THERMO KING ThermoLite 110W Solar Panels Installation Guide

THERMO KING ThermoLite 110W Solar Panels

Kits 401417 and 401418

For the following applications:

1. Trailer Roof Top Mounted Solar Panel(s)
2. Bus Roof Top Mounted Solar Panel(s)
3. Tractor Fairing Mounted Solar Panel(s)

| 401417

Base Kit

| 401418

Expansion Kit

---|---|---
Item| Description| Part Number| Qty.| Qty
1.| Solar Panel, 110W Assembly| 452769| 1| 1
2.| Charge Controller| 422579| 1|
3.| Fused Battery Harness| 422456| 1|
4.| Y-Expansion Cable| 422453| | 1
5.| Hardware Kit| NSS| 1| 1
6.| Nameplate| NSS| 1|
7.| Warranty Registration| NSS| 1| 1
8.| Installation Instructions| NSS| 1| 1
Optional Extension Harnesses Available: 422405 – 8 ft.

401293 – 11.5 ft.

422406 – 25 ft.

422407 – 50 ft.

Solar Panel Installation Best Practices

Important: BEFORE beginning the solar panel installation disconnect all power to the refrigeration unit including standby power (if equipped). Also disconnect all power at the batteries for solar panel installation onto tractors or buses and on trailers equipped with a lift gate

• Prior to installation, familiarize yourself with the components supplied in your kit.
• Follow installation instructions specific to your installation kit and model refrigeration unit.
• Plan the solar panel layout and wire routing prior to permanently mounting any components.
•  DO NOT block the solar panel with antennas, telematics modules, etc. This will greatly reduce the output of the solar panel and inhibit its ability to supply power to maintain and support the battery or batteries it is connect to.
• Make sure wire routes are free from abrasive materials and have adequate clearance from hot surfaces.
• Holes used for routing harnesses through metal frames, skins or structures should be smooth and non-marring and lined with a grommet.
• Remove solar panel fuse (located on the solar panel harness) prior to panel installation.
• Tractor with APU – DO NOT connect solar panels to TriPac Envidia APU Batteries.
• Solar panel electrical harnesses routed inside the refrigeration unit must be secured to other harnesses or to a solid frame structure with insulated clamps or cable ties to prevent making contact with rotating or hot components.
• DO NOT attach electrical harnesses to copper tubing, exhaust components or fuel lines.
• Solar Panel Test Procedures must be performed to complete the installation.
• Fill out the Warranty Registration Form after completing the installation.

Installing Solar Panels with Adhesive Backing

Note: If panel is intended to be removed in the future, use only mechanical fasteners to secure. ThermoLite solar panels utilize a very aggressive 3M VHB adhesive to secure panels to surfaces. This adhesive creates a long-lasting bond that develops its maximum bonding strength 72 hours after installation. The following procedures should be followed to ensure reliability of the adhesion for panel mounting.

Surface Preparation

Smooth fiberglass surfaces such as those used in Class 8 Tractors & Transit Buses often utilize a heavy gloss or contain mold release wax. This significantly affects the solar panels ability to adhere properly to the surface. To help improve the adhesion, all mounting surfaces should be roughened up using Scotch-Brite™ pads, steel wool, or sand paper. The rougher the surface the better the adhesion.
If surfaces have degraded due to UV and weather exposure, the application and adhesion of solar panels on non-metallic surfaces, even if cleaned thoroughly, may require additional evaluation of adhesion strength. Surfaces showing loose fibers or color fading should be considered to have bond strength reductions. Mechanical fasteners and edge sealing should be added.

Cleaning the Surface
Ensure installation location is clean and free of any dirt. Clean surface with isopropyl alcohol or appropriate de-greasers before installing panel. All cleaning residue must be removed and surface completely dry before installing panel.

Adhering the Panel

Remove adhesive backing paper and firmly press panel down over the entire area to ensure the panel is properly adhered to the surface. This is critical to prevent moisture between the surfaces. Testing the adhesive grip after installing the panel by lightly pulling up on the panel is recommended. The addition of both mechanical fastening and edge sealing is recommended when possible.

