CANADIAN ENERGY 9003724 200-400 Watts Off-Grid Solar Kits Installation Guide

CANADIAN ENERGY 9003724 200-400 Watts Off-Grid Solar Kits Installation Guide

INTRODUCTION

Congratulations on purchasing a high quality renewable energy product where building your own off-grid solar system has never been easier. Although installation is quick and professional using the materials included in your kit, it is important to read this manual and understand all the mechanical and electrical requirements prior to beginning installation.

The installer must be familiar and conform to all the safety precautions cited in this manual as well as any local jurisdictions that must be adhered to.

1.1 SAFETY PRECAUTIONS

CAUTION: Working with and installing electrical equipment is dangerous. Potential hazards include, but are not limited to, electrocution and electrical fires. Always consult a licensed electrician when installing any electrical equipment.

CAUTION: When solar panels are placed in sunlight or other light sources, they produce electrical energy and a voltage will appear on the output terminals. To avoid a shock hazard, keep the panel covered with a dark material during installation and avoid contact with the output terminals. Before handling the solar panel, test the voltage output of the solar panel with a voltmeter to confirm it is not outputting voltage.

1.1.1 Wiring and Connections

• Wiring size and installation must comply with the National Electrical Code (NEC).
• Observe correct polarity with all inter-connections between the solar panel, charge controller, and the battery. Reverse polarity may cause damage.
• Make sure all wire connections are tight and secure, loose connections may cause sparks, intermittent behavior and damage.

1.1.2 Environment

• Do not perform installation in the presence of any flammable materials.
• Make sure you work in a well-ventilated area
• Use properly insulated tools and remove metal items such as rings, bracelets, and watches.

PRODUCT OVERVIEW

CANADIAN ENERGY offers many varieties of preconfigured off-grid solar kits designed to be modular and easily expandable. Each kit is capable of a wide variety of power production needs from simply trickle charging batteries to fully supporting the power needs of a cabin or RV.

2.1 FEATURES

• Auxiliary power for RV’s and boats. Popular with commercial RV retrofitters
• Great for camping or remote cabins. Power devices in remote back country locations
• Easy way to provide power for sheds, light poles and gates without the need for trenching and laying cables
• Provide back-up power for critical appliances like a refrigerator during a power outage.

2.2 KIT COMPONENTS

IMPORTANT: Not all of the components listed are included with each kit. The quantity and exact model of each item will vary depending on the kit ordered.

2.2.1 Solar Panel

The solar panel is a set of solar photovoltaic modules that generate electricity and are available in multiple wattage options; with either Monocrystalline or polycrystalline solar cells.

2.2.1.1 Monocrystalline – Polycrystalline

Monocrystalline solar cells are manufactured using a single crystal of silicon and are dark black in color. Polycrystalline, on the other hand, are blue in color and are manufactured by using multiple silicon crystals that are melted and poured into a cast.

2.2.2 Solar Charge Controller

The solar charge controller regulates the battery charge and prevents overcharging of the batteries thus increasing battery performance and lifespan.

2.2.2.1 PWM

PWM (Pulse Width Modulation) Controllers use a FET switch to rapidly connect a power source, to a battery. The switch “opens” and “closes” many times a second, to control the charge.

2.2.3 MC4 Connectors

Single-contact connector used to connect solar panels; See Section 4.3 for additional information.

2.2.4 MC4 Branch Connectors

Splitter/Combiner connector used to easily interconnect solar panels.

2.2.5 Solar Panel Cable

Assembly of copper electrical conductors available in 10AWG sizes. The cable is provided as a 40 foot length, but will need to be cut into two 20 foot sections for a positive and negative cable.

2.2.6 Solar Panel Mounting Z-Brackets

Mounting brackets are used to secure panel to a flat surface. There are four (4) brackets used for each solar panel and include the following fasteners used to secure the bracket to the panel:

a. 1/4” diameter stainless steel bolts (1/2” long)
b. Stainless Steel flat washers and lock washers
c. K-Lock stainless steel nuts (will not vibrate loose)

2.2.7 Inverter

An electronic device that converts the battery DC voltage (Direct Current) provided from the solar panel/battery to an AC voltage (Alternating Current).

The inverter, if included, will connect directly to the 12V battery and will provide 120VAC outlets used to power typical household items.

2.3 REQUIRED TOOLS

• Two adjustable wrenches
• Wire crimping tool
• Wire stripper
• Philips head screwdriver
• Bolt to secure Z-Bracket to mounting surface (4x per panel); e.g.: lag bolt, carriage bolt, etc.
• Batteries (Deep Cycle preferred)
• Fuses (Not included. Must be appropriately sized)
• Digital multimeter

CHARGE CONTROLLER INSTALLATION

NOTE: The charge controller you receive depends on the kit ordered. Please refer to the controller instructions specific to the model you received.

