PowerFilm SOLAR PowerDrive Golf Car Solar Panel Instruction Manual
- June 4, 2024
- PowerFilm SOLAR
Table of Contents
SOLAR PowerDrive Golf Car Solar Panel
Installation Manual
Get ready to experience the benefits of using a PowerDrive Golf Car
Solar Panel!
Extended Battery Life
A PowerDrive Golf Car Solar Panel generates and feeds electricity into the
batteries constantly, even in low-light, therefore less power is required to
charge the batteries each night, saving 20% or more in yearly electrical costs
and increased battery lifetime. PowerFilm’s study shows the number of charge
cycles increased by more than 50%.
Increased Driving Range
Our testing has shown that the power produced by a PowerDrive Golf Car Solar
Panel, on a typical sunny day, is enough to increase driving range by as much
as 50%. This also represents a savings of 25% of the average electricity used
in one day. The added distance equals fewer dropped rounds on the course (or
additional range for a utility vehicle in and around “campus”) and less time
spent dealing with the hassle of under-performing cars. In addition, 25% more
drive time means extra driving for individuals residing in golf course
communities, neighborhoods, and retirement communities. For commercial fleets
and maintenance vehicles, PowerDrive Solar Panels will get you through the
work day every day.
Reduced Charging Costs
If you have a golf car and are driving without a portable means of charging,
you constantly pull energy from your batteries without putting any charge back
into your vehicle. PowerDrive generates and feeds electricity into golf car
batteries during daylight, even in low-light, saving an estimated 20 percent
yearly electrical costs. The PowerDrive Solar Panel will not replace your
standard means of charging, but it will make conventional charging times
shorter and save you money on your electrical bill.
Environmental Advantages
The PowerDrive Solar Panel creates, on average, enough electricity per year to
offset nearly 175 pounds of carbon dioxide production (calculation determined
by US EPA website using 110kWh of power produced by the PowerDrive Solar
Panel in one year). Planting two trees today would take 10 years of growth to
remove that amount of CO₂ from the atmosphere.
Easy Installation
The PowerDrive panel installs quickly, with no special tools, and looks great.
Simple to follow instructions (each step being clearly described with helpful
diagrams) ensure frustration-free installation. Other systems require
completely replacing the canopy, we think it’s smarter to use the canopy you
already have.
Features and specifications of vehicles are subject to change without notice. Vehicles, as photographed, may include options not included on the base model. The performance will vary according to a number of factors, including local weather patterns, age and condition of vehicle batteries, and course terrain.
Setup
- Verify your car model
- Park car
- Place the car in Tow Mode to begin any electrical work (Figure 1).
Tools Needed
- Drill
- 5/16 inch drill bit
- 1/8 inch drill bit
- 5/16 inch hex nut driver
- Bit smaller than 1/8”
- 9/16” Insulated wrench
- Phillips screw driver
- Socket set
- Heat gun (optional)
- Current clamp (optional)
- Digital multi-meter (optional)
- Electrical tape (optional)
Kit Contents
- (1) PowerDrive Golf Car Solar Panel
- (1) Charge controller (36V or 48V)
- (3) Plastic cabling clips (1 provided as an extra)
- (4) 3/4-inch self-tapping screws
- (10-13) 3/4-inch self-tapping male snaps
- (3) 1/4-inch rubber grommet (2 provided as extras)
- (1) 15-foot extension cable
- (1) 4-foot o-ring cable
Kit Dependent
- (10-13) 8-32 thread male snaps
- (10-13) 8-32 thread acorn nuts
- (10-13) #8 lock washers
Step 1
Place the PowerDrive panel on the golf car top with the junction box (small
box on panel) toward the rear of the car. Make sure that it is centered and as
flat as possible (Figure 2).
Step 2
Using a marker, mark on the bottom surface of the naps on the solar panel
(Figure 3). Transfer the mark by pressing the snap on the panel down on the
car top.
Step 3
Using a 1/8 inch drill bit, drill through the center of the marks on the car
top. The number of marks will depend on your vehicle model (Figure 4).
Step 4
Use a handheld Phillips screwdriver to mount the snaps on the top (Figure 5).
Make sure each snap is securely fastened without overtightening. If you have a
thinner-walled top, use the machine threaded screws with the acorn nut and
lock washer on the back side (Figure 6).
