Installation & Operation Manual. Transit Solar-powered LED Lighting System. Attachment 2. PV-Shelter RMSxxF REV

Transcription

1 Transit Solar-powered LED Lighting System Attachment 2 PV-Shelter RMSxxF REV

2 Contents Page Introduction Page How it Works Page Data Logging /Retrieval - Assembly Page Installation and Assembly Page Page Page Page Page Troubleshooting - Maintenance/ Product Care - Batteries - Contact and Re-order Information - Appendix A: RMSxxF Exploded View - Appendix B: RMSxxF Exploded View - Appendix C: Warranty REV Page 2 of 18

3 Introduction The Urban Solar Corporation RMSxxF stand alone solar powered LED lighting system has been designed specifically to meet the requirements for lighting the barrel roof type transit shelter. The system has been engineered to integrate with the shelter s mechanical design in order to provide an aesthetic look and a very simple installation procedure. Currently there are four sizes available the RMS30F, RMS60F, RMS90F and the RMS50F. The different models are identical except for solar array size. The size required depends on the local solar conditions, required lighting levels and duration as well as shelter construction. REV Page 3 of 18

4 How it works The RMS series shelter lighting system provides lighting using state of the art LED luminaires, batteries and solar panels, integrated with an intelligent programmable energy control module (ECM). Electricity generated by the solar panels is directed to the ECM which regulates the charging of the battery bank and switches on the power to the LEDs. The ECM is factory programmed to provide variable calendar based lighting profiles (on time duration and intensity) to match the available solar insolation and user preferences. The main system components are described below: PV Array (solar module) The PV array consists of one, two, or three 30W solar modules mounted to a metal framework. Alternatively, a single 50W solar module can be used for some applications. The solar panel array size is selected to provide enough solar charging for the system to operate dusk till dawn, at a specific brightness level, year round at a given geographical location. Batteries The battery bank is composed of two or three 18 amp-hour 12 Volt cells. The batteries are sealed, lead acid, rechargeable, and provide a minimum of 5 days autonomy (i.e. the system could operate for a minimum of 5 days with absolutely no solar charging for example during heavy snowfall). Luminaires The LED luminaires contain high power white LEDs. The luminaires are driven well below their maximum power rating to increase efficiency and extend the already long life. ECM The Energy Control Module is the central control of the lighting system. It controls battery charging and regulates the power to the LED luminaires. The ECM also monitors the system performance to ensure the batteries will not be damaged by over charging, and will turn off the LEDs if the battery voltage falls below the low voltage disconnect (LVD) setting. Once the batteries have been sufficiently charged above the LVD, the ECM will turn the LEDs back on again. The ECM is factory programmed for a specific operation profile based on the customer requirements for LED on-time and brightness level, and depends on the geographical location and solar array size. Using a calendar based approach, the LED light levels and on-times can be optimized for maximum performance year round. Operating Profile The RMSxxF has a built in programmable energy control module (ECM). The standard operating profile has luminaires automatically turning on after dusk at full brightness, and turning off at dawn this is the dusk till dawn (D/D) profile. However, in some locations, and depending on the season, there may be insufficient sunlight to support the D/D profile all year long. Therefore, the RMSxxF is pre-programmed at the factory to set a calendar based operating profile to maximize the light intensity and duration based on NASA solar insolation data for the region. For example, an RMS30F in Seattle might be programmed for D/D lighting for the months of May through September, and then a shorter lighting duration and/or lower intensity from October through April (for example, dusk+6hrs/dawn-2hrs, at 75% intensity). Since the programming is calendar based, the lighting levels and durations can be adjusted and optimized on any time interval. REV Page 4 of 18

5 Data Logging /Retrieval Assembly The ECM keeps a daily log of critical operating parameters such as battery voltage, solar panel and LED Current. This data can be retrieved in the field in order to assess the system performance. This gives engineering staff at Urban Solar Corp the ability to continuously evaluate performance of the solar charging capabilities and compare real time performance to the modeled simulations. Typically the RMSxxF is shipped completely assembled and ready for installation. All that is required is to install the power module to the shelter ceiling, run the wiring harnesses and mount the solar array to the roof of the shelter. In some cases the batteries may be shipped separately and can be wired during the installation process. For wiring details refer to the wiring schematic. UNLESS OTHERWISE SPECIFIED DO NOT SCALE DRAWING INTERPRET DIMENSIONS AND TOLERANCES PER ASME Y TOLERANCES APPLY AS SHOWN BELOW DECIMALS ANGLES.X ±.1.XX ±.01.XXX ±.005.XXXX ±.0005 DESIGNED BY THIRD ANGLE PROJECTION D HANKE DRAWN BY David Hanke INCHES PROPRIETARY COPYRIGHT 2008 BY Urban Solar Corp., Victoria, BC, Canada ALL RIGHTS RESERVED. NO PART OF THIS DOCUMENT MAY BE REPRODUCED STORED IN A RETRIEVAL SYSTEM, OR TRANSMITTED IN ANY FORM, WITHOUT THE WRITTEN PERMISSION OF Urban Solar DATE DATE TITLE SIZE 18/02/2009 B CAD REFERENCE 07/04/2009 RMS 60F concept Urban Solar 4041 Elise Place Victoria, BC, Canada, V8X 4K1 (T) (F) DRAWING NO SHEET 1 OF 1 B REVISION figure 1. RMSxxF components REV Page 5 of 18