Insure all terminating connections are clean and tight to prevent arcing and overheating. The controller must be installed in an area that satisfies all of the following conditions:

1. Dry: Avoid any location where water can contact the controller
2. Cool: Ambient air temperature between 30°F and 105°F (0°C and 40°C)
3. Ventilated: Allow at least 2 in (50 mm) of clearance above and below and at least 1 in (25 mm) on each side for proper air flow.

CAUTION: All electronic circuits may be damaged by static electricity. To minimize the likelihood of electrostatic damage, discharge yourself by touching an electrical ground (e.g.: copper pipe) prior to handling the unit.

3.1 MOUNTING

The Solar Controller has two mounting options.

1. Surface mount: The quickest and easiest way to mount the unit is to use the two plastic spacers and self tapping screws supplied and mount the unit to a flat surface.
2. Flush (panel) mount: Before deciding to use this mounting method, please ensure there is sufficient depth behind the controller or in the cavity. (Refer to Diagram below) Using the dimensions shown in the following diagram, mark a 105mm x 130mm rectangle where you wish to mount the controller and cut-out the panel opening then use the two self- tapping screws supplied to secure the unit.

IMPORTANT: Loose connectors result in excessive voltage drop and may cause over heated wires and melted insulation, which can lead to solar system failure and electrical fires.

3.2 CONNECT CONTROLLER TO BATTERY

It is important to adequately size your battery cable according to your system size, taking into account any future expansion that may be implemented. For additional information regarding wire size, please refer to the CANADIAN ENERGY website or contact us directly. Two lengths of cable will be required, a positive (+) and a negative (-). It is recommended to identify each cable or use a different colored cable for each connection (eg: black and red). Connect the wire designated as positive (+), usually red, to the BATTERY terminals on the charge controller labeled ‘BAT +’ and tighten the terminal with a screwdriver. Connect the wire designated as negative (-), usually black, to the BATTERY terminals on the charge controller labeled ‘BAT -’ and tighten the terminal with a screwdriver.

NOTE: The polarity should be identified on the screw-down terminals of the charge controller; however, the naming convention of the terminals may differ slightly, depending on the model of the solar controller that came with your Kit

Once the connections are made to the battery terminals on the charge controller, make sure the battery post terminals are clean and free from corrosion.

It is recommended to use a battery cable lug appropriately sized to fit the post of your battery. Connect the remaining loose end of the wire designated as positive (+), to the positive post/terminal of the BATTERY. Connect the remaining loose end of wire designated as negative (-), to the negative post/terminal of the BATTERY

As soon as the battery is connected to the charge controller, the controller will power automatically and should indicate a battery voltage is applied (eg: green LED). The diagram below shows the connection for controller to battery.

SOLAR PANEL INSTALLATION

4.1 LOCATION

Determine a location for the solar panel that is in direct sunlight and clear of any shading by adjacent obstacles such as trees, roof overhangs, etc. Ideally, the panels will be positioned to minimize the wiring distance between the solar panel and the charge controller and will have sufficient space to access the panel for servicing should it be required.

For Northern Hemisphere installations, the solar panels should be mounted at angle facing true south (true north for Southern Hemisphere installations). The mounting angle should be equal to the latitude location of where you are installing the solar panels. For example, the latitude of Miami, Florida, USA is 25 degrees. Therefore, solar panels installed in this area should ideally be facing true south at a tilt angle of 25 degrees.

Due to design constraints in many installations, you will not be able to mount the solar panel facing true south at the ideal tilt angle. In
these cases, try to come as close as possible to the ideal mounting configuration as this will maximize the power output from the solar panels.

For Northern Hemisphere installations, face the solar panel true south at a tilt angle equal to the geographical latitude of where the solar panel is installed.

4.1.1 RV and Trailer solar panel placement

1. Planning a path down from the roof is the most critical factor, ensure your cables can reach from the roof down to the charge controller. Extension cables may be required (not included in this kit).
2. Check for shading from A/C units, satellite dishes and antennas. If possible do not place your solar panels in close proximity to these units as shade will directly affect the output of your solar panels.
3. Solar panels should be located a minimum of 3 feet from the front of the unit in order to reduce wind load on the panels. DO NOT hang solar panels over the edge of the RV or Trailer.

