery (with no other electrical components in between) and also that both the connector and the cables connecting it are rated to the power of your kit.

• Q. Can rain damage the solar kit?
  A. No, it won’t damage the kit as the panels and controller are fully waterproof, but we recommend wiping and drying the kit after rain to avoid rust, corrosion or discolouration.

Maintenance

It is recommended to perform the following tasks (with the power disconnected) at least twice a year to keep the kit in good working condition:

• Clean the solar panel glass using a regular household glass cleaner, then wipe and dry the kit.
• Use a suitable lubricant on hinges.
• Remove any dirt or insects from the frame.
• Check all the wires to ensure that the insulation is not damaged from serious solarisation, frictional wear, dryness, insects or vermin etc. Maintain or replace wires if necessary.

Warranty

This product is covered by a 1 year warranty provided by Photonic Universe which guarantees the quality of assembly, wiring and materials for the kit and the solar charge controller.
The warranty does not cover:

• The fuse
• Usual wear and tear
• Unauthorised modifications
• Mechanical damage or damage in transit

Technical specifications

Solar panels:

FWP- 150M
Cell type| mono| mono| mono| mono| Mono| mono
Folded size (mm)| 345 x 470 x 60| 345 x 645 x 60| 505 x 550 x 60| 505 x 690 x 60| 505 x 770 x 70| 505 x 1005 x 70
Net weight (kg)| 5.4| 8.0| 8.8| 10| 12.8| 15.0
Max. power (W)| 40| 60| 80| 100| 120| 150
Max. power voltage (V)| 17.5| 17.5| 17.5| 17.5| 17.5| 17.5
Max. power current (A)| 2.29| 3.43| 4.57| 5.71| 6.86| 8.6
Open circuit voltage (V)| 21.6| 21.6| 21.6| 21.6| 21.6| 21.6
Short circuit current (A)| 2.47| 3.7| 4.94| 6.17| 7.4| 9.26

Specifications under standard test conditions (STC): 1000W/m2, AM 1.5, 25 °C. Data provided for the solar panels only, without the effect of the solar charge controller.
Solar charge controller:

Electrical and mechanical parameters

Nominal system voltage| 12V DC
Maximum battery voltage| 16V (for 12V battery)
Rated current| 10A
Self-consumption| ≤9mA
Overall dimensions| 108.5 x 63 x 25.6 mm
Net weight| 0.26 kg
Working temperature| -35°C to +55°C
Storage temperature| -35°C to +80°C
Temperature compensation coefficient

Temperature compensation coefficient (TEMPCO)1| ****

-3mV/℃/2V (25°C ref)

Battery voltage:

Battery voltage parameters (temperature at 25°C)

 | Sealed| Gel| Flooded| User 2
Over voltage disconnect| 16V| 16V| 16V| 9～17V
Charging limit| 15.5V| 15.5V| 15.5V| 9～17V
Over voltage reconnect| 15V| 15V| 15V| 9～17V
Equalise charging| 14.6V| ——| 14.8V| 9～17V
Boost charging| 14.4V| 14.2V| 14.6V| 9～17V
Float charging| 13.8V| 13.8V| 13.8V| 9～17V
Boost reconnect| 13.2V| 13.2V| 13.2V| 9～17V
Equalize duration| 120 min| ——| 120 min| 0～180 min
Boost duration| 120 min| 120 min| 120 min| 10 ～180

min

Battery voltage parameters for load terminals (optional) (temperature at 25°C)

 | Sealed| Gel| Flooded| User 2
Low voltage reconnect| 12.6V| 12.6V| 12.6V| 9～17V
Under voltage warning reconnect| 12.2V| 12.2V| 12.2V| 9～17V
Under voltage warning| 12.0V| 12.0V| 12.0V| 9～17V
Low voltage disconnect| 11.1V| 11.1| 11.1V| 9～17V
Discharging limit| 10.6V| 10.6V| 10.6V| 9～17V

Appendix

Advanced system monitoring & programming methods
The controller is pre-programmed with factory default parameters, such as a sealed battery type and a light on/off load working mode. If these settings or other parameters need to be changed, or if you would like to be able to monitor in-depth charging information for your system, the kit’s controller can be connected to one of the following products below:

There are four connection options which enable you to view and adjust charging parameters through the controller’s RS485 communication port:

1. MT50 remote meter
   • Requires RS485 to RJ45 connection cable (product code BW2MT50)
2. PC connection (monitoring software “Solar Station Monitor”)
   • Requires RS485 to USB connection cable
3. Smartphone or tablet connection (monitoring app “Solar Station Monitor”)
   • Requires RS485 to USB cable and OTG mobile cable
4. Wi-Fi module (EBOX-WIFI) for wireless connectivity to a smartphone or tablet (monitoring app “Solar Station Monitor”)
   • Requires RS485 to RJ45 connection cable (product code BW2MT50)

These connection methods and accessories will unlock the following additional features of your solar charging kit:

1. Monitoring of charging parameters:
   The additional accessories above allow you to view important charging parameters such as:

   • Solar panel voltage
   • Solar panel current
   • Battery state of charge
   • Load voltage and current (if optional load terminals are used)
   • Records of accumulated charge and discharge energy
   • Records of min/max voltages
   • Other parameters

2. Programming of Battery Type and other parameters:
   Communication methods also allow you to adjust many charging and load settings of the solar charge controller, including:

   • Battery type (sealed, gel, flooded and user-defined)
   • Charging voltages (for user-defined battery type only) and duration of charging stages
   • Load cut-off voltage and reconnect voltages
   • Other parameters relating to charging or discharging

3. Programming of load working modes (for optional load terminals):
   Optional load terminals of the solar charge controller can also be programmed to switch the load on / off at required times:

   • Manual Mode
     The load can be switched on via button or remote-control command using one of the communication options above.

   • Light ON/OFF (provided as default without additional accessories required)

   • Light ON + Timer

   • Real-time control
     Control the load ON/OFF time by setting a real-time clock.

Note: In the Light ON/OFF mode and Light ON + Timer mode, the load is turned on after a 10 min delay.

References

• 12V solar panels charging kits for caravans, motorhomes, boats, yachts, marine

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