RAD 24-Volt Solar Interface Systems (SIS) User Manual
Contents
1. 1 2 iid NAME HARANI DI INN CT 1 Green LED CHARGING charging the batteries SUNSAVER 10 a Oe 2 Red LED LOAD DISCONNECT Load ee m SOLAR LOAD SEALED disconnection because battery voltage is too low N 1 Load 10 4 2 112 1116 8 5 seer Flooded 3 Terminal connections for solar modules o ot 7 ty ale attery 4 Terminal connections for batteries 73 73 5 Terminal connections for the loads 2 2 2 2 2 P 6 Jumper for selecting the battery type sealed battery or flooded battery d 1984B021 2 3 4 5 6 Figure 6 1 SunSaver Charge Controller CAUTION The solar system is delivered with two gel type batteries sealed batteries When using this type of battery the jumper 6 must NOT be removed PHCENIX CONTACT 6 1 RAD SIS 24 Solar Interface Systems Section 6 Operation 6 2 6 3 General Safety Precautions Keep this manual in a safe place e g in the enclosure for future reference It contains important information that must be observed when installing and maintaining the SunSaver charge controller and the batteries 6 2 1 Charge Controller 6 2 2 Batteries JAN WARNING The nominal voltage and the nominal current of the charge controller must no2. 1984A056 1 Straight Body 1 2 in hub Conduit End Cap 1 2 in Flexible Metallic Conduit Conduit Watertight Jacket Compression Ring Seal Compression Nut Figure 4 10 Conduit Connection at Enclosure RAD SIS 24 Solar Interface Systems Section 4 Installation Procedures pd 22 e 2 a P From Wireless Radio on Electronics Panel From Battery i Connections on Electronics s Panel From the Battery Grommet Electronics Cables Panel H a From Wireless 2 Hole Output Connection E Grommet Protective Earth on Electronics TIE Ground Terminal Panel pir Attaching Hardware aT Grommet Upper Shelf 4 Hole Grommet 7 Voltage Protector 27 1984A060 8 See Note A Lower Shelf SN N Note Any type of sealed connector can be used for external wire runs However the connector should meet To NEMA 4 requirements Antenna To Wireless To Solar Product Module Figure 4 11 Example of Shelf to Shelf Wiring PHCENIX CONTACT RAD SIS 24 Solar Interface Systems Section 4 Installation Procedures Solar Module Sol
3. Solar Module Mounting Rail E Junction Box Bw CH Eo Mounting Hole for Positioning Telescoping Struts at Desired Angle zo Typical 3 places 45 Southern Latitude Telescoping Struts m w View m m sal Lower Pole i B dd Note 1984A090 Always fasten struts together using two bolts Mounting Pole 63 5 to 76 2 mm 2 1 2 in to 3 in Schedule 40 View A A or Equivalent Figure 4 8 Setting Up the Solar Module Bracket Assembly Our example uses a setup angle of 459 PHCENIX CONTACT 4 12 14 12 13 RAD SIS 24 Solar Interface Systems Section 4 Installation Procedures Position one of the solar modules so that the mounting holes at the top of the solar module frame are aligned with the holes in the upper mounting bracket Then install and tighten the attaching hardware Position the solar module so that the mounting holes at the bottom of the solar module frame are aligned with the holes in the lower mounting bracket Then install and tighten the attaching hardware Using a compass rotate the lower pole bracket including strut assembly and solar module so that it is facing the proper geographical direction for your area Then tighten the two lower pole bracket clamps 14 Using a protractor slide the upper pole bracket up or down on the pole until the desired solar module tilt angle is achieved A Mounting Pole 63 5 mm 76 2 m
4. 6 1 General Safety Precautions 6 2 6 2 1 Charge Controller iini eem ce ween na 6 2 0 2 2 eere ere aste re tdeo eee Cry 6 2 Connecting the Charge Controller sse 6 2 Indication Elements erret tt t ede e e Lian 6 4 641 Green 455 54225045 REDE 6 4 6 4 2 Red PED ice ite ie c eiit Eos 6 4 19 11 16 6 4 ETOS 6 4 06 6 1 Battery Charging 6 5 6 6 2 Battery Voltage is Too High 6 6 6 6 3 Operating Error of the Load 6 6 6 6 4 System Goes Into Low Voltage Disconnect LVD State Too Often 6 7 Solar Charging System 6 7 6 7 1 Test the Solar Module Open Circuit Voltage 6 7 6 7 2 Test the Solar Module Short Circuit 6 8 The SunSaver charge controller is a fully automatic controller for photovoltaic systems See Figure 6 1 It provides electronic protective functions for both the controller and solar modules The batteries are charged using an algorithm for pulse width modulation with constant voltage which has been optimized for photovoltaic systems
5. 2 RAD 24 Volt Solar Interface Systems SIS User Manual For 40 60 80 and 100 watt Systems RAD SIS 24 Solar Interface Systems User Manual PHCENIX ii CONTACT INSPIRING INNOVATIONS RAD 24 Volt Solar Interface Systems SIS User Manual Provides 40 60 80 or 100 watts of solar power for wireless products RAD SOL SET 24 40 40 watt RAD SOL SET 24 60 60 watt RAD SOL SET 24 80 80 watt RAD SOL SET 24 100 100 watt Headquarters U S PHOENIX CONTACT P O Box 4100 Harrisburg PA 17111 0100 Phone 800 888 7388 717 944 1300 Fax 717 944 1625 E mail info 9 phoenixcon com Website www phoenixcon com Technical Service Phone 800 322 3225 Headquarters Canada PHOENIX CONTACT Ltd 235 Watline Avenue Mississauga Ontario 142 1P3 Phone 905 890 2820 Fax 905 890 0180 Technical Service Phone 800 890 2828 RevB Issued June 2007 1984B RAD SIS 24 Solar Interface Systems User Manual This Manual Contains Information on the Phoenix Contact RAD SOL SET 24 Solar Interface Systems SIS The information given herein is based on data believed to be reliable but Phoenix Contact Inc makes no warranties expressed or implied as to its accuracy and assumes no liability arising out of its use by others This publication is not intended to be taken as a license to operate under or recommendation to infringe upon
6. s ad 5 0 kg 11 0 Ib ems UL Listed 1984A097 1 PHCENIX CONTACT 2 3 RAD SIS 24 Solar Interface Systems Section 2 Technical Data 2 2 Dimensions Solar Modules Figure 2 1 provides dimensions for 40 60 80 and 100 watt systems Screw head Projection 2 8 mm 0 11 in Max gt gt pical 4 502 mm 19 8 A Typical Assembly Consists of Two Photovoltaic Modules 20 Watt Photovolta Module 2 required for 40 Watt System ic I4 424 mm 16 7 9 f FRONT VIEW View A A Mounting Hole Y 9 5 mm 0 38 in Dia P 5177 6 Places le Grounding Hole Eg EZ 4 1 mm 0 16 in Dia 28 48 68 2 Places 23 ne R9 ess Y 289 1 ES 3 ERR M Ege 35 20 mm ES c Junction Box 0 8 in a8 ES 1 1 vl 17 468 mm 18 4 in 1984A075 7 BACK VIEW Screw head Projection 2 8 mm 0 11 in Max Typical 6 502 mm 19 8 in Eb 17 mm 0 7 in 30 Watt Photovoltaic Module 2 required for 60 Watt System A 3 594 mm 234 in p FRONT VIEW View A A Mounting Hole 9 5 mm 0 38 in Dia 6 Places Grounding Hole 4 1 mm 0 16 in Dia 2 Places T Junction Box 17 mm 468 mm 18 4 in BACK VIEW
7. 0 7 in 54 mm 2 1 in 40 Watt Photovoltaic Module 2 required for 80 Watt System 6 526 mm 20 7 in 9 FRONT VIEW View A A Mounting Hole 9 5 mm 0 38 in Dia 3 9 9 Places 2 19 5 0 767 in gt le T 76 96 mm 152mm 031 in nu 493i Y n 1 v 18844077 1 ke 613 mm 24 133 in ers 28 9 mm 1 142 in BACK VIEW 552 5 5 54 gt 50 Watt _ 36 99 mm Photovoltaic 3 1417 in amp A Module 2 required for 100 Watt System 8 View 1 Mounting Hole 9 5 mm 0 38 in Dia 9 Places A 5 s 5 8 19 5 0 767 in gt T P 1 76 96 mm 3 031 152 74 Eu in 613mm 24 13 in BACK VIEW 19844083 Figure 2 1 Solar Module Dimensions 2 4 PHCENIX CONTACT 2 3 RAD SIS 24 Solar Interface Systems Dimensions SIS Enclosure Figure 2 2 provides dimensions for the SIS enclosure 1984A062 Figure 2 2 Enclosure Dimensions Section 2 Technical Data PHCENIX CONTACT RAD SIS 24 Solar Interface Systems Section 2 Technical Data
8. 10 OHS 1 130 Wireless Radio Upper Shelf RS422 RS485 Serial Devices 5 26 mm 10 AWG Red 5 26 10 AWG Black 5 26 mm 10 AWG Black 1 1244 Lower Shelf 3 31 mm 12 AWG White Protective z Earth PE 3 31 12 AWG Red Ground To Solar Module Figure 7 2 SIS Enclosure Electronics Panel 1984A052 4 PHCENIX CONTACT RAD SIS 24 Solar Interface Systems Section 7 Ordering Data Table 7 2 Parts List for Figure 7 2 Description Order No 10 11 12 13 Universal end bracket end clamp 1 screw Charge controller Vertical cover holder for protective cover Item 5 Universal end bracket end clamp 3 screws used with cover holder Item 3 U shaped protective cover clear plastic cut to 69 7 mm 2 75 in Cartridge fuse terminal block MAINS PLUGTRAB header base unit accepts plug Item 8 MAINS PLUGTRAB plug 24AC used with header Item 7 Terminal block feed through 1 level Terminal block feed through 3 level with equipotential bonding Protective
