Download Service and Troubleshooting Procedures

Service and Troubleshooting Procedures
Sol® products may appear different but all have similar components and purpose. The
following guide will help troubleshoot issues with all of Sol’s outdoor lighting products. In order
to troubleshoot properly, first you must familiarize yourself with the various components. The
main components are:
1. Battery or Battery Array
3. Solar Panel or Array
2. Solar Controller
4. Light or other Load
Most if not all cases items #1 and #2 are located in the battery enclosure or close to it.
Typical Sol ® Solar Lighting Products
Solar Panels
Solar Panel
Solar Panels
F
Battery Enclosure
with Batteries &
Controller
LED Fixture
LED Fixture
20/20™ & 10/10™ Models (TT Series)
Side of Pole Mount (SP Series)
Battery
Enclosure
with Batteries
Controller
Top of Pole Mount (TP Series)
LED Fixture
Battery
Enclosure
with Battery
Controller
GreenWay (GY Series)
Flat Mount Models (AL/TL/SH Series)
What to Bring
1.
2.
3.
4.
5.
Digital Volt Meter (DVM) able to measure 20 amps (Preferred)
Spare Controller (if needed/ordered from Sol) and Fuse,
Spare Gel Cell Batteries
Cleaning Supplies for Solar Array and Fixture
Optional Equipment – Battery Load Tester
Check for Shading and Proper Sun Path
For proper operation, a solar system cannot
have any objects blocking its sun path from the
9am – 3pm sun position. Consider the east
horizon is 9:00, the sun’s highest position is
12:00, and the west horizon is 3:00. As seen in
the side example, the system receives
afternoon shading (Approx. 1pm). The lower
example shows shading at 12 noon during the
winter months, but none during the summer,
spring or fall. In both cases the units will
function correctly until the winter months. Then
the system will start turning off early and not
operate well during cloudy/rainy periods.
If shading is a potential problem, here are a few
alternatives:
1. Place system in another location to avoid
shading.
2. Raise mounting height.
3. If shading is caused by trees, trim or cut them
back.
Sun path and obstructions should not be overlooked, systems installed years ago may have
been fine but local changes may have caused shading issues. Examples are trees growing, tall
buildings built or overhead power lines installed.
Solar powered equipment needs sun to operate correctly so Weather plays an important part
of how the system works. If weather has been bad, low sun or cloudy, you may encounter low
battery voltages, any testing should be on days with bright sunshine.
TSP-01
REV: 7/12
Where to Start
1. Start with the condition of the battery and status of the charge controller. Visually
inspect for signs of corrosion or fault!
2. Check fuse!
3. Check the charge controller, charge light on? Is the unit in LVD mode? If LVD light is lit
you should find the battery voltage on the low side. Controller tests will not be 100%
accurate in LVD mode.
4. Measure battery voltage, voltage should be between 11.9 vdc to 13.2 vdc for a 12-volt
system and 23.8 vdc to 26.4 vdc for a 24-volt system.
During daylight the charge led should be lit, if the charge led is turning on and off about
every 10 seconds or so, check the fuse. If the fuse is good, then check battery voltage. If
battery voltage is over 13 volts, then the controller is functioning properly in the charge
mode; if under 10 volts then battery needs replacement. These conditions will cause the
controller to cycle on and off.
The controller is the brain of the system, most problems are a result of the controller working
correctly but the technicians do not know how it works. To explain it simply; it regulates how
much energy is absorbed from the sun and stored in the batteries, it also monitors how
much power is removed from the batteries. When the system has the proper amount of sun
everyday (about 10% more then was used by the light at night) the batteries will recharge
fully in about 4 hours. On days where the sun’s input is less then the amount used by the
light at night the system starts to use it’s battery backup. If the weather stays bad, more and
more backup is used until the system reaches a preset voltage (LVD = 10.8vdc) 21.6 vdc for
24 volt systems, low voltage disconnect and shuts the system off. The system will remain off
until the voltage of the batteries reaches a preset voltage (LVD Reconnect =12.8vdc) 25.6 vdc
for 24 volt systems. Example: If the system reaches LVD, takes approximately 2 -3 days to
recharge the batteries, and the technician arrives to check it out after day 1, he will find the
system looks fine. The battery voltage is 12vdc (24 vdc for 24 volt systems) but does not
realize it needs to reach 12.8vdc (25.6 vdc for 24 volt systems) before the controller will allow
the system to operate.
Technicians must be trained in order to properly understand and diagnose the system.
TSP-01
REV: 7/12
Testing Sol EternO® Controllers
Fig 3.
Press the TEST button until a distinct click is heard and felt.
This button performs two functions:
a. Confirm rotary switch selection
To verify that the rotary digital switch is set at the desired position, press the TEST button.