Installation Tips

1. Before screwing into the roof of your unit, place a small dab of sealant on the roof and screw through the sealant. Ensure the whole screw, Z-bracket or mounting hardware are covered in sealant.
2. If possible, keep the solar panels close together if you have the two panel kit.
3. If the unit will be parked in trees the awning or passenger side will generally have more sunlight and the panels should be installed on that side of the unit.
4. Screw into roof trusses when possible. (wood roof with membrane)
5. Ensure the solar panels do not block access to other areas of the roof for maintenance and future inspections.

4.2 LAYOUT – PLACEMENT

For systems using more than one panel that will connect together, the 30” connection cable may limit the possible orientation of the inter-connected panels. Proposed orientations are located in Section 5 but user applications may not have the necessary space available to achieve this layout. In these cases, the use of MC4 extension cables may be required to connect panels together. These are available through CANADIAN ENERGY in multiple lengths to accommodate your installation.

4.3 MC4 CONNECTORS

The output wires from the junction box of the solar panel are terminated with 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 “-”).

The MC4 connectors are compatible for use with AWG #10 wire/cable with an outer insulation diameter between 2.5 and 6.0mm. The MC4 connectors provide a reliable and water resistant way for conveniently making electrical connections between solar panels and the extension cable.

4.3.1 MC4 Connector Assembly Instructions

1. Strip 1/4” of the insulation from the cable end to be terminated with the MC4 connector using a wire stripper. Be careful not to nick or cut the conductor.
2. Insert the bare conductor into the crimping area (Item 6) of the metallic mating contact and crimp using a special purpose crimping tool. If a crimping tool is not available the wire may be soldered into the contact.
3. Insert the metallic mating contact with the crimped wire through the Housing Nut and rubber bushing (Item 3) and into the insulated housing, till the metallic pin fits snug into the housing.
4. Tighten the Housing Nut (Item 3) onto the connector housing. When the nut is tightened, the internal rubber bush is compressed around the outer jacket of the cable and thus, provides water-tight sealing.

4.3.2 MC4 Connector Installation Instructions

Push the Two Connector pairs together such that the two locking tabs on the MC4 Female Connector (Item 7) align with the two corresponding locking slots on the MC4 Male Connector (Item 8). When the two connectors are coupled, the locking tabs slide into the locking slots and secure. To uncouple the two connectors, press the ends of the locking tabs (Item 7) as they appear in the open locking slot (Item 8) to release the locking mechanism and pull the connectors apart.

CAUTION: Make sure that no current is flowing when uncoupling is attempted.

4.3.3 MC4 Branch Connectors

MC4 Branch Connectors are used to interconnect solar panels together. There are two different branch connectors, one type accepts two male MC4 connectors on the input side and has a male MC4 connector for its output. The other type accepts two female MC4 connectors and has a female MC4 connector for its output.

MC4 Branch connectors do NOT require any preparation. The metal female and male pins are pre-installed at the factory inside the MC4 Branch Connectors. This means that the MC4 Branch Connectors can simply be snapped into place.

4.4 CONNECT SOLAR PANEL(S) TO CHARGE CONTROLLER

IMPORTANT: Do NOT connect the solar panels to the solar charge controller until the solar charge controller has been completely connected to the 12 volt battery as stated in Sec 3.2.

CAUTION: High voltages may be present on the solar panel output wiring. Solar panels produce electricity when exposed to light. Use caution and avoid touching any conductors in the system circuit to avoid electric shock.

Insert the stripped ends of the extension cable from Sec 4.4 into the appropriate terminal on the charge controller. Positive PV lead is connected to the positive terminal (marked “PV +”) of the charge controller and the negative PV lead is connected to the negative terminal (marked “PV -”) of the charge controller.

Use a Philips screwdriver to tighten the terminals on the charge controller and secure the connections. Once you connect the solar extension cables into the charge controller PV terminals, you may remove the covering of the solar panels. The controller should indicate a charging solar panel if there is enough sunlight.

IMPORTANT: A properly sized fuse needs to be placed in the positive wire connecting the solar panels to the charge controller.

4.5 MOUNTING

You may now secure the solar panels to their permanent structure. The solar panels should be mounted to a flat surface that is strong enough to handle the weight bearing load of the solar panels. If the panels will be mounted on a roof, make sure the material is strong enough to provide support to the solar panel including wind loading. To minimize wind loading effects in an RV or mobile application, place the panel’s longest edge parallel with the direction of wind travel.

1. Use the included Z-Brackets and fasteners (four Z-Brackets per solar panel) to attach the solar panel to the flat mounting surface.