9. entrer ro 1 1 1 4 X Current Documentation on the 1 1 2 15 Product Description 22844 a ri 1 2 A Components Assemblies 1 2 1 6 System e a a de 1 2 1 7 Systemi Power Flow 1 2 1 8 Unpacking and Inspection cierre EE e tlc 1 5 1 1 General Thank you for your purchase of this Phoenix Contact Solar Interface System SIS Phoenix Contact Solar Interface Systems are designed to provide reliable remote power for your wireless products throughout the year 1 2 Safety Electricity even at low voltages can be dangerous For your protection Phoenix Contact recommends that installation maintenance and repairs be performed by licensed or qualified personnel in strict accordance with applicable health safety building and electrical codes In order to guarantee the safe use of your device we recommend that you read this manual carefully 1 3 About this Manual This manual contains the information necessary to understand install operate and order parts for Phoenix Contact Solar Interface Systems SIS and associated components The table of contents at the front of this manual provides a paragraph by paragraph breakdown of the subject matter covered in each section For your protecti
10. PHCENIX CONTACT SECTION 3 SIS Location Considerations Section 3 Contents 3 1 Solar Insolation Values Worldwide 4 200 00 000 3 1 3 2 Checking Sun Path for Obstructions 3 1 3 3 Solar Module 3 3 3 4 Solar Module Tilt Angle ort E e Er e tent eie 3 4 3 1 Solar Insolation Values Worldwide It is important that solar energy provided by the SIS is sufficient to meet your load require ments Figure 3 1 is a map showing average solar insolation values around the world The map values stated are worse case and in units of kilowatt hours per square meter For specific solar insolation values applicable to your area or for help with calculating daily load require ments and appropriate array size call Phoenix Contact Technical Service at 800 322 3225 3 2 Checking Sun Path for Obstructions CAUTION The solar array must be located in an open area that will receive unobstructed sun during the entire day through out the year After determining the general location for your Solar Interface System check sun path at that location for obstructions 1 On a clear day stand at the exact spot where the Solar Interface System is to be installed Note In the winter the sun will rise to the south of due east and set to the south of due west Likewise in the summer the sun will rise to the north of due east and set to the north of due west
11. Grounding should be in accordance with the 2002 Na tional Electric Code Refer to articles 690 and 250 of the NEC 1 Attach a 5 26 mm 10 AWG wire to the solar module as shown in Figure 4 17 Then run the wire to a suitable earth ground 1 52 ar a N View Looking at Underside of Solar Module Supplied with Solar Module Figure 4 17 Grounding of Solar Module PHCENIX CONTACT 4 20 4 13 4 14 4 15 RAD SIS 24 Solar Interface Systems Section 4 Installation Procedures Installing the Antenna Install the antenna per the antenna mounting instructions Phoenix Contact offers a variety of antenna solutions See the title page of this manual for contact information Note The antenna cable plugs into the surge protector in the SIS enclosure Therefore when installing the antenna make sure that the enclosure end of the antenna cable has an industry standard N type male connector Installing Flexible Conduit Mounting Brackets Your SIS package contains three flexible conduit mounting brackets See Figure 4 18 To meet specification the distance between brackets should be 0 914 m 3 ft or less See Figure 4 1 for approximate placement of the mounting brackets 3 8 914 27 Sty M Clan Sh Flex Conduit Bg Mounting Bracket A No 10 4 5 Pan head Pt Self tapping Screw EN Length as required Far lt e 2 Ay V M 3 DEL Tap Drill
12. 1984A094 1 Table 2 7 RAD SOL PAN 12 30 Solar Module Specifications 60 watt System Total power output at peak sun eu EET 594 mm 23 4 in MGE Neu tue 502 mm 19 8 in 55 dE 50 mm 1 97 in eR 3 9 8 5 Ib UL Listed 1984A095 1 Table 2 8 RAD SOL PAN 12 40 Solar Module Specifications 80 watt System Total power output at peak sun bove uc c c LS ML 526 mm 20 7 in 6522 mm 25 7 in EP 36 mm 1 42 in Weight KG Ib ss dicetur nint ht ap REDE mete 4 5 kg 9 9 Ib Genrtitication ApproVal p mod Rad ep d unused UL Listed Lll 1984A096 1 Table 2 9 RAD SOL PAN 12 50 Solar Module Specifications 100 watt System Total power output at peak sun icm 16 7V AUS 3 00 Mm 50 W Dimensions 158 639 25 2 Width 222 652 25 7 658 an aa 54 2 1 Weight
13. 57 moea SOLAR BATTERY LOAD SEALED Solar In lire for m ala me Bes ee Ses Openers Lals VC MORNINGSTAR y 1984B021 3 Jumper Installed for sealed batteries between terminal no 5 and the SEALED OR FLOODED SELECT terminal Figure 6 2 SunSaver Charge Controller Terminal Number Identification and Jumper The six connection terminals of the charge controller are labeled on the controller and must be connected as described in the following steps and in accordance with the wiring diagram shown in Section 4 Figure 4 2 Figure 6 2 identifies the SunSaver charge controller s terminal numbers and the jumper location CAUTION Make sure that live wires do NOT touch the metal housing of the charge controller 1 Connect the batteries to terminals 1 and 2 under the heading BATTERY 2 Connect the solar modules to terminals 3 and 4 under the heading SOLAR Note that the green LED CHARGING will light up as soon as the solar modules generate current 3 Connect the loads to terminals 5 and 6 under the heading LOADS Note that if the red LED LOAD DISCONNECT is on the battery voltage is too low In this case recharge the batteries prior to starting the system Note When using sealedbatteries make sure the jumper is installed between terminal 5 under the heading LOAD and the terminal labeled SEALED OR FLOODED SELECT Re
14. See Figure 4 1 for an example configuration In addition the pole must accommodate an antenna and the SIS enclosure Dimensions for the solar module and enclosure can be found in Section 2 of this manual 4 6 Installing the SIS Enclosure The white powder coated aluminum unit is designed to meet NEMA and 4 stan dards Figure 4 2 is a wiring diagram of the various components that make up the SIS The mounting system allows the enclosure to be mounted on a pole or to a wall See Figure 4 3 Note The SIS enclosure has two mounting flanges one at the top of the enclosure and one at the bottom of the enclosure How ever U bolts or lag bolts have not been provided with the SIS for attaching the enclosure Therefore if U bolts or lag bolts are needed to attach the enclosure they will have to be obtained from your local hardware store PHCENIX CONTACT m RAD SIS 24 Solar Interface Systems Section 4 Installation Procedures Solar Module Antenna Pole Bracket Assembly 2 Solar Module Junction Box Antenna Cable Wire Wrap UV resistant or Stainless Steel Clamp 1 2 in 1 2 in peed Conduit Conduit Coupling Connectof Flexible Conduit Mounting Bracket Wire Wrap UV resistant or Stainless Steel Clamp As required 77 4 6 AWG Wire Lug for Grounding Enclosure Surge Voltage Protection Adapter for An
15. 1 Enclosure aluminum prewired with electronics RAD SOL ENCL 24V 1 28 85 58 2 2 Battery 12 volt gel valve regulated sealed 40 Ah RAD SOL BAT 12 40 2 56 06 945 2 Battery 12 volt gel valve regulated sealed 70 RAD SOL BAT 12 70 2 56 06 94 6 2 Battery 12 volt gel valve regulated sealed 84 Ah RAD SOL BAT 12 84 2 56 06 94 7 3 Coax cable surge protection adapter for radio antenna CN UB 280DC BB 1 28 18 850 4 Solar module 20 W RAD SOL PAN 12 20 2 See Note 4 Solar module 30 W RAD SOL PAN 12 30 2 See Note 4 Solar module 40 W RAD SOL PAN 12 40 2 28 85 553 4 Solar module 50 W RAD SOL PAN 12 50 2 28 85 45 6 Additional components available upon request Note Panel is available through special order Contact your sales representative 1984B072 PHCENIX CONTACT 13 31 6 AWG Electronics Panel RAD SIS 24 Solar Interface Systems Section 7 Ordering Data SEALED OR PV BATTERY LOAD FLOODED Q SELECT 9 15 S F
16. Next check that load operations are functioning properly Install fuse No 1 Solar Module See Figure 5 1 Once fuse No 1 is installed you should see the green charging LED on the charge load controller light up See Figure 5 2 Furthermore depending on sunlight intensity you should see the battery voltage start to rise Your solar array output will depend directly on sunlight intensity Only during the peak sun hours on a very clear day will you see the full rated current from the array When shutting down the system it is always best to remove fuse No 1 Solar Module first Refer to Figure 5 1 Then remove fuse 2 Battery and fuse No 3 Load This will remove the high voltage charging source from the circuit Normally you do not want to have the solar module array active fuse installed without the battery circuit activated Charging LED Green mcm T EC CONTROLLER 9 e VU di TEMP Sense T ir latin SEALED Remove SOLAR BATTERY LOAD OH s z 827 mia 59000 Bat Lala 5 1984A021 2 Figure 5 2 Charge Load Controller Charging LED 5 2 PHCENIX CONTACT 6 1 6 2 6 3 6 4 6 5 6 6 6 7 6 1 General SECTION 6 Charge Controller Section 6 Contents GONG