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Step 5
Snap the solar panel onto corresponding snaps so that one end is secure
(Figure 7). Repeat steps 2-4 to mark and secure the opposite end, stretching
the panel as you mark the holes so that the panel lays flat. Then repeat these
steps for the side snaps.
Step 6
Locate the included 15 ft. extension cable (Figure 8).
Note: Cable routing will differ depending on the installation method.
Follow your preferred installation method:
Method A (recommended): Offers better wire concealment.
Method B (optional): Offers faster installation
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Method A
- Remove any bolts that pass through the down tube to ease the routing of the cable.
- Drill a 5/16” hole in the side of the right rear strut shown in (Figure 9) then install the provided grommet. Drill the hole as close as possible to the top in order to hold the cable (Figure 10).
- Drill 5/16” holes into the underside of the car top as shown in (Figure 11) according to your model.
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Method A (Continued)
- Snap plastic cabling clips into holes and clip the ring around the cable to secure the cabling (Figures 12 and 13).
- Route the cable through the grommet, out the bottom of the strut, and in between the seat support and the rubber boot (Figure 14-16).
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---|---|---|---|--- - To ensure that the cable is protected from rubbing or chaffing and that it is not routed over the batteries, pull excess cabling into the battery compartment (Figure 17-18).
Method B
- Route the cable along the strut and secure it with zip ties (Figure 19).
- Secure the cable in between the seat support and the rubber boot (Figure 20).
- To ensure that the cable is protected from rubbing or chaffing and that it is not routed over the batteries, pull excess cabling into the battery compartment (Figure 21-22).
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Step 7
If heat shrink is used (recommended), place it over the wire first before
attaching the Delphi Connector (Figure 23-24).
Step 8
The ribbed side of the wire should be placed into slot A of the Delphi
Connector. The smooth side of the wire should be placed into slot B. Slide the
metal pins inside their respective slots until a very light click is heard
(Figure 25).
After inserting metal pins in the Delphi Connector and before heat shrinking,
verify with a multi-meter or voltmeter that the pin is positive relative to
pin B (panel must be in some light to take this measurement). The multi-
meter/voltmeter connects with the red lead to pin A and the black lead to pin
B and should read between +12v and +22v.
Note: A negative voltage reading on pin A, would indicate the cables are
connected backward. You should immediately stop the panel installation until
it is corrected by consulting PowerFilm if needed
(515-292-7606).
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Step 9
If heat shrink is used, a heat gun can be used to secure the heat shrink
around the rear of the connector. If you do not have access to a heat gun, the
connector can be wrapped with electrical tape to help keep water out of the
connector (Figure 26).
Step 10
Mount the charge controller beside the batteries on the floorboard using the
two self-tapping screws and the 5/16” hex nut driver. Do not over-tighten
screws (Figure 27-30).
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Step 11
Insert the solar connector into its mating connector on the charge controller
(Figure 31).
Step 12
Using the 9/16” insulated wrench, take the included ring terminal cable and
connect the red marked end by placing it on the battery pack system (+). The
remaining ring terminal should be placed on the battery pack system negative
(-) (Figure 32-33).
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Step 13
Take the other end of the ring terminal cable and connect it to the charge
controller output. There may be a “pop” as it is connected which is completely
safe and is due to the internal capacitors in the charge controller being
charged (Figure 34).
A current clamp can be used to
indicate that a charge is entering the battery. Put the current clamp around
the positive (ribbed) wire of the three-foot o-ring cable (Figure 35 ). The
current clamp should read (+ + +).
If only a digital multi-meter is
available the installer can drive the car outdoors and measure the voltage on
the battery system (Figure 36 ). Measure the battery voltage again after ten
minutes to an hour to observe if the voltage has gone up.
NOTE: Voltage may go up as little as 0.1V depending on the sun conditions
and the time left to charge.
Congratulations on installing your PowerDrive Golf Car Solar Panel! We hope
you enjoy the benefits it will add to your car for years to come.
For any questions please contact PowerFilm at
www.powerfilmsolar.com or
515-292-7606
Certifications
- CE (Directives 2014/30/EU and 2014/35/EU)
- MIL-STD-810G
- RoHS
- Berry Amendment Compliance
Full compliance statements are available at:
www.powerfilmsolar.com
Documents / Resources
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PowerFilm SOLAR PowerDrive Golf Car Solar
Panel
[pdf] Instruction Manual
PowerDrive Golf Car Solar Panel, Golf Car Solar Panel, Solar Panel, PowerDrive
Solar Panel
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