Important: For solar panel to adhere properly, both the application surface and air temperature must be above 45 F (7 C). Adhesive will develop maximum bond strength in 72 hours.

Mechanical Fastening
ThermoLite solar panels have grommets around the edge to provide for mechanical fastening using screws or rivets. It is advised that all installations utilize at least one type of mechanical fastener to ensure panels do not come loose. All holes MUST BE FILLED with sealant before inserting any fastener to ensure a sealed joint. It is also advised to apply sealant over the fastener once installed.

Edge Sealing
It is recommended to seal/caulk around the perimeter of the solar panels to help prevent water and debris from entering under the panels.

Trailer Roof Top Installations

Important: BEFORE beginning the installation, refer to “Solar Panel Installation Best Practices,” p. 3.

1. Thoroughly prepare surface per  Installing Solar Panels with Adhesive Backing p. 4 Failure to properly prepare mounting surface will result in poor adhesive strength of the solar panel.

2. Solar panel installation can be either the front or back of the truck box or trailer
   a. If refrigeration unit is present with existing two-pole (two wire) connections with a wire gauge of 12 AWG or larger to the liftgate batteries, then the panels should be installed on the roof of the trailer near the front to utilize the existing connectors.
   b. Front of trailer installations are generally preferred so vehicles parked against a building will not shade the solar panels and reduce performance.
   c. Considering installing the solar panels away from the tractor and refrigeration unit exhaust systems. The panel may be positioned length wise or perpendicular to the trailer roof edge. Exhaust soot build-up on the panel can result in decreased performance if not cleaned off regularly.
   d. The junction boxes should be positioned closest to the edge of the trailer end and lined up with planned wire route.
   e. If scrapers are to be used for winter snow removal, position the panel with the long edge containing the junction box aligned to the front edge of the trailer so the sloped edge of the junction box is facing forward.
   f. If the battery box is located at the very rear of the trailer, the solar panel(s) could be located at the rear of the trailer with protected cable routing down the back.
   

3. Plan the panel layout and wire routing prior to permanently mounting any equipment. Familiarize yourself with the components to be installed. Make sure wire routes are free from abrasive materials and have adequate clearance from hot surfaces. Any holes through metal frames, skins or structures should be smooth and non-marring or be lined with a grommet prior to routing wires.
   
   a. Maximum of three (3) 110W panels connected in parallel.
   b. Utilize the y-cables to connect multiple panels together in parallel.

4. Secure any excess cable off the roof if possible. Any rooftop cables should be secured using mechanical fasteners, p-clamps or high-bond adhesives.

5.  The extension harnesses are provided with one non-plugged end and a loose connector housing. Verify the polarity of the cable to the panel and charge controller prior to routing the wire. Plan your route and route the wiring starting with the non-plugged end.

6.  Route the extension harness down the front or back of the trailer and through any existing conduits if possible.
   a. Add grommets to holes in frame or skins as needed to protect wiring.
   b. Route towards the battery box or connections to the batteries to be charged using existing cables.

7. Verify that any existing cables used meet or exceed the wire gauge of the wiring supplied with the solar panels.
   a. Do not route the cable next to any heat sources or any sharp edges without adequate clearance or additional cable protection.
   b. If the cables are routed through new or existing holes in metal structures, grommets
   (installer provided) must be used to protect the cables.

8.  Secure the charge controller near the batteries or adjacent to the existing two pole front of trailer connection points using mechanical fasteners.
   

9. Once the wiring is in place, take the loose connector end provided and plug the white wire into position “A” and the black wire into position “B”.
   a. Pull back slightly on the wire after hearing a “click” to make sure the terminal is properly seated.
   b. Fold the retainer clip onto the back of the connector until you hear a “click”. Make sure the retainer clip is secured.

10. Connect the extension harness to the charge controller.

11. Connect the battery terminal harness to the charge controller and route the white/red wire to the positive terminal on the battery or to the two pole connection location. If existing wiring is to be utilized it must meet or exceed the 12 AWG wire gauge of the wiring supplied with the solar panels.
    NOTE: If the existing wiring quality or gauge is in question, add additional new solar panel extension cables as needed and route the panel wiring to the battery box location and install the charge controller and battery harness at the battery box location as seen in Fig 7

12. Attach the black wire to the negative ground of the battery or to a common ground stud or terminal.

13.  Clean surface and attach supplied nameplate on the lift gate battery box or near the solar panel terminal connection. The label must be visible to servicing technicians to warn of additional charging sources.
    