2. Attach the Z-Brackets to the four oval shaped holes on the backside of the solar panel using the included fasteners.

3. Secure the solar panel to the mounting surface by bolting the four Z-brackets to the mounting surface. Note: The bolt to secure the Z-Bracket to the mounting surface is not included in this kit. This is because the bolt type (lag bolt, carriage bolt, etc) and bolt length will depend on the mounting surface type (metal, wood, and fiberglass) and thickness. See image for reference.

4. Use of appropriate sealant is requirent (not included). A common sealant type is self-levelling lap sealant.
   

4.6 FUSING

It is necessary to add fuses or circuit breakers to the Complete Off-Grid Solar Panel Kits. While the systems will function without fuses or circuit breakers, fusing protects the system from accidental short circuits, power surges, and accidental incorrect wiring. An ATC fuse can be used (available at auto parts stores) or a circuit breaker can be purchased at most hardware stores.

PANEL PLACEMENT AND WIRING

BATTERIES

The battery is a critical component in your renewable energy system to store the power generated by your solar panels and provide a relatively constant source of power when the grid is down, or during periods when your photovoltaic system is not producing power. Although batteries are not one hundred percent efficient, they are predictable and stable enough for reliable long-term service.

CANADIAN ENERGY recommends deep cycle lead-acid batteries and discourages the use of car or marine batteries. This is because car and marine batteries are designed to give a large burst of energy when starting a vehicle and are not made for deep discharges. However, deep cycle golf cart batteries are an excellent alternative.

6.1 TYPES

There are three main types of batteries that are commonly used in renewable energy systems, each with their own advantages and disadvantages.

1. Flooded or “wet” batteries are the most cost efficient and the most widely used batteries in photovoltaic applications. They require regular maintenance and need to be used in a vented location.
2. Gel Cell uses a silica additive in its electrolyte solution that causes it to stiffen or gel, eliminating some of the issues with venting and spillage.
3. Absorbed Glass Mat (AGM) construction method suspends the electrolyte in close proximity with the plate’s active material.

Gel Cell and AGM batteries are both sealed, requiring virtually no maintenance. They are more suitable for remote applications where regular maintenance is difficult, or enclosed locations where venting is an issue.

6.2 SIZING

Most deep cycle batteries are classified and rated in amp-hours. Amp-hours is the term used to describe a standardized rate of discharge, measuring current relative to time. It is calculated by multiplying amps by hours. The generally accepted rating time period for most manufacturers is 20 hours. This means that the battery will provide the rated amperage for about 20 hours until it is completely discharged.

To determine the number or charge size of batteries you need, you must first determine how much energy storage you need in Watt-hours (Wh). If you are connected to the utility grid, you can use your monthly utility bill to calculate your average energy usage or you can multiply the wattage of the appliances you use (or intend to use) by the number of hours you use them in a day. Because Watts = Amps x Volts, and you want to know the number of Amp- hours, you would divide the number of Wh by the voltage of your system.

As an example: you calculate your usage to be 1,000 watt-hours (or 1 kWh) per day and your system is on a 12-volt battery bank, then you need 83 amp-hours of useful storage (1000/12). However, lead-acid batteries cannot be fully discharged so the battery bank should be double the useful storage capacity. For this example, your battery bank should be 166Ah or larger

6.3 WIRING BATTERY BANKS

Batteries can be wired together and configured in ‘banks’ to achieve the desired battery bank voltage, such as 12V, or to achieve the relevant size for your system needs. This can be done with series, parallel, or series/parallel connections as shown below.

TROUBLESHOOTING AND SUPPORT

7.1 MAINTENANCE

The following maintenance is recommended to ensure optimum performance and longevity of the solar system:

• Clean the glass surface of the solar panel when necessary. Always use water and a soft sponge or cloth for cleaning. A mild, non-abrasive cleaning agent can be used to remove dirt.
• Check the electrical and mechanical connections every six months to verify that they are clean, secure and undamaged.
• Inspect the solar panels and make sure the surfaces are 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 flooded wet cell lead acid batteries are used.
• Check and replace damaged components if necessary.

7.2 LIMITED WARRANTY

CANADIAN ENERGY warrants that Solar Panel Off-Grid Kit (the “Product”), will be free from manufacturing defects in materials and workmanship under normal authorized use consistent with product instructions for a period of one (1) year from the date the original purchaser (“Customer”) receives the Product (the “Warranty Period”). This warranty extends only to the original purchaser. The Customer’s sole and exclusive remedy and the entire liability of CANADIAN ENERGY, its suppliers and affiliates for breach of the warranty is, at CANADIAN ENERGY’s option, either (i) to replace the Product (or defective component part(s)) with a new or reconditioned Product (or component part(s)); (ii) to repair the reported problem; or (iii) to refund the purchase price of the Product. Repaired or replaced products are warranted for the remainder of the original warranty period only. No employee, agent, dealer or other person is authorized to give any warranties on behalf of CANADIAN ENERGY not expressly set forth in this limited warranty.