17. Section 4 Installation Procedures 6 AWG Protective Earth PE 7 SS Conductive Ground Wire Not supplied 522 p bo Wire Lug Figure 4 4 Enclosure Earth Ground Connection 1984A035 3 Copper tin 1 4 in Mounting Screws 2 PHCENIX CONTACT RAD SIS 24 Solar Interface Systems Section 4 Installation Procedures 4 8 Removing Fuses from Electronics Panel WARNING For your protection and protection of the equipment when making solar module battery or load connections always make sure that the SIS fuses are removed from the fuse terminal blocks located on the electronics panel of the enclosure Prior to installing the antenna solar module or other equipment remove the three fuses from the fuse terminal blocks on the SIS electronics panel See Figure 4 5 Aluminum _ Enclosure Electronics Panel No 1 Fuse Holder Solar Module No 2 Fuse Holder Battery No 3 Fuse Holder Load U Shaped Protective Cover Holder 5 x 20 Cartridge Fuse 125 V 10A Typical Screw Cap 27 Fuse Holder pU Typical 1984A063 1 Attaching Screw 4 places E 5 Figure 4 5 Solar Module Battery and Load Fuses PHCENIX CONTACT RAD SIS 24 Solar Interface Syste
18. See Figure 4 7 View A Secure the radio in place by installing an end bracket on either side of the radio Wire the radio as directed by the installation instructions that came with the radio Once wired plug the antenna adapter connector into the radio Remove the NEMA hole seal from one of the innermost holes in the upper shelf See View B Slide a hole grommet over the antenna adapter cable and install it into the hole Then run the adapter cable down to the surge protector on the lower shelf See View C Screw the antenna adapter connector onto the surge protector Right angle Plug Connection NS 35 Mounting Rails View B Remove Install Hole Seal Grommet SIN 74 Antenna Adapter NEMA Cable Hole Seal 5 Hole Grommet Antenna Adapter Cable Upper Shelf 5 Washer 19844070 Nut Surge Voltage Protection Adapter To Antenna Figure 4 7 Installing Wireless Radio and Antenna Adapter PHCENIX CONTACT RAD SIS 24 Solar Interface Systems Section 4 Installation Procedures 4 11 Installing the Solar Modules Notes A 4 57 m 15 ft length of flexible conduit and two 6 09 m 20 ft lengths of 3 31 mm 12 AWG wire one red and one white were supplied with the system If the solar module is to be installed higher than 2 44 m 8 ft above the enclosure y
19. damage If after some charging time the batteries reach 40 to 50 of their normal power the load is automatically reconnected and the red LED will go OFF Operation Errors With all fuses installed the system should be operating normally During normal operation depending on weather conditions the battery voltage will vary from approximately 23 0 to 28 6 volts If the battery voltage falls below 23 0 volts the controller will go into LVD Low Voltage Disconnect and open the load connections It will then let the batteries recharge up to approximately 25 2 volts before reconnecting the loads to the battery During normal operation the battery voltage should not change rapidly During the day and after a night of discharge the voltage will climb slowly up to the charge regulation set point Depending on the present and previous sunlight conditions the batteries may or may not reach the full charge regulation set point during the day JAN WARNING Electricity even at low voltages can be very dangerous For your protection Phoenix Contact recommends that all electrical installations maintenance and repairs be performed only by licensed and or properly qualified individuals and in strict accordance with applicable health safety building and electrical codes CAUTION A battery may cause serious damage when short cir cuited Observe all precautions when working on live circuits The SunSaver charge controller does not
20. 00 in Weight kolb iit oct tt ementi epa ii iem eut ein 19 1 kg 42 Ib 1984A099 Table 2 5 RAD SOL BAT 12 84 Solar Battery Specifications 80 100 watt System JV DO rer ceteros valve regulated lead acid deep cycle gelled electrolyte cte lead calcium 2 2 2 E 12V Ampere Hour Ah capacity 84 Ah at a 100 hour discharge rate Dimensions mm in 276 9 10 9 Width 172 7 6 8 E IU T 251 5 mm 9 9 in Weight Kg 24 26 kg 53 5 Ib 1984B064 RAD SIS 24 Solar Interface Systems Section 2 Technical Data Table 2 6 RAD SOL PAN 12 20 Solar Module Specifications 40 watt System Total power output at peak sun ioter ree 16 8V 1 19A Watts ctae 18W Dimensions mm in E apre 424 mm 16 7 in etes 502 mm 19 8 in WPICKMOSS 50 1 97 Weight 10 16 3 kg 6 5 Ib Gertitication ADDroVal cent Ep tov cates sin UL Listed
21. 2 Using a compass as a guide look toward the horizon due east of your position Then PHCENIX CONTACT 6 2 8 0 E RAD SIS 24 Solar Interface Systems Section 3 Location Considerations X p 12 PHCENIX CONTACT Figure 3 1 Average Daily Solar Insolation Values 5 JeJOS 2522 9S10M 3 2 RAD SIS 24 Solar Interface Systems Section 4 Location Considerations turn and look to the horizon due west of your position See Figure 3 2 3 Make sure there are no obstructions that will shade your Solar Interface System between 9 00 am and 4 00 pm during the summer and winter sun paths Also consider shading from future growth or buildings N Figure 3 2 Checking Summer and Winter Sun Paths for Obstructions 1984A069 3 3 3 Solar Module Orientation If your site is located in the northern hemisphere face the solar module true south See Figure 3 3 Similarly if your site is located in the southern hemisphere face the solar module true north Solar Module gt gt 1984 071 Southern Northern Hemisphere Hemisphere Figure 3 3 Solar Module Orientation PHCENIX CONTACT RAD SIS 24 Solar Interface Systems Section 3 Location Considerations 3 4 Solar Module Tilt Angle Once the solar module has been attached to the structure you will need to adjust the tilt angle of the module to obtain opti
22. 24 Solar Interface Systems Section 4 Installation Procedures Wall Mounted Enclosure Pole Mounted Enclosure Note Hardware items mounting configurations shown in this illustration represent only some of the possibilities that you can use to mount the enclosure If using a mounting configuration that is different than Surface Mount that shown make sure hardware is of sufficient size Application 25 and quality to support the enclosure Through Hole Mount Application Description 1 Hex head lag bolt 1 2 in SS length as required 2 Lock washer 1 2 in SS 3 Flat washer 1 2 in SS 1 75 in OD 0 1000 in thickness 4 Hex head machine bolt 1 2 12 NC SS length as required 5 Hex nut 1 2 12 NC SS 6 Pipe 1 1 2 in Schedule 40 2 875 OD 7 U bolt 1 2 12 NC SS 4 50 in long 3 00 in ID 1984A061 Figure 4 3 Installing SIS Enclosure Earth Ground 4 7 System Grounding The negative for your SIS must be connected to earth ground On the bottom lower shelf of the enclosure you will find a grounding terminal See Figure 4 4 All SIS chassis grounds are channeled through this terminal This system should be grounded per the 2002 National Electric Code Refer to Articles 690 and 250 of the NEC We recommend using a 13 30 mm 6 AWG grounding cable not supplied for making the earth ground connection PHCENIX CONTACT RAD SIS 24 Solar Interface Systems
23. Earth PE ground terminal block Antenna adapter right angle MCX N M Coax cable surge voltage protection adapter E NS 35 N RAD SOL CHG 24 10 VAH E UK A U 69 7 mm 19 UK10 DREHSI 5x20 PT BE FM UK5N MINI PS 12 24DC 24DC 1 DIKD 1 5 PV USLKG 5 RAD CON MCX 90 N SS CN UB 280DC BB 08 00 88 6 28 85 44 3 1201468 1201442 50 21 11 0 M 3005109 2839282 2839318 30 04362 27 15 092 04 41 50 4 28 85 207 28 18 850 Additional components available upon request 1984B053 1 PHCENIX CONTACT SECTION 8 Warranty Repair Information Section 8 Contents 8 1 Solar Interface System SIS Limited 8 1 8 1 Solar Interface System SIS Limited Warranty Phoenix Contact Inc warrants its Solar Interface System products against defects in materi als and workmanship under normal use and service for a period of 12 months from the date of purchase During the warranty period products determined by Phoenix Contact to be defective shall at the option of Phoenix Contact either be repaired at a location authorized by Phoenix Contact and returned free of charges for parts labor or shipping or replaced with an equivalent product Defective parts replaced by Phoenix Contact shall become the property of Phoenix Contact This Limited Warranty does not cover on site repair of products Defective prod ucts must be returned to Phoenix Contact to be repaired or replaced Phoenix Contact