14. 1Reinstall fuse in solar wire harness and reconnect all battery connections.

15. Perform “Solar Panel Test Procedures,” p. 20 to complete the installation.

16. Fill out the Warranty Registration Form after completing the installation
    Note: Depending on the installation, all kit components may not be used.

Bus Roof Top Installations

Important: BEFORE beginning the installation, refer to “Solar Panel Installation Best Practices,” p. 3 .

Note: It is recommended that one 110W solar panel be installed for each bus battery.

1. Thoroughly prepare surface per “Installing Solar Panels with Adhesive Backing,” 4 Failure to properly prepare mounting surface will result in poor adhesive strength of the solar panel.

2. Maximum of three (3) 110W panels connected in parallel.

3. Utilize the Y-cables to connect multiple panels together in  parallel.
   Extension Harnesses Connections

4.  Extension harnesses are provided with one non-plugged end and a loose connector housing. Verify the polarity of the cable to the panel and charge controller prior to routing the wire. Plan your route and route the wiring starting with the non-plugged end.

5. Attach 25 ft. extension harness to the solar panel connector and route harness down the front or back of the bus and through an existing doors/panels and into the battery compartment.

6. Remove 2-pin connector (attached to harness) and route harness through a rubber grommet and into tractor’s battery box.

7.  Attach 2-pin connector to harness by releasing the locking tab, inserting wires until they are fully seated, and closing locking tab securely.
   • White wire (B+) into socket A
   • Black wire (B-) into socket B
   Charge Controller and Battery Harness Connections

8. Connect charge controller to extension harness.

9. Remove fuse from battery harness and connect to charge controller.

10. Connect terminal rings from battery harness to battery:
    • Black to Negative (-)
    • White to Positive (+)
    

11. Secure controller inside battery compartment.

12.  Clean surface and attach supplied nameplate near the battery box or the solar panel terminal connection. The label must be visible to servicing technicians to warn of additional charging sources.
    

13.  Install fuse in solar wire harness and reconnect all battery connections.

14.  Perform “Solar Panel Test Procedures,” p. 20 to complete the installation.

15.  Fill out the Warranty Registration Form after completing the installation.
    Note: Depending on the installation, all kit components may not be used.

Class 8 Tractor Cab Installation

Important: BEFORE beginning the installation, refer to “Solar Panel Installation Best Practices,” p. 3.

1. Thoroughly prepare surface per “Installing Solar Panels with Adhesive Backing,” p. 4 Failure to properly prepare mounting surface will result in poor adhesive strength of the solar panel.

2. Position solar panel onto roof of the cab — away from the exhaust exit.

3. Peel back the top 4 inches of the backing paper and begin to apply panel to surface.

4. With panel properly positioned, remove remainder of backing paper and firmly press panel down over the entire area. Repeat several times to ensure the entire panel is properly adhered to the surface. This is critical to prevent moisture between the surfaces.
   Extension Harnesses Connections

5.  Extension harnesses are provided with one non-plugged end and a loose connector housing. Verify the polarity of the cable to the panel and charge controller prior to routing the wire. Plan your route and route the wiring starting with the non-plugged end.

6. Attach 25 ft. extension harness to the solar panel connector and route harness down the rear of the cab and over to the tractor’s batteries.
   a. Secure harness with supplied clamps and band wraps.

7.  Remove 2-pin connector (attached to harness) and route harness through a rubber grommet and into tractor’s battery box.

8. Attach 2-pin connector to harness by releasing the locking tab, inserting wires until they are fully seated, and closing locking tab securely.
   • White wire (B+) into socket A
   • Black wire (B-) into socket B
   Charge Controller and Battery Harness Connections

9. Connect charge controller to extension harness.

10. Remove fuse from battery harness and connect to charge controller.

11. Connect terminal rings from battery harness toTRACTOR BATTERIES ONLY:
    • Black to Negative (-)
    • White to Positive (+)

12. Secure controller inside battery compartment

13. Clean surface and attach supplied nameplate near the battery box or the solar panel terminal connection. The label must be visible to servicing technicians to warn of additional charging sources.