6 figure 2. Power module figure 3. Power Module with LID removed (shown with ECM and batteries) REV Page 6 of 18

7 figure 4. Batteries and brackets (3) COPYRIGHT 2008 BY Urban Solar Corp., Victoria, BC, Canada ALL RIGHTS RESERVED. NO PART OF THIS DOCUMENT MAY BE REPRODUCED STORED IN A RETRIEVAL SYSTEM, OR TRANSMITTED IN ANY FORM, WITHOUT THE WRITTEN PERMISSION OF Urban Solar DATE 07/07/2012 PROPRIETARY COPYRIGHT 2008 BY DRAWN BY D HANKE figure 5. Solar module assembly RMS60F TITLE Urban Solar Corp., Victoria, BC, Canada ALL RIGHTS RESERVED. NO PART OF THIS DOCUMENT MAY BE REPRODUCED STORED IN A RETRIEVAL SYSTEM, OR DATE TRANSMITTED IN ANY FORM, WITHOUT THE WRITTEN 07/07/2012 PERMISSION OF Urban Solar PROPRIETARY DRAWN BY REVISION PAGE TITLE DRAWING NO REV D HANKE Page 7 of C DRAWING NO C REVISION PAGE Urban 4211 Solar Commer Victoria, BC, C (T)

8 figure 6. ECM with Solar, LED and battery connections figure 7. Battery jumper harnesses REV Page 8 of 18

9 Installation and Assembly Please read the entire installation procedure before starting as the order of operations is optional. Determine the mounting location on the ceiling of the shelter. The power module base should be positioned so that it can be secured to the shelter roof ribs near each end i.e. centered on two roof ribs. Typically the module will be positioned at the center of the shelter. Using appropriate hardware (TEK screw), mount the power module base to the ceiling and ensure it is secured with a minimum of four (4) screws fastened directly through the roof ribs. Pilot holes will likely need to be drilled in the power module base and roof ribs use a 13/64 drill bit for the pilot holes. figure 8. figure 9. Note the following steps (4-7) can be performed before the module is mounted to the shelter ceiling as it may be easier to do in the shop it is at the discretion of the installation crew. It will make mounting to power module to the ceiling of the shelter more difficult because of the weight of the batteries, but makes battery wiring much easier. REV Page 9 of 18

10 3. Insert batteries in to the power module and secure with the battery hold down straps provided. figure 10. Be cautious when handling the battery pack. It is capable of generating hazardous short-circuit currents. Remove all jewelry (bracelets, metal-strap watches, rings) before attempting to handle or disassemble the battery pack. Contact Urban Solar if further instruction is required. USE EXTREME CAUTION WHEN INSTALLING BATTERY HARNESSES. ALWAYS WEAR INSULATING GLOVES WHEN CONNECTING BATTERIES. AVOID CONTACT OF FREE POSITIVE RING TERMINALS WITH NEGATIVE TERMINALS OF BATTERY OR ANY PART OF THE CHASSIS figure 11. RMS60F wiring diagram REV Page 10 of 18

11 Battery wiring batteries are wired in PARALLEL. Use the 2 black jumper cables to connect all of the black terminals together, and use the 2 red jumper cables to connect all the red terminals together. Attach the black main negative battery power cable coming from the ECM to one of the negative battery terminals. Remove the inline fuse and attach the red fused main positive battery power cable coming from the ECM to one of the positive battery terminals. Use wire ties to tidy up wiring and tuck neatly out of the way. Installed solar panel on shelter roof. figure 12. Installed solar panel on shelter roof Determine solar panel positioning then mark and drill holes for mounting to the shelter roof ribs. Drill a hole through the roof for routing the solar panel wiring into the power module. The hole should line up with one of the larger wire feed through holes in the power module base. Route the solar panel wires through to the power module then secure panels to the roof using security screws provided. Caution do not short the solar panel positive leads to the negative leads or to any part of the metal work on the chassis or shelter. Use electrical tape to insulate leads when routing solar panel wiring For the RMSxxF when there are two or more solar panels, the panels are wired in parallel. Connect both positive solar leads to the positive (red) lead from the ECM as shown. Connect both negative solar leads to the negative (black) lead from the ECM. Use marrettes (wire nuts) to make connections. Hold the power module lid up and make the connection for the luminaire to the control module as shown. Coil up any excess wiring and use wire wraps or zip ties to neaten up and tuck away all wiring. REV Page 11 of 18