24. If the system is going into LVD too often your daily load power draw may have exceeded the solar system output a Recalculate your present load requirement If the recalculation shows that the solar system is properly sized batteries with a higher capacity or a larger solar module can be used Please contact Phoenix Contact Technical Support if the calculation shows that the dimensions of your solar system are not sufficient Here you will learn whether it is possible to expand the components in order to increase the output power of your solar system c Your sealed gel cell batteries should last between 2 to 4 years depending on the regular depth of discharge and temperature experienced A symptom of diminished battery capacity is the load working during the day but not at night In this case the battery voltage drops down to the LVD or load disconnect set point at night and then rises up out of LVD in the day with the solar charging current You will see evidence of this during the day if you turn the solar module on and off If the voltage falls rapidly with the solar module off and then rises rapidly when turned on it is time to replace the batteries Note Spare batteries are available from Phoenix Contact See Section 7 Ordering Data 6 7 Solar Charging System 6 7 1 During normal operation the available current from the solar module s will be fed through the controller directly to the batteries until the Charge Termina
25. No 27 814 Du 3 6 mm Hole Cla Sn 1984A032 3 Ps Figure 4 18 Flexible Conduit Mounting Bracket Installing the Battery CAUTION Use caution when making battery connections Your system has two 12 volt batteries Battery to battery inter connect cables are connected in series SIS batteries are shipped fully charged However if batteries have been in storage for a long period of time the charge in the battery may be weakened We recommend that you always check the resting open circuit voltage of the battery to avoid problems If voltage reads below 12 4 volts recharge the batteries before they are installed Always use a well regulated constant voltage charger Set charger no higher than 13 8 volts at a charge rate of no more than 10 amps per battery PHCENIX CONTACT 223 RAD SIS 24 Solar Interface Systems Section 4 Installation Procedures JAN WARNING Solar modules can produce hazardous voltages when ever exposed to sunlight even when not in full sunlight Therefore when working with PV modules or making wiring connections during the daytime cover solar mod ules with an opaque material JAN WARNING For your protection and protection of the equipmentwhen making solar module battery or load connections always make sure that the SIS fuses are removed from the fuse terminal blocks located on the electronics panel of the enclosure For safety cover the solar module during installation and wiring of the batte
26. PHCENIX CONTACT m RAD SIS 24 Solar Interface Systems Section 4 Installation Procedures 4 1 4 2 4 3 General This section provides the information necessary to install the Phoenix Contact Solar Inter face System SIS Before installing the SIS you should become familiar with SIS compo nent names as defined in Section 1 and solar module orientation requirements outlined in Section 2 Safety Precautions Before attempting to install and wire this SIS please read all instructions carefully We recommend placing this manual in the SIS enclosure for future reference JAN WARNING Solar modules can produce hazardous voltages when ever exposed to sunlight even when not in full sunlight Therefore when working with PV modules or making wiring connections during the daytime cover solar mod ules with an opaque material N WARNING For your protection and protection of the equipmentwhen making solar module battery or load connections always make sure that the SIS fuses are removed from fuse terminal blocks located on the electronics panel of the enclosure J N WARNING To prevent short circuits and damage to the equipment when installing the battery 1 Exercise extra caution when placing the battery into the enclosure 2 Always double check your positive and negative polarity before connecting the battery cables Always use insulated tools when working on electrical equipment Tools and Equipment No
27. SIS 24 Solar Interface Systems Section 4 Installation Procedures Item inti escription No 1 Universal end bracket end clamp 1 screw 2 Charge controller 3 Vertical holder for protective cover Item 5 4 Universal end bracket end clamp 3 screws used with cover holder Item 3 5 U shaped protective cover clear plastic cut to 69 7 mm 2 75 in 6 Cartridge fuse terminal block 7 MAINS PLUGTRAB header base unit accepts plug Item 8 8 MAINS PLUGTRAB plug 24AC used with header Item 7 9 Terminal block feed through 1 level 10 Terminal block feed through 3 level with equipotential bonding 11 Protective Earth ground terminal block 12 Antenna Adapter MCX N M 13 Coax cable surge voltage protection adapter with N connector Battery 12V gel cell sealed X2 Wireless Radio Upper Shelf 1 RS422 RS485 Serial Devices 5 26 10 AWG Black 5 26 mm 10 AWG Black aa Lower Shelf a I 3 31 mm 12 AWG White Protective Earth PE 3 31 12 AWG Red Ground Solar Module 1984A052 3 Figure 4 2 SIS Configuration Wiring Diagram PHCENIX CONTACT RAD SIS
28. any patents PHCENIX iv CONTACT RAD SIS 24 Solar Interface Systems Table of Contents User Manual Table of Contents SECTION 1 Introduction 14 IEEE 1 3 About this Manual 1 4 Current Documentation on the 1 5 Product DescrIptlOr scooter ree reges A Components and Assemblies 1 6 System 1 7 System Power FIOW 1 8 Unpacking 2 Technical Data RT 2 2 Dimensions Solar Modules 2 3 Dimensions SIS Enclosure 3 SIS Location Considerations 31 Solar Insolation Values Worldwide 3 2 Checking Sun Path for Obstructions 3 3 Solar Module Orientation 3 4 Solar Module Tilt Angle SECTION 4 Installation Procedures retenir tena 4 2 Safety Precautions 4 3 Tools and Equipment 44 Additional Material Considerations 4 5 Mounting 4 6 Installing
29. ar Module Junction Box Solar Module Conduit Pole Mount 1 2 in Flexible Bracket Assembly 1 12 AWG Sealing 2 Position Cord Grip Straight Conduit Conduit Compression Compression Wire Nut Wire Seal Connector Connector End Cap Ring Seal Nut Body NPT 1984B057 2 Figure 4 12 Conduit Connection at Solar Module PHCENIX CONTACT RAD SIS 24 Solar Interface Systems Section 4 Installation Procedures 4 12 2 Wiring the Solar Module Junction Box JAN WARNING Solar modules can produce hazardous voltages when ever exposed to sunlight even when not in full sunlight Therefore when working with PV modules or making wiring connections during the daytime cover solar mod ules with an opaque material 1 For safety cover the solar module during installation and wiring to reduce the danger of arcing or shock 2 Cutthe wires to the solar module junction box to desired length Then strip the wires as shown in Figure 4 13 Strip Length 7 6 5 8 5 12 AWG Wire 1984A041 Figure 4 13 Wire Size and Strip Length Requirements 3 Remove the screws from the cover of the junction box and open the cover See Figure 4 14 Note The junction box has two hole positions for installing watertight conduit fittings Straight through fittings have been supplied with your SIS These fittings will also act as strain reliefs for the conduit Cover Base Cover Locking Screw Bypass Di
30. c et ds 10mA Operating itr t te 40 to 85 C Wire Size tr cee ee ol 10 AWG 5 2 mm 1984B065 Table 2 3 RAD SOL BAT 12 40 Solar Battery Specifications 40 watt System uc EE valve regulated lead acid deep cycle gelled electrolyte lead calcium Nominal Voltage eet 12V Ampere Hour Ah Capacity 48 Ah at a 100 hour discharge rate Dimensions mm in 8 197 0 7 75 Wid EN rae rier errr 169 0 6 63 Height 175 0 mm 6 88 in Weight mE 14 5 kg 32 5 Ib 198BA098 Table 2 4 RAD SOL BAT 12 70 Solar Battery Specifications 60 watt System valve regulated lead acid deep cycle gelled electrolyte PMN lead calcium Nominal valtage ecce E R ER 12V Ampere Hour Ah capacity 70 Ah at a 100 hour discharge rate Dimensions mm in 259 0 10 19 169 0 6 63 e Height 178 0 7