14. Reinstall fuse in solar panel battery harness and reconnect all battery connections.

15. Perform “Solar Panel Test Procedures,” p. 20 to complete the installation.

16. Fill out the Warranty Registration Form after completing the installation.
    Note: Depending on the installation, all kit components may not be used.

IMPORTANT!
Connect Solar Panel(s) to Tractor Batteries ONLY. DO NOT Connect to TriPac ENVIDIA APU Batteries.

Expansion Panel Installation and Wiring Guide

1. Place additional panel(s) in their chosen locations and mount according to the instructions.
2. Connect provided parallel y-cable(s) together and secure using brand wraps and clamps.
   • Up to 72W may be connected into a single 5amp charge controller.
   • Up to 400W may be connected into a single 20amp charge controller.
   WIRING DIAGRAM: EXPANSION PANEL WIRING
   WIRINING DIAGRAM: SINGLE PANEL WIRING
   

ThermoLite Charge Controller

STATUS LIGHT FUNCTION

Flashing Green = Battery charging / Controller connected correctly.
Solid Green = Controller connected to battery / Solar input may or may not be connected correctly*
No Light = Controller not connected / extremely low or dead battery.

*__** Status light will illuminate solid green even if harness is connected in reverse. Ensure status light is flashing green to verify correct installation.

Solar Panel Test Procedures

There are two types of 5A Charge Controllers:

1.  Controller with LED status lights.
2. Controller without LED status lights.
   The test procedures are different depending on the type of charge controller you have.
   NOTE:  Charge controllers can take up to one minute to turn on.
   

Charge Controller with LED Status Lights

This charge controller has three LED status lights that indicate battery charging and system operation. If you have this version controller refer to the Status Light Function table below to verify solar panel operation. Also see “Solar Panel Troubleshooting Guide” if necessary.

Status Light Function

Flashing Green| Solar panel working properly and charging
Solid Green| Battery fully charged
Flashing Yellow| Marginal battery, charging
Solid Yellow| Marginal battery, not charging (night time)
Flashing Red| Extremely low battery, charging
Solid Red| Extremely low battery, not charging (night time)
No light| Controller not connected/extremely low or dead battery

Charge Controller without LED Status Lights

This charge controller does not have LED status lights to indicate battery charging and system operation. If you have this type of controller you must use the “Test Procedure” on the following page to verify solar panel operation. Also see “Solar Panel Troubleshooting Guide” if necessary.

Test Procedure

To properly test the solar output you must have the following items:

• Halogen lamp (500W or greater) or be outdoors in the
• Voltage meter
• Amp clamp or Ammeter

1. Attach voltmeter on the battery and measure the

   • Voltage must be less than 8V for the solar panel controller to turn on.
   • If battery voltage is not less than 8V, then put a 12V load on the battery.
     

2. 2. Move vehicle outdoors into the daylight. If indoors, put at least a 500W halogen lamp  approximately 24” above the solar panel and turn lamp on.
   NOTE:  The solar panel controller may take up to a minute to turn on. The solar panel must be connected to the battery in order to turn on the charge controller.

3. Attach voltmeter on the battery and measure the voltage.
   a. Voltage reading should begin increasing or stay the same.

4. Place amp clamp around the positive cable from the solar panel.
   a. Amperage reading should be greater then 300 mA
   

ThermoLite™ Solar Panel Kit Warranty
All ThermoLite solar panels installed by an authorized Thermo King dealer and registered within the first twelve (12) months of installation receive five (5) years parts and labor warranty coverage from date of installation. ThermoLite solar panels installed by an authorized Thermo King dealer not registered in that time will automatically receive five (5) years plus 90 days parts and labor coverage from date of manufacture.
Customer installed ThermoLite solar panels registered within the first twelve (12) months of installation receive five (5) years parts warranty coverage from date of installation. Customer installed ThermoLite solar panels not registered in that time will automatically receive five (5) years plus 90 days parts coverage from date of manufacture.
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