The red LED will flash once per second. Count these LED flashes to confirm the correct
switch setting. Each of the 10 LIGHTING CONTROL positions has a unique number of
flashes. These are as follows:
Switch Setting
OFF
5
6
7
8
# of Flashes Switch Setting
0
12
1
3/2
2
4/2
3
6/2
4
D/D
# of Flashes
5
6
7
8
9
NOTE: Rotate the rotary switch one full cycle if there is an incorrect or no LED flash (except
for OFF setting).
b. Turn system lights on
Pressing the TEST button will turn the system lights on to verify correct installation or for
troubleshooting a system problem.
The lights can be turned on anytime (day or night) for 5 minute intervals. The lights can be
turned on repeatedly with the TEST button except when the system is in LVD (load
disconnect/red LED on). In LVD the TEST button will only work 3 times to avoid damaging
the battery. If pressing the TEST button causes a load disconnect (LVD), the lights will turn
off. Wait 5 minutes and press TEST again to turn the lights on in LVD.
TSP-01
REV: 7/12
Testing Sol EternO® 4 Controllers
After the battery is installed and the components are connected, press the test button
(Figure 4). When the test button is pressed the three LEDs will flash sequentially green,
yellow then red. Count the number of flashes for each led. This represents the three digit
SW code. The test button can be pressed as many times as necessary to get an accurate
count.
Test Button
Diagnostic
Indicators
Fig. 4
Sol EternO4 LED indicator definitions:
Green LED: Lamp is on or the controller is attempting to turn the lamp on.
Yellow LED: The battery charger is active.
Flashing Red LED: The Red LED will flash if the battery becomes disconnected or battery
voltage is inadequate(below 10.5V).
Red LED: Low Voltage Disconnect. In the event of a low voltage disconnect, the lamp is
turned off for the remainder of the night. The Red LED will remain illuminated throughout
the following day as a diagnostic aid regardless of battery voltage.
Yellow & Red LED: Charger is on. The system was in LVD during the previous night. The
Red LED will remain illuminated throughout the following day as a diagnostic aid regardless
of battery voltage.
Green & Red LED: Lamp Fault. If the green and red LEDs are illuminated simultaneously,
the controller cannot start the lamp. This can be caused by high wiring resistance between
the controller and the lamp, a short circuit, open circuit, or a problem with the lamp itself.
Flashing Green, Red, and Yellow: Indicates test code is installed.
TSP-01
REV: 7/12
* If the battery voltage is too low, contact Sol Customer Service at +1-772-286-9461.
After the lighting system is tested and found to be satisfactory, secure the battery box cover
to the battery box, using the 1/4”-20 x 1/2” hex head bolts and lock key (optional).
Testing the Batteries
Testing the batteries can be done in various ways.
To get a simple status condition of the battery, do the following:
1. Measure and record battery voltage.
2. Do system test as described earlier.
3. Measure and record voltage after 15 – 20 minutes. Voltage should be approximately
the starting voltage minus one or two hundredths. If voltage is dropping sharply,
batteries need replacing. To get a better status condition of the battery, have the
battery load-tested by an automotive repair shop or with a hand held tester as shown
in fig. 5
Fig 5
TSP-01
REV: 7/12
Troubleshooting Guidelines
The system may need a full day of peak sun to reset all of its circuits after installation. If the system is
installed during a period of inclement weather or late in the day, it may not operate the first night.
PROBLEM
POSSIBLE CAUSE
SOLUTION
The light does not turn
on at all.
1. The batteries are discharged.
1. Charge the batteries.
2. The batteries are bad.
2. Replace the batteries
3. The LED fixture is bad.
3. Replace the LED fixture
4. A fuse is blown.
4. Replace the fuse
5. Controller is bad.
5. Check the controller
1. The run time is incorrectly set.
1. Contact Sol for assistance.
2. The run time exceeds the
maximum run time for your
model and location.
2. Contact Sol for assistance.
3. Low battery voltage caused by
inclement weather.
3. Allow for two to three days of
consecutive sunny weather to
charge the battery pack.
4. Low battery voltage caused by
shading of the PV panel.
4. Clear tree branches and other
obstructions from the vicinity of
the PV panel.
5. The batteries are bad.
5. Replace the batteries
1. Low battery voltage caused by
inclement weather.
1. Allow for two to three days of
consecutive sunny weather to
charge the battery pack.
2. Low battery voltage caused by
shading of the PV panel.
2. Clear tree branches and other
obstructions from the vicinity of
the PV panel.
3. The batteries are bad.
3. Replace the batteries
The fuse blows
repeatedly.
1. There is a short circuit in the
wiring.
1. Check all system wiring for a short
circuit.
The battery voltage is
less than 9.0 volts.
1. One (or both, if there are two)
controller is bad.