31. ch attach the cable to the battery s positive post Check to make sure that the black cable is attached to the negative post and the red cable is attached to the positive post 4 22 PHCENIX CONTACT RAD SIS 24 Solar Interface Systems Section 4 Installation Procedures Rubber Padding for Battery Red Black Cable Cable 1 4 in Lock 5 Washer See Detail A 1 4 in Lock Washer ex 1 4 in Flat Washer 7 Ring Terminal See Detail A 1984A091 1 Figure 4 20 Installing the Batteries PHCENIX CONTACT 4 23 RAD SIS 24 Solar Interface Systems Section 4 Installation Procedures 4 16 Final Checkout Before installing fuses to energize your system check the following parameters 1 Check your solar module input wiring for proper open circuit voltage and polarity 2 Check your battery wiring for proper voltage and polarity 3 Check polarity of wiring to loads CAUTION To avoid damage to the electronic components during start up and shutdown modes fuses must be removed and reinstalled in the proper sequence Refer to Section 5 of this manual for the proper start up and shutdown procedures 4 Once your battery connections have been made and you have checked your polarity careful
32. contain fuses circuit breakers or parts that can be maintained by the user 6 4 PHCENIX CONTACT RAD SIS 24 Solar Interface Systems Section 6 Operation 6 6 1 Battery Not Charging The following procedure lists the basic steps for removing an error 1 Check if green CHARGING LED is ON During the day the green LED must be ON 2 Check if the correct battery type sealed or flooded has been selected Refer to Paragraph 6 3 for Connecting the Charge Controller 3 Check that all wires have been connected properly to the terminals Check all terminals for correct polarity or 5 Measure the open circuit voltage of the solar module as described under Paragraph 6 7 Solar Charging System WARNING Remove the solar module fuse See Figure 6 3 Then disconnect the solar modules from the load controller Electronics Panel No 1 Fuse Solar Module No 2 Fuse E Wh 19844093 Figure 6 3 Solar Module Battery and Load Fuses Note As solar isolation varies around the world different permissable loads are available 6 Measure load to see if it exceeds the maximum solar isolation power available to the system 7 Check for voltage drops between the charge controller and battery A high voltage drop would cause inadequate charging of the batteries PHCENIX CONTACT RAD SIS 24 Solar Interface Systems Section 6 Operatio
33. d Control Functions 1 8 Unpacking and Inspection SIS components were inspected before shipment After unpacking inspect each component for possible damage that may have occurred during shipping Items supplied with your Solar Interface System are shown in Figure 1 1 If items are missing or damaged if you have any questions please call Phoenix Contact Technical Service at 1 800 322 3225 PHCENIX CONTACT 1 5 RAD SIS 24 Solar Interface Systems Section 1 Introduction SECTION 2 Technical Data Section 2 Contents 2 1 lec 2 1 2 2 Dimensions Solar Modules 4 840 8 0 00 0001 2 4 2 3 Dimensions SIS Enclosure 0 2 5 2 1 General This section provides technical information about the components that were supplied with your Solar Interface System SIS You should become familiar with the specifications for the items listed in Tables 2 1 thru 2 9 Figures 2 1 and 2 2 provide the basic dimensions for the solar modules and the SIS enclosure Phoenix Contact Solar Interface System SIS Solar charge controller Solar batteries Solar modules Phoenix Contact reserves the right to make any necessary changes that advances the technology and performance of the product Table 2 1 Phoenix Contact Solar In
34. d connect the meter probes to the PV and PV terminals of the solar module You should be reading the maximum Short Circuit Current for the given sunlight intensity on the solar module Short circuit current varies with sunlight intensity You will probably see less than the full rated amps most of the time Estimate the given sunlight intensity and correlate it with the current reading Refer to Section 2 for the voltage and current specifica tions of your modules If you suspect a problem contact Technical Support at 1 800 322 3225 6 8 SECTION 7 Ordering Data Section 7 Contents 7 1 EIE 7 1 7 1 This section provides the information necessary to identify the various components of your solar interface system and to order replacement parts 1984B081 Figure 7 1 SIS Components PHCENIX CONTACT T RAD SIS 24 Solar Interface Systems Section 7 Ordering Data Table 7 1 Parts List for Figure 7 1 Description Solar interface system 24 volt 40 watt RAD SOL SET 24 40 1 56 05 94 1 Solar interface system 24 volt 60 watt RAD SOL SET 24 60 1 56 05 942 Solar interface system 24 volt 80 watt RAD SOL SET 24 80 1 56 06 28 5 Solar interface system 24 volt 100 watt RAD SOL SET 24 100 1 56 05 943
35. fer to Figure 6 2 CAUTION The solar system is delivered with two gel type batteries sealed batteries When using this type of battery the jumper must NOT be removed Do connectany wires from SOLAR BATTERY or LOAD terminals to the SEALED OR FLODED SE LECT terminal 4 Ground the negative pole of the battery to ensure efficient grounding of the solar system PHCENIX CONTACT 6 3 RAD SIS 24 Solar Interface Systems Section 6 Operation 6 4 6 5 6 6 Indication Elements 6 4 1 6 4 2 Green LED The green LED CHARGING will come ON as soon as sunlight is available for charging the battery The LED will be OFF in the dark The SunSaver charge controller charges the batteries using a pulse width modulation method Therefore the battery is always provided with a certain amount of power Although the charging current is very low when the batteries reach their fully charged state the green LED is ON during daylight This indicates proper operation of the charge controller Red LED SunSaver models with an automatic load disconnect LVD Low Voltage Disconnect function are provided with a red LOAD DISCONNECT LED As soon as the charging state of the batteries falls below the low voltage disconnect set point the load is disconnected and the red LED will come ON This indicates that the controller has disconnected the load to protect the batteries from deep discharging and possible
36. harge Controller sse 6 2 6 4 Indication 6 4 641 orit eret 6 4 042 iet sb ae erent cela pide eae 6 4 6 5 hace oie 6 4 66 gc 6 4 6 6 1 Battery Not Charging ee rnt etr rtr tea nbn un xe uh ante 6 5 6 6 2 Battery Voltage is Too High 6 6 6 6 3 Operating Error of the Load 6 6 6 6 4 System Goes Into Low Voltage Disconnect LVD State Too Often 6 7 6 7 Solar Charging System 6 7 6 7 1 Test the Solar Module Open Circuit Voltage 6 7 6 7 2 Test the Solar Module Short Circuit Current 6 8 PHOENIX CONTACT RAD SIS 24 Solar Interface Systems User Manual Table of Contents Table of Contents SECTION 7 Ordering Data 7 1 m 7 1 SECTION 8 Warranty Repair Information 8 14 Solar Interface System SIS Limited 8 1 PHCENIX CONTACT vii RAD SIS 24 Solar Interface Systems User Manual Table of Contents PHCENIX CONTACT viii 1 Introduction Section 1 Contents Wel er 1 1 1 2 1 1 1 3 JAboutthis
37. is not responsible for the operation damage availability or loss of use of the customer supplied equipment being used with a Solar Interface System SIS This warranty is void under the following circumstances 1 Abnormal use of the product or use in violation of the instructions provided in this manual 2 Improper and or unauthorized installation or repair of system components PHCENIX CONTACT 8 1 RAD SIS 24 Solar Interface Systems Section 8 Warranty Repair Information 8 2 Solar Interface Systems User Manual The information given herein is based data believed to be reliable but Phoenix Contact makes no warranties expressed or implied as to its accuracy and assumes no liability arising out of its use by others This publication is not to be taken as a license to operate under or recommendation to infringe any patent Headquarters U S PHOENIX CONTACT P O Box 4100 Harrisburg PA 17111 0100 Phone 800 888 7388 717 944 1300 Fax 717 944 1625 E mail info phoenixcon com Website www phoenixcon com Technical Service Phone 800 322 3225 Headquarters Canada PHOENIX CONTACT Ltd 235 Watline Avenue Mississauga Ontario 142 1P3 Phone 905 890 2820 Fax 905 890 0180 Technical Service Phone 800 890 2828 PHCENIX CONTACT