7.3 RESTRICTIONS

No warranty will apply if the Product (i) has been altered or modified except by CANADIAN ENERGY; (ii) has not been installed, operated, repaired, or maintained in accordance with instructions supplied by CANADIAN ENERGY; (iii) has been subjected to abnormal physical, thermal or electrical stress, misuse, negligence, or accident. If CANADIAN ENERGY determines that the problem with the Product is not due to a manufacturing defect in CANADIAN ENERGY’s workmanship or materials, or otherwise does not qualify for warranty repair, then the Customer will be responsible for the costs of all necessary repairs and expenses incurred by CANADIAN ENERGY.

7.4 DISCLAIMER

CANADIAN ENERGY (“CANADIAN ENERGY”) is not assembling the Complete Solar Panel Off-Grid Kit, or any other product offered by CANADIAN ENERGY. CANADIAN ENERGY, and its directors, officers, and employees disclaim, and by purchasing a
CANADIAN ENERGY product you accept all liability and responsibility for damage to property, injury, or death arising out of or related to the use or misuse of any product offered by CANADIAN ENERGY.

EXCEPT FOR THE EXPRESS LIMITED WARRANTY SET FORTH IN THE PREVIOUS PARAGRAPH, CANADIAN ENERGY DISCLAIMS ALL WARRANTIES, EXPRESS, IMPLIED AND STATUTORY INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WITH RESPECT TO ANY PRODUCTS PROVIDED BY CANADIAN ENERGY. NO ORAL OR WRITTEN INFORMATION OR ADVICE GIVEN BY CANADIAN ENERGY, ITS DEALERS, DISTRIBUTORS, AGENTS OR EMPLOYEES SHALL IN ANY WAY INCREASE THE SCOPE OF THIS WARRANTY. CANADIAN ENERGY DOES NOT WARRANT THAT THE QUALITY OR PERFORMANCE OF THE PRODUCTS WILL MEET YOUR REQUIREMENTS OR THAT YOU WILL BE ABLE TO ACHIEVE ANY PARTICULAR RESULTS FROM USE OR MODIFICATION OF THE PRODUCTS.
Some jurisdictions do not allow the limitation or exclusion of implied warranties or how long an implied warranty may last, so the above limitations may not apply to you. In any such jurisdiction, the warranty shall be limited to the minimum warranty and period required by law.

CANADIAN ENERGY EXPRESSLY DISCLAIMS ALL LIABILITY FOR BODILY INJURIES OR DEATH THAT MAY OCCUR, DIRECTLY OR INDIRECTLY, BY USE OF THE PRODUCT BY ANY PERSON.

7.5 LIMITATION OF LIABILITY

UNDER NO CIRCUMSTANCES WILL CANADIAN ENERGY OR ITS AFFILIATES OR SUPPLIERS BE LIABLE OR RESPONSIBLE FOR ANY LOSS OF USE, INTERRUPTION OF BUSINESS, LOST PROFITS, LOST DATA, OR INDIRECT, SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES OF ANY KIND REGARDLESS OF THE FORM OF ACTION, WHETHER IN CONTRACT, TORT (INCLUDING NEGLIGENCE), STRICT LIABILITY OR OTHERWISE, EVEN IF CANADIAN ENERGY OR ITS AFFILIATE OR SUPPLIER HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGE.

Some jurisdictions do not allow the exclusion or limitation of incidental or consequential damages, so these limitations may not apply to you. Neither CANADIAN ENERGY nor its affiliates or suppliers will be held liable or responsible for any damage or loss to any items or products connected to, powered by or otherwise attached to the Product. The total cumulative liability to Customer, from all causes of action and all theories of liability, will be limited to and will not exceed the purchase price of the Product paid by Customer. This warranty gives the Customer specific legal rights and the Customer may also have other legal rights that vary depending on the jurisdiction.

NOTES

Canadian Energy is Canada’s stored and renewable energy expert. When you’re looking for the best option for renewable energy or energy storage, we have it. If you need batteries, mobile power or back up power, we’ve got those too. We have branches across the nation to provide the best product range, technical support and value for our customers every day.

CDNRG.COM

References

• Battery Suppliers | Transportation & Solar Batteries | Canadian Energy

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