1. Check the controller(s)
2. The batteries are bad.
2. Replace the batteries
The light does not stay
on for the expected
period of time.
The light turns on at
dusk but does not turn
on again at dawn (split
run time).
The red LED on the
controller remains
illuminated.
The light does not
operate every day.
The above table assumes the installation of the original equipment was to manufacturer’s
specifications.
TSP-01
REV: 7/12
Preventive Maintenance and Service
Preventive maintenance and service should be performed only by qualified
personnel.
Be very careful when working with batteries. Short circuits can draw thousands of
amps from the battery, and gel batteries can generate explosive gases. Observe all
precautions when working with energized circuitry.
Do not short circuit the PV array or load while it is connected to the controller. This
will damage the controller.
Tree Branch Clearing
Trim tree branches (and remove any other obstructions) in the vicinity of the solar
panel(s) once every three months.
Solar Panel Cleaning
The solar panel(s) should be cleaned once every 6+ months depending on rainfall in your
region for optimumperformance.
1. Using a non-streaking window cleaner and a soft cloth, thoroughly wipe down
the solar panel(s) to remove any dirt and grime that may have accumulated.
A plastic scraper may also be needed for removing bird droppings.
2. Dry the solar panel(s) with a soft clean cloth.
3. Repeat Steps 1 and 2, if necessary, until all dirt and grime have been removed.
Solar panels can get very hot when the sun is out. It is advisable to
clean solar panels during the early morning hours.
Fuse Replacement
Occasionally, the fuse that is used to protect the Top of Pole Mount system circuitry may
have to be replaced. Be sure that the replacement fuse matches the specifications of the
original fuse. One spare fuse has been provided with your system.
The spare fuse is attached to the battery box cover. If the fuse needs to
be replaced, be sure to also check operation of the controller.
1. Open the battery box.
2. Remove the fuse cover on the fuse holder.
3. Remove the existing fuse, insert the new fuse, and replace the fuse cover.
4. Test the system (see page19).
5. Close the battery box.
TSP-01
REV: 7/12
LED Fixture Replacement
1. Loosen the fasteners that secure the fixture to the mounting arm or pole.
2. Slide the light fixture off the arm or remove from mounting bolts if no arm.
3. Unplug the connection plugs and remove luminaire.
4. Insert the new luminaire.
The LED in the fixture is not serviceable. The entire LED fixture
assembly must be replaced.
5. Re-connect the luminaire plugs together.
6. Press TEST button on the controller until a distinct click is heard and felt. The LED
fixture will illuminate for five minutes.
7. Close the battery box, and replace or close the fixture cover.
Battery Replacement
1. Remove or open battery box cover.
2. Disconnect the battery harness from the controller.
3. Disconnect the ground wire from the battery.
4. Remove the battery/batteries from the battery box.
5. Disconnect the battery cables from each of the old battery/batteries and attach
to the new battery/batteries.
6. Place the new battery in the battery box. Connect the ground wire to the battery.
7. Re-connect the battery harness connector to the controller.
8. Replace the battery box cover.
TSP-01
REV: 7/12
Troubleshooting Flowchart
What type of fault is the system exhibiting? Choose the corresponding flowchart below.
1. Light does not come on.
2. Light turns off early
3. Light flickers
Light does not come
1
Check Harness
and fuse
0v
< 11v
Measure
Battery
GOTO Check Battery
> 11v
Press Test
OFF
State of
light
ON
GOTO Check Battery
Flickers
Fixture is disconnected or
damaged. Check harness
from EternO4 to light
fixture for short circuits
and discontinuities. Check
light fixture for water
intrusion or other visual
signs of damage.
GOTO Light Flickers
3
Fast
2
Light Flickers
Frequency of flicker
Slow
Possible large resistance in
connection to fixture.
Check harness.
Light Turns Off early
GOTO Check Battery
TSP-01
REV: 7/12
Troubleshooting Flowchart – cont.
Check Battery
Fail
Replace Batteries
Load Test
Batteries
Pass
Replace
Charge
No
Yes
Measure PV
Voltage
0V
Check PV
Harness
Is charge LED
On?
>0 V
No
Wait 2 min
Is Charge LED
ON?
Yes
Measure PV
Voltage
16–22V
Replace
Charge
Controller
< 15v
Batteries are not being adequately charged.
Clean panels, trim trees, check that all panels
are connected, Check system sizing
TSP-01
REV: 7/12
Sol Inc. | 3210 SW 42nd Avenue | Palm City, Florida 34990
www.solarlighting.com
E-mail support: [email protected]
Phone: 1.772.286.9461 | 1-800-959-1329 (US /CANADA)
Fax: 1.772.286.9616
Office Hours: Monday - Friday: 8:30am to 5:00pm (EST)
© 2012 Sol Inc. All rights reserved.