38. ly energize the system by installing the three fuses as described in Section 5 of this manual PHCENIX CONTACT 4 24 5 Start up amp Shutdown Procedures Section 5 Contents 5 1 CIS c 5 1 5 2 Shutdown 51 Start Up Once the solar module battery and load connections have been made and you have checked your polarity carefully energize the system by installing the three fuses in the order described in the following paragraphs See Figure 5 1 Di Aluminum lt Enclosure Electronics Panel No 1 Fuse Holder Solar Module No 2 Fuse Holder Battery No 3 Fuse Holder Load Cover _ Holder U Shaped Protective Cover 2 5 x 20 Cartridge 125 10 Screw Cap Fuse Holder Typical Attaching Screw 4 places Figure 5 1 Fuses for Solar Module Battery Load PHCENIX CONTACT 5 1 RAD SIS 24 Solar Interface Systems Section 5 Start up amp Shutdown Procedures 5 2 Shutdown 1 1 Install fuse No 2 Battery See Figure 5 1 This will connect the battery to the charge load controller Check battery voltage at the controller terminals 1 and 2 under BAT TERY Install fuse No 3 Load See Figure 5 1 This applies DC battery voltage to the charge load controller terminals 5 and 6 under LOAD
39. m 2 1 2 in to Schedule 40 or Equivalent Upper Pole 77 i Bracket Stainless Steel b Band Clamp D Typical 4 places Solar Module Two 40 watt panels Strut Assembly Consists of 2 struts Lower Pole Bracket 800 0 min 37 5 in Solar Module Mounting Rail L 6 Strut Assembly LUC 2 Consists of 2 struts 2 296527 le 5 2 9 5 0 38 Dia s Holes Typical View A A 7 2 J 1984A077 12 Figure 4 9 Installing the Solar Module Bracket Assembly PHCENIX CONTACT 4 13 RAD SIS 24 Solar Interface Systems Section 4 Installation Procedures 4 12 Wiring the Enclosure JAN WARNING Solar modules can produce hazardous voltages when ever exposed to sunlight even when not in full sunlight Therefore when working with PV modules or making wiring connections during the daytime cover solar mod ules with an opaque material For safety cover the solar module during installation and wiring to reduce the danger of arcing or shock Obtain the two 6 09 m 20 ft 3 31 mm 12 AWG wires red and white flexible conduit 4 57 m 15ft two 12 7 mm 1 2 in conduit connectors 12 7 mm 1 2 in coupling and 12 7 mm 1 2 in cord grip connector supplied with your SIS 4 12 1 Enclosure Wiring 1 2 11 12 Check that both ends of the conduit are cut straight and are not bent If nece
40. module mounting bracket with stainless steel hardware NEMA 4 rugged aluminum outdoor equipment enclosure with separate NEMA battery compartment white powder coated finish lockable Sealed gel cell deep cycle batteries Pre wired and installed electronics panel with charge load controller fuses and labeled terminal blocks 16 System Topology Each SIS is a stand alone DC solar power system that uses photovoltaic modules to charge a sealed deep cycle battery Power from the battery is then used to power your equipment A typical SIS installation is shown in Figure 1 2 1 7 System Power Flow Power flow is controlled by a charge controller located on the electronics panel inside the enclosure A diagram of the SIS power flow is shown in Figure 1 3 1 2 RAD SIS 24 Solar Interface Systems Section 1 Introduction 12 AWG 12 AWG Wire Red Wire White Aluminum Enclosure with Electronics Panel Flexible Conduit Jacketed Solar Module Pole Mount Bracket Assembly Bracket for 1 2 in Flexible Conduit Cord Grip C Conduit 7 Connector golat wiet ser p S ESSI NS 0 Surge Voltage Protection Adapter for Radio Antenna 1 2 in Galvanized Installation Coupling Instructions TE Figure 1 1 Components and Assemblies of the Phoenix Contact Solar Interface Sys
41. ms Section 4 Installation Procedures 4 9 Installing Coax Cable Surge Protector Your SIS includes a coaxial cable surge protector for protecting the antenna and radio s Install the surge protector as described in the following procedure 1 Locate the NEMA hole seal on the lower shelf and remove See Figure 4 6 View A 2 Fabricate and install a ground wire 2 08 to 1 31 mm 14 to 16 AWG between the surge protector and earth ground terminal 3 Install surge protector and tighten the lock nut Wing Nut Retaining Washer Fabricate 14 16 AWG Ground Wire Ring Terminal 14 16 AWG M3 Screw 1 4 in Screw Phillips Head Philips Head 2 Lock Washer 08 Nat Ring Terminal 14 16 AWG Screw Coax Cable Surge Voltage Protector CN UB 280 VDC Access Screw for Replacing Gas Arrester CN UB G1 Copper tin 6 AWG Protective Earth PE Conductive Ground Wire Not supplied Lock Washer 6 AWG 2 hole Earth Ground Wire Lug 1 4 in Mounting Screws 2 Nut O B 1984A035 1 Figure 4 6 Installing the Coax Cable Surge Protector PHCENIX CONTACT 4 9 RAD SIS 24 Solar Interface Systems Section 4 Installation Procedures 4 10 Installing Radio and Antenna Adapter 1 2 Snap the radio onto the mounting rail
42. mum performance The tilt angle is based on the latitude at your SIS location Therefore you will need to know the approximate latitude of your SIS location before setting the tilt angle Use the map below to determine the appropriate tilt angle o o o os 8 5 5 5 gt D D Q Q e a A io o lo N o B Q Lo O Y c 3 5 i 5 Prime Prime Meridian Meridian e o o o o o o o o o o bod o ite Lo ite 1 Lo o N co o e 5 st 28 n Y 29 0 8 a d o n te N o S o o I o 8 d 8 54 A i Q e eo OD 8 o 12 D 005 oS g 64 lt 5 lt 5 lo ac o za 55245 Qo gt 925 o g 5 28 25 4 Figure 3 4 Solar Module Orientation PHCENIX CONTACT 3 4 SECTION 4 Installation Procedures Section 4 Contents eae 4 2 4 2 Safety Precautions 4 2 4 3 Tools and Equipment unes ricerca
43. n 8 Disconnect the battery cables from terminals no 2 and no 3 of the charge controller Then measure the voltage between the cables If battery voltage is reduced the battery ies may be damaged or defective Replace battery ies if necessary Measure the voltage of the solar modules and the voltage of the battery at the charge controller a If voltages at the terminals are the same within one or two tenths of one volt the solar modules are charging the batteries b If the photovoltaic voltage is almost as low as the open circuit voltage of the cells and the battery voltage is low the charge controller is not charging the batteries Check battery for damage or defects 6 6 2 Battery Voltage is Too High 1 2 3 Disconnect the solar modules from pins 3 and 4 of the charge controller Check if the maximum end of charge voltage 14 1 V to 14 7 V is exceeded Check if the correct battery type sealed or flooded has been selected Refer to Paragraph 6 3 for Connecting the Charge Controller Check that all wires have been connected properly to the terminals a With solar modules disconnected unhook the wire momentarily from the positive pole of the battery Then reconnect it At this point the green CHARGING LED should be OFF b With solar modules disconnected measure the voltage at the SOLAR terminals 3 and 4 of the charge controller If the green CHARGING LED is ON or if battery voltage is prese
44. nt at the SOLAR terminals the charge controller might be damaged Replace charge controller if necessary c Reconnect the solar modules to pins 3 and 4 of the charge controller 6 6 3 Operating Error of the Load 1 2 3 Check if voltage is applied at the load Check if a system fuse has failed See Figure 6 3 The charge controller does not contain any fuses or circuit breakers Check that the load and other terminals on the charge controller and on the battery have been connected properly Check that voltage drops in the system wiring are not too high Check that LEDs on the charge controller indicate the proper state Refer to Figure 6 1 a If the red LOAD DISCONNECT LED is ON the load has been disconnected because of low battery voltage This is a normal state if the load requires more power than that provided by the solar modules Poor weather or sunlight conditions could exist Measure the voltage between BATTERY terminals 1 and 2 on the charge controller If voltage is below the low voltage disconnect value power will not be available to the load Measure the voltage between LOAD terminals 5 and 6 of the charge controller If no voltage is present the charge controller might be damaged Replace if necessary 6 6 6 6 4 RAD SIS 24 Solar Interface Systems Section 6 Operation System Goes Into Low Voltage Disconnect LVD State Too Often
45. ode Negative Positive Screw Terminal Screw Terminal Positive Screw Terminal Negative Al Screw Terminal RAD SOL PAN 24 20 RAD SOL PAN 24 40 RAD SOL PAN 24 30 RAD SOL PAN 24 50 Solar Modules Solar Modules Figure 4 14 Solar Module Junction Boxes PHCENIX RAD SIS 24 Solar Interface Systems Section 4 Installation Procedures 4 Locate the two hole knockout positions in the junction box Then remove the knock outs from the holes 5 Install the watertight fittings in the holes as shown in figure 4 15 Figure 4 15 Installing Watertight Conduit Fittings Note Solar modules are connected in series WARNING For your safety leave the opaque cover over the solar module until all wiring tasks have been completed 6 Runa3 31 mm 12 AWG red wire from the control cabinet through the watertight fitting and into the junction box of the first solar module See circuit diagrams in Figure 4 16 7 Crimp a wire lug onto the end of the red wire Then connect the red wire to the positive terminal 8 Runa3 31 12 AWG red wire from the junction box of the first solar module through the conduit and watertight fitting of the second junction box Crimp a wire lug onto the end of the wire and connect it to the appropriate terminal of the second junction box 9 Runa3 31 12 AWG white wire from the control cabinet through the watertight fitting and in