12 Power-Up and Final Testing 14. The final step is to apply power to the unit by installing the inline fuse on the positive battery lead. Upon power-up, the LEDs should blink briefly and turn off if the solar panel is in daylight; if installing at night, the LEDs will blink and then turn on. Swipe a magnet here to activate self-test feature figure 13. ECM is marked with a label The RMSxxF also has a self-test feature that is activated by swiping a magnet over the reed switch located inside the ECM. The ECM is marked with a label showing where to swipe the magnet as shown The self-test, when activated, will provide information on system health by flashing the LEDs in a predetermined sequence. On activation the LEDs will flash 3 times quickly, pause, and then flash slowly giving one to four flashes depending on the state of charge of the batteries. If the lights do not flash the system requires troubleshooting see manual. 1 flash 0-25% battery system could fail soon or is in LVD 2 flash 25-50% battery caution, system might be under performing 3 flash 50-75% battery system is good 4 flash 75% or greater (100%) battery system is receiving optimal charging The battery bank size and system load have been carefully selected to maintain the energy balance for the specific solar region. Expect to see three or four flashes on the battery diagnostic test near the end of the day. If there are 2 or less flashes the system could be under performing or not getting enough solar charging due to very poor weather, a poor solar site (shaded), or both. Note: Install solar powered lighting system within 3 months of delivery. Sealed lead acid batteries will self discharge in storage. It is recommended that installation occur as soon as possible after delivery to ensure the maximum life cycle of batteries is recognized. Battery warranty will be void for systems that are not installed within 6 months of delivery by Urban Solar Corp. REV Page 12 of 18

13 15. Replace the power module lid and secure with Torx Security fasteners provided. The RMSxxF installation process is now complete. The LEDs will turn on approximately 30 minutes after sunset. figure 14. RMSxxF Power Module REV Page 13 of 18

14 Troubleshooting In the event the RMS30/60F fails to turn on after dark (or simulated darkness): Check that the panel is completely dark. If there is a street-light directly overhead this can sometimes provide enough light to simulate daytime. If you are using a cover to simulate darkness ensure that the panel is completely covered and totally dark. Open the power module lid, remove the fuse in the positive battery connect lead, and measure the battery voltage across the battery terminals: If the battery voltage is <11.0Volts contact Urban Solar Corp for assistance. If the voltage is between 11.0 and 11.9V then the battery needs to be charged before the lights will activate. When the battery voltage falls to less than 11.9V, the ECM protects the battery from over-discharge by disconnecting power to the luminaires. Once the system has had sufficient time and sunlight to recharge and the battery voltage reaches 12.4 Volts, the ECM will reconnect power to the luminaires, and the system will function normally. Charging will occur naturally in the field and the unit can be checked again after a few sunny days. Alternatively a battery charger may be used please consult Urban Solar Corp. If the battery voltage is >11.9V the lights should activate. Ensure the panel is in complete darkness. Remove the fuse from the positive lead of the battery and check to make sure the fuse is not blown. Replace the fuse if required. Remove the fuse and wait 10 seconds, then reconnect the fuse. If lights activate then the problem is solved. Note - this can be repeated up to 5 times to reboot the ECM controller. If the above steps do not restore normal operation, contact Urban Solar for assistance. REV Page 14 of 18

15 Maintenance/ Product Care Batteries Although the system is designed to be maintenance free, optimal performance requires clean solar panels and lenses. Clean on an annual basis or as required. Use water and a soft sponge or cloth for cleaning and a mild, non-abrasive cleaning agent for more stubborn residue. Rinse well. Be cautious when handling the battery pack. It is capable of generating hazardous short-circuit currents. Remove all jewelry (bracelets, metal-strap watches, rings) before attempting to handle or disassemble the battery pack. Contact Urban Solar if further instruction is required. IMPORTANT MAINTENANCE NOTE! Over time dirt and debris may collect on the solar module (panel). Excess dirt or grime will reduce battery charging and thus can lead to premature battery failure and or lack of performance. Urban Solar recommends at a minimum an annual cleaning of the solar module. Water and soap are recommended rather than simply spraying the solar panel. Please see manual or contact Urban Solar for more information. Consult your local municipal by-laws for information on recycling the cells. DO NOT THROW THE CELLS IN THE GARBAGE! Contact and Re-order Information If you have any questions or feedback we would like to hear from you. Please visit our website or feel free to contact us directly at or techsupport@urbansolarcorp.com Urban Solar Corporation 4211 Commerce Circle Victoria, BC Canada, V8Z 6N6 REV Page 15 of 18