46. on Phoenix Contact recommends that installation maintenance and repairs be performed by licensed or qualified personnel in strict accordance with applicable health safety building and electrical codes 1 1 RAD SIS 24 Solar Interface Systems Section 1 Introduction Specifications within the text of this manual are given in the International System of Units SI with English equivalents in parentheses Fully capitalized words within the text indicate markings found on the equipment Warnings Cautions and Notes are used to emphasize critical instructions WARNING An operating procedure practice etc which if not care fully followed could result in personal injury CAUTION An operating procedure practice etc which if not strictly observed could result in damage to the equipment NOTE Highlights important information about an operating procedure or the equipment 1 4 Current Documentation on the Internet Make sure you are always working with the latest documentation published The latest changes or additional information can be found on the Internet at http www phoenixcon com under PRODUCTS select Info Service 1 5 Product Description A Components and Assemblies Components and assemblies that make up the Phoenix Contact 24 40 Solar Interface System are identified in Figure 1 1 The major components of the system are Photovoltaic solar modules Solar
47. ou will need to obtain a longer length of both the conduit and the two 3 31 mm 12 AWG wires Instructions for the solar module s have been provided with the system Familiarize yourself with the instructions before installing your module 1 Refer to Section and calculate the solar module orientation and tilt angle for your geographical area 2 Determine the height at which the solar module will be installed on the pole Refer to Figure 4 1 NOTE To achieve the proper solar module orientation the solar module bracket assembly will have to be rotated and reposi tioned after installation Therefore pole bracket clamps and solar module bracket bolts should not be tightened until bracket assembly is attached and properly oriented 3 See Figure 2 1 for dimensions of the various solar modules 4 Figures 4 8 and 4 9 show a typical installation of a side of pole mounting bracket assembly Our example is based on the RAD SOL SET 24 80 system installed at an angle of 45 5 Using a blade type screwdriver loosely install the lower pole bracket at the desired height on the pole 6 Loosely install the upper pole bracket approximately 800 mm 31 1 2 in above the lower pole bracket NOTE Figures 4 8 and 4 9 show the bracket assembly struts config ured for a tilt angle of 45 The tilt angle is based on the length of the 2 piece telescoping strut assembly and the distance between the two pole brackets Moving the inside s
48. re 4 2 4 4 Additional Material Considerations 4 3 4 5 Mounting POLS ero 482 5281 8 4 4 3 46 Installing the SIS EncloSUte 4 3 4 7 System 4 6 48 Removing Fuses from Electronics Panel 4 8 4 9 Installing Coax Cable Surge Protector 4 9 4 10 Installing Radio and Antenna 4 10 4 11 Installing the Solar Modules 4 11 4 12 Wiring the Enclosure 4 14 4 12 4 Enclosure Wining seansini eene cerei 4 14 4 12 2 Wiring the Solar Module Junction Box sene 4 18 4 12 3 Grounding the Solar Module sees 4 20 4 13 Installing the Antenna eiie terere rnit aec 4 21 4 14 Installing Flexible Conduit Mounting Brackets 4 21 4 15 Installing the Battery Rer rg t rn eres 4 21 AAG Final 4 24 Electricity even at low voltages can be very dangerous For your protection Phoenix Contact recommends that all electrical installations maintenance and repairs be performed only by licensed and or properly qualified individuals and in strict accordance with applicable health safety building and electrical codes
49. ry to reduce the danger of arcing or shock Also check that the fuses have been removed from the fuse terminal blocks If fuses have not been removed shut down your SIS as described in Section 5 of this manual JAN WARNING To prevent short circuits and damage to the equipment when installing the battery 1 Exercise extra caution when placing the battery into the enclosure 2 Always double check your positive and negative polarity before connecting the battery cables Always use insulated tools when working on electrical equipment 2 Figure 4 19 shows the serial cable connections for the SIS two battery configuration You should become familiar with the layout of these connections 12 volt Gel Battery Black Cable 10 AWG Red Cable 10 AWG e Ring Terminal 10 AWG Typical 1984A087 1 Red Interconnect Cable 10 AWG Figure 4 19 Diagram Showing Two Batteries Connected in Series Using a 7 16 in wrench remove the attaching bolts flat washers and lock washers from the positive and negative terminal post of both batteries See Figure 4 20 Carefully place the batteries on the rubber mat in the battery compartment Slide back the protective boot on the red battery cable Then using a 11 1 mm 7 16 in wrench attach the cable to the battery s negative post Slide back the protective boot on the black battery cable Then using a 11 1 mm 7 16 in wren
50. ssary trim one or both ends of the conduit Remove the hole knockout from one of the enclosure hole locations See Figure 4 10 Obtain a conduit connector Insert the body of the connector into the hole of the enclosure and install the locknut Slide the compression nut and compression ring over the watertight jacket of the conduit Screw the conduit end cap onto the end of the conduit Insert the end of the conduit into the connector body and tighten the compression nut Insert the two 3 31 mm 12 AWG wires into the flexible conduit Leave approxi mately 76 2 to 91 44 cm 30 to 36 in of wire available at the enclosure to reach the enclosure s electronics panel Run the wires from the conduit through the enclosure s upper shelf Install a hole grommet in the upper shelf as shown in Figure 4 11 Then run the wires up to the enclosure s electronics panel Cut wires to proper length and crimp a fork terminal to the end of each wire Attach the two wires to the enclosure s electronics panel Refer to the wiring diagram shown in Figure 4 2 for wire terminations Assemble the conduit connector conduit coupling and cord grip connector as shown in Figure 4 12 Then attach the conduit to the bracket assembly Run the wires from the cord grip connector to the solar module junction box 4 14 PHCENIX CONTACT Hole Knockout RAD SIS 24 Solar Interface Systems Section 4 Installation Procedures
51. t be exceeded Only use a charge controller with a 24 volt battery or two 12 volt batteries connected in series Do NOT short circuit the solar modules and the loads as long as they are connected to the charge controller Otherwise damage to the charge controller may occur Protect the charger controller against direct sunlight Also ensure that there is adequate space for air circu lation around the charge controller Only use copper wires with a minimum insulation rating for 75 167 F and a cross section of at least 3 31 mm 12 AWG Ground the negative wire of the system according to local regulations WARNING Exercise extra caution when handling the batteries Lead acid batteries may produce explosive gasses and high short circuit currents Observe all the instructions supplied with the battery Connecting the Charge Controller The SunSaver charge controller is mounted on a vertical surface in the control cabinet Adequate space for air circulation is provided above and below the controller CAUTION Make sure that the current strength of the solar module and the loads does not exceed the rated values of the SunSaver model installed 6 2 PHCENIX CONTACT RAD SIS 24 Solar Interface Systems Section 6 Operation LOAD SUNSAVER 10 CHARGING DISCONNECT um TEMP Sense
52. tem SIS PHCENIX CONTACT RAD SIS 24 Solar Interface Systems Section 1 Introduction Solar Module Antenna Pole Bracket Assembly 2 Solar Module Junction Box Antenna Cable Wire Wrap UV resistant or Stainless Steel Clamp A Wire Wrap Black or Stainless Steel Clamp Cord Grip 1241 1 2 As required Adapter Conduit Conduit Coupling Connectof 1 2 Up to Approximately Conduit Jacketed 8 ft 2 44 m Using Conduit Provided Flexible Conduit Mounting Bracket Aluminum Enclosure Electronics Control Panel Wire Wrap UV resistant Battery or Stainless Steel 813 Clamp As required 6 AWG Wire Lug for Grounding Enclosure nm 1 2 in Conduit Surge Voltage Protection Connector Adapter for Antenna Cable 1 2 in Flexible Conduit Jacketed Protective Earth PE Ground Cable Pole 2 1 2 in to 3 in 63 5 mm to 76 2 mm Schedule 40 or Equivalent Protective Earth PE As per local electrical code Grade 1984A079 2 Figure 1 2 Example of Typical Solar Interface System Installation PHCENIX CONTACT RAD SIS 24 Solar Interface Systems Section 1 Introduction Solar Array System Controller Charging Load Regulator Control Sealed Battery Bank 1984A005 Figure 1 3 Diagram of the Solar Interface System Charge an
53. tenna Cable Pole 2 1 2 in to 3 in 63 5 mm to 76 2 mm Schedule 40 or Equivalent Grade A Wire Wrap Black or Stainless Steel Clamp As required 1 2 in Flexible Up to Approximately Conduit Jacketed Aluminum Enclosure 8 ft 2 44 m Using Conduit Provided Panel Battery 1 2 in Conduit Connector 1 2 in Flexible Conduit Jacketed Protective Earth PE Ground Cable 7 Protective Earth PE Electronics Control As per local electrical code Figure 4 1 SIS Configuration Example 1984A079 2 PHCENIX CONTACT 13 31 6 AWG Electronics Panel 2 SEALED PV BATTERY LOAD OR I8 4 a ICON TAE rrr PLUGTRAB QQ PES 292 O 4 24218 m RAD
54. terface System Specifications yc EET mm 24V DC Solar module input wattage 40 60 80 100 W Load requirements fas see load calculator www phoenixcon com wireless Wireless transmitters receivers amp repeaters see wireless interface products www phoenixcon com wireless ls l t rs And CONVENES see www phoenixcon com wireless Surge voltage proteclion see www phoenixcon com from Products menu select Online Catalog then choose TRABTECH Antena see antenna selector www phoenixcon com wireless Pole Size e dence tle ici 2 5 in 2 875 in OD to 3 in 3 50 in OD schedule 40 or equivalent 1984A067 2 1 RAD SIS 24 Solar Interface Systems Section 2 Technical Data Table 2 2 RAD SOL CHG 24 10 Solar Charge Controller Specifications Nominal voltage xU hee eibi Hed 24V DC ge E 10 Rated load 10 Regulation voltage Sealed battery Temperature compensation MV C 56 mV Self CONSUMPTION iO e
55. the SIS Enclosure 4 7 System Grounding essen 4 8 Removing Fuses from Electronics PHCENIX CONTACT RAD SIS 24 Solar Interface Systems User Manual Table of Contents Table of Contents vi 4 9 Installing Coax Cable Surge Protector 4 9 4 10 Installing Radio and Antenna Adapter 4 10 4 11 Installing the Solar Modules 4 11 4 12 Wiring the EncloSUre tete deen 4 14 4 12 1 09600000 4 14 4 12 2 Wiring the Solar Module Junction 4 18 4 12 3 Grounding the Solar Module sss 4 20 4 13 Installing the Antenna 4 21 4 14 Installing Flexible Conduit Mounting Brackets 4 21 4 15 Installingithe Battery tei Ren 4 21 4 16 GHECKOUL doe FREE 4 24 SECTION 5 Start up amp Shutdown Procedures 0 ET 5 1 5 2 5 2 6 Charge Controller 61 METTE 6 1 6 2 General Safety Precautions 6 2 6 2 1 Gharge Controller cete 6 2 6 2 2 55 61 1 45455 4528 2 22525250015022 24450082526525252018568 552 0 88 55 308032 6 2 6 3 Connecting the C
56. tion Voltage is reached If you suspect a problem with charging from the solar module check the following Test the Solar Module Open Circuit Voltage JAN WARNING Solar modules can produce hazardous voltages when ever exposed to sunlight even when not in full sunlight Unless sunlight is required for testing purposes always cover the face of the solar module s completely with an Opaque material to stop the production of electricity First remove fuse No 1 Solar Module from its fuse holder See Figure 6 1 Using a multimeter check the voltage at the PV and PV terminals of the charge controller Voltage should read between 18 and 21 volts depending on solar module cell temperature If not you may have a problem with the solar modules Next check each module separately If you suspect a problem contact Technical Support at 1 800 322 3225 PHCENIX CONTACT 6 7 RAD SIS 24 Solar Interface Systems Section 6 Operation 6 7 2 Test the Solar Module Short Circuit Current JAN WARNING Solar modules can produce hazardous voltages when ever exposed to sunlight even when not in full sunlight Therefore when working with PV modules or making wiring connections during the daytime cover solar mod ules with an opaque material First remove fuse No 1 Solar Module from the fuse holder See Figure 6 1 You will need to use a digital multimeter configured for DC amps Carefully isolate each solar module in your array an
57. to the junction box of the first solar module See circuit diagrams in Figure 4 16 10 Crimp a wire lug onto the end of the white wire Then connect the white wire to the appropriate terminal 11 Runa3 31 mm 12 AWG white wire from the junction box of the first solar module through the conduit and watertight fitting of the second junction box Crimp a wire lug onto the end of the white wire and connect it to the appropriate terminal CAUTION Make sure that wires are connected properly Check that terminal screws and watertight fittings are tight 12 Check all wire connections Then install the junction box cover plate PHCENIX CONTACT ais RAD SIS 24 Solar Interface Systems Section 4 Installation Procedures No 2 Solar Module No 1 Solar Module Red Solar Modules RAD SOL PAN 24 20 40 watt Systems RAD SOL PAN 24 30 60 watt Systems White No 2 Solar Module No 1 Solar Module Solar Modules 2 RAD SOL PAN 24 40 80 watt Systems d Red RAD SOL PAN 24 50 100 watt Systems 9 ST ite MER RUN RC Figure 4 16 Circuit Diagrams for Series Wiring of Two Solar Modules 4 12 3 Grounding the Solar Module CAUTION If the mounting pole or structure is nonconductive we recommended running a separate wire to earth ground
58. tools were supplied with your SIS However we suggest that you have the following tools to ensure a successful installation e Compass Protractor 4 2 Slotted head screwdriver Phillips head screwdriver Wire cutters Stripping tool e Crimping tool e Multimeter e Open end wrench set standard e Socket set standard e Pliers e Hacksaw e Utility knife RAD SIS 24 Solar Interface Systems Section 4 Installation Procedures 4 4 Additional Material Considerations The following is a list of materials you may need to complete the installation Foundation Earth ground rod ground cable and clamps per local codes Mounting pole 63 5 mm to 76 2 mm 2 1 2 in to 3 in diameter Suitable for mount ing antenna solar module and enclosure Antenna External antenna cable Internal antenna adapter see ordering data Wire for connecting external sensors switchgear etc U bolts for pole mounted installations or lag screws for wall mounted installations Wire wraps Radios and accessories Visit our web site http www phoenixcon com Antenna splitter for multiple radios Visit our website http www phoenixcon com End clamps for additional DIN rail mountable product see ordering data 4 5 Mounting Pole To accommodate the solar module bracket assembly provided with the SIS the outside diameter of the mounting pole must be in the range of 63 5 mm to 76 2 mm 2 1 2 in to 3 in
59. trut inward shortening total length one hole position increases the tilt angle about 5 Similarly moving the strut outward increasing total length reduces the tilt angle about 5 In addition when changing total strut length the distance between pole brackets will also change The distance between pole brackets will increase for tilt angles greater than 45 or decrease for angles less than 45 7 Using Figures 4 8 and 4 9 as a guide determine appropriate strut assembly length to achieve the required solar module tilt angle for your particular geographic location 8 Set the struts to the determined length Then using at least two bolts fasten the two struts together and fully tighten See Figure 4 8 View A A Next loosely install the strut assemblies to the lower pole bracket using the attaching bolts PHCENIX CONTACT RAD SIS 24 Solar Interface Systems Section 4 Installation Procedures 9 Obtain the two solar module mounting rails Loosely attach one of the mounting rails to the upper pole bracket using the attaching bolt Similarly loosely attach the second mounting rail to upper pole bracket 10 Loosely attach each of the mounting rails to their corresponding strut assemblies at the proper hole location previously determined Stainless Steel Band Clamps Typical 4 places Solar Module Junction Box a 0000000 IS pper Pole Bracket Solar Module Solar Module
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