16 Appendix A: RMS60F - Exploded View UNLESS OTHERWISE SPECIFIED DO NOT SCALE DRAWING INTERPRET DIMENSIONS AND TOLERANCES PER ASME Y TOLERANCES APPLY AS SHOWN BELOW DECIMALS ANGLES.X ±.1.XX ±.01.XXX ±.005.XXXX ±.0005 DESIGNED BY THIRD ANGLE PROJECTION D HANKE DRAWN BY David Hanke INCHES PROPRIETARY COPYRIGHT 2008 BY Urban Solar Corp., Victoria, BC, Canada ALL RIGHTS RESERVED. NO PART OF THIS DOCUMENT MAY BE REPRODUCED STORED IN A RETRIEVAL SYSTEM, OR TRANSMITTED IN ANY FORM, WITHOUT THE WRITTEN PERMISSION OF Urban Solar DATE DATE TITLE SIZE 18/02/2009 B CAD REFERENCE 07/04/2009 RMS 60F concept Urban Solar 4041 Elise Place Victoria, BC, Canada, V8X 4K1 (T) (F) DRAWING NO SHEET 1 OF 1 B REVISION figure 15. RMS60F - Exploded View REV Page 16 of 18

17 Appendix B: RMS60F Solar Panel - Exploded View PROPRIETARY COPYRIGHT 2008 BY Urban Solar Corp., Victoria, BC, Canada ALL RIGHTS RESERVED. NO PART OF THIS DOCUMENT MAY BE REPRODUCED STORED IN A RETRIEVAL SYSTEM, OR TRANSMITTED IN ANY FORM, WITHOUT THE WRITTEN PERMISSION OF Urban Solar PROPRIETARY COPYRIGHT 2008 BY Urban Solar Corp., Victoria, BC, Canada ALL RIGHTS RESERVED. NO PART OF THIS DOCUMENT MAY BE REPRODUCED STORED IN A RETRIEVAL SYSTEM, OR TRANSMITTED IN ANY FORM, WITHOUT THE WRITTEN PERMISSION OF Urban Solar DRAWN BY TITLE D HANKE DATE 07/07/2012 DRAWN BY D HANKE DATE 07/07/2012 figure 16. RMS60F Solar Panel TITLE DRAWING NO C REVISION DRAWING NO PAGE C REVISION PAGE Urban 4211 Solar Commer Victoria, BC, C (T) REV Page 17 of 18

18 Appendix C: Warranty Urban Solar Corporation ( the manufacturer ) will warrant, for a period of five (5) years from the date of delivery that all Urban Solar Corp. solar-powered LED shelter lighting systems will comply with published product specifications. Date of delivery shall be defined as the day after the product or system leaves the manufacturers facility. This warranty covers all parts for each entire lighting system installed, excluding batteries, which have a prorated three (3) year warranty. No other warranty is stated or implied. This warranty shall not be assigned without the express written consent of the manufacturer. The warranty on any replacement products will not extend beyond the five years from original installation date. Please note that the customer is responsible for return of defective products to the manufacturer. The manufacturer makes no warranties, expresses or implied concerning the goods furnished hereunder other than they shall meet the manufacturer s current sales specifications. Any recommendations made by manufacturer concerning the use, design or application of said goods are believed reliable, but the manufacturer makes no warranty of results to be obtained. The buyer assumes all responsibility and liability for loss or damage resulting from the handling or use of said goods. Prorated Battery Warranty 36 Month Prorated Battery Warranty 0 to 12 months 13 to 24 months 25 to 36 months 100% of the original battery purchase price will be refunded or applied to the purchase of a new unit 50% of the original battery purchase price will be refunded or applied to the purchase of a new unit 25% of the Prorated original battery Battery purchase Warranty price will be refunded or applied to the purchase of a new unit Note: Install solar powered lighting system within 3 months of delivery. Sealed lead acid batteries will self discharge in storage. It is recommended that installation occur as soon as possible after delivery to ensure the maximum life cycle of batteries is recognized. Battery warranty will be void for systems that are not installed within 6 months of delivery by Urban Solar Corp. REV Page 18 of 18