Installation Manual Replacement Roof Top HSC-205 / HSC-270

Transcription

1 Installation Manual Replacement Roof Top HSC-205 / HSC-270 Golf Cart Models: Club Car DS (2000 and up) Club Car Precedent E-Z-GO TXT & RXV Yamaha DRIVE Star Car Bad Boy Buggy / Tomberlin STEALTH *** SEE ADDENDUM FOR WIRING *** 1

2 Congratulations on your new Solar Rooftop!!! The Helios Design Group thanks you for your purchase and your support for solar power. We trust you will be 100% satisfied with your purchase and you enjoy free solar power for years to come. We are fully dedicated to the design and development of solar power and most of all your satisfaction. Package / Panel Contents: Solar Roof Top w/ Attached Vehicle Specific Brackets Power Cable / Harness Zip Ties & Mounting Bases Bolts / Nuts / Washers Watts-Up Meter ( optional power monitoring meter / logger ) Tools & Requirements for Install: Wire Cutter / Stripper (14-18 gauge stranded) Wire Crimper ( or a Combo Stripper / Crimping Tool ) Power Drill ( optional ) 5/8 Bit and 7/8 Bit ( optional ) Ratchet & 7/16 Socket and a 7/16 Wrench 7/8 Wrench (most common for battery terminal bolts) Two People REQUIRED for removing the roof and installing solar top Digital Multimeter (to measure DC Direct Current Voltage ) 2

3 Installation Warning: This installation should be conducted by a trained technician. It involves the handling of high voltage connections. The under surface of the solar roof assembly is covered by a thin white film, this film must remain free of stress, impact or deep scratches at all times or performance of the system may be permanently jeopardized. Please note that installation REQUIRES two people during the removal of the original cart roof and mounting of the solar roof top assembly. Please read each step entirely before proceeding. 1) Remove stock golf cart top. Keeping hardware will allow reinstallment of the original top later, but is not necessary for the kit installation. 2) Route power cable on the driver side rear post. For most model cars the power cable can be routed through the 1-inch square post of the roof top supports. - It is optional to install and drill for the wire strain relief for the power cable as pictured below behind your seat. - You can route the power cable into your car without drilling but it is recommended to install the strain relief included as it will lock in the cable from it being pulled after install. (liquid-tight tubing and connector pictured first are an optional installation accessory) 3

4 3) For Bad Boy Buggy you must cable tie the power cable to the roof support posts as they are sealed and continuous square bars. 4) DO NOT PLUG IN Power cable to the solar roof top panel until all installations and wiring has been completed. Failure to follow this step can result in a damaged panel or electric shock. 5) Open your battery compartment and locate the main battery terminals that provide the car with 48 or 36 volts DC depending on your model. Most cars are 48v please confirm location of your battery terminals as pictured. 6) Cable Tie the power cable to existing cables or use the provided mounting bases to secure your solar power cable to the battery compartment. If you want to keep the extra cable in the battery compartment, please coil the cable in a circle and cable tie it so it does not come loose from a mounting point do not kink the power cable in a zig-zag pattern. 7) Install your new solar rooftop with two people and place the solar roof in-line with the original mounts of the car. The gauge will be towards the front of the car and the power cable plug will be at the rear of the car driver side. 8) Install a washer on the bolt sides. The lock-nut be installed on the inside of the car for safety and esthetic purposes. 4

5 9) For EZ-GO TXT & Bad Boy Buggy / Tomberlin there are no angle brackets as pictured. Please use the four bolts with a washer through the rooftop support beams in the front and back. a. Install the Rubber bumpers / spacers between the roof bracket and your solar roof so the solar roof does not rub against the roof support brackets of the car b. Hand screw the bolts and washer as to not strip the threaded mounts in the panel. c. Do not use excessive force on tightening please use a few drops of blue thread lock on the bolt to keep vibrations from loosening the roof from the mounts. d. We recommend Blue Loctite 242 Available at your local hardware store or mass-merchant stores. 10) For Club Car Precedent You will notice your harness and plug wrapped and cable tied. Cut the cable tie and DO NOT PLUG the Cable into the panel leave it disconnected. You will route the cable through the rain gutter / rear post. The wire will come out of the drivers side rear wheel well you will then route it back up into the battery compartment. (it is a good idea to use a flashlight from battery compartment shining down towards the wheel well so you and you install partner can see how to route the cable) You will use the factory bolts to fasten your new solar roof to the rear supports. 11) Hand tighten all connect points do not use excessive force. Please screw all nuts in by hand before using tools to tighten all connections to avoid stripping threads in the bolt or nut. 12) At this point your panel should be mounted securely to the roof posts. Continue and strip back and crimp your battery terminals to the cable and connect to your according battery posts. Please confirm your 48volt or 36volt battery posts before making all connecting using a digital multimeter. The unit must be connected across all 48V to function properly. It is advisable to make the electrical connections in the shade, not under sunlight. Make sure the area your installation area is well ventilated and free from any combustible vapors or substances. 5

6 As a precaution to the Step #13 below you may experience a spark when you connect your power cable to the panel. This spark is normal and is caused by the capacitors in the charge controller from the solar panel. 13) Confirm once more you have connected to 48volts (36volts on some cars) and Plug in your power cable to the solar roof-top. 14) The batter gauge at the front portion of the roof will now illuminate and show your battery capacity of your car. 15) You are now ready to begin solar charging your golf car with the new HSC-205 / HSC-270 solar roof top. User Guide & FAQ s Frequently Asked Questions: Charging Capacity: Your solar system will output the following charging specs per hour in 100% sunlight condition averaging about six hours per day regionally dependant. 205w Solar Roof 48v: 4.25 amps per hour 270w Solar Roof 48v: 5.6 amps per hour 205w Solar Roof 36v: 5.65 amps per hour 270w Solar Roof 36v: 7.5 amps per hour Our Digital MPPT Charge Controller will continue to operate and output current under low light or minimal light conditions (cloudy day) but will not offer full output as listed above when exposed to lower light conditions. Cleaning: Your Solar Panel should be free of dust and debris at all times. Use only a damp towel with water and mild glass cleaner to clean the glass on the solar panel. The solar panel itself is fully water proof allowing for any type of weather exposure. DO NOT spray water in the underside of the roof where the angled roof edges are located above the driver/passenger and front (where gauge is located). The solar panel should be kept clean of dust and debris to provide 100% performance and charging to your golf / electric / lsv. 6

7 Always check & maintain your battery fluid levels along with keep all battery post bolts and lugs secure and snug on your cables. Helios Controller Status Lights The Status light is located next to the power plug of the panel. Inside the round hole in the roof you will find a Blinking LED where it shows the charging status of the controller. Below you will find the LED color and sequence chart. The HELIOS Maximum Power Point Tracking Solar Battery Charger a status LED. When you first connect your charger to the battery, The LED will blink red and then green for approximately one second, so that you can confirm that the LED is operational. During operation, the LED blinks green to indicate that your charger is powered and charging, and the LED may blink red to indicate errors. Green LED: Short blinks every 2 seconds:... Battery connected, Standby Short blinks every half second:... Charging with low current Long blinks, on 30% of the time:... Charging with medium currents Long blinks, on 80% of the time:... Charging with high currents Long blink-short blink... Overload, limiting current Constant on:... Battery is Fully Charged Red LED: Two Blinks:... Over-Temperature Three Blinks:... Over-Current Four Blinks:... Battery Under-Voltage Five Blinks:... Battery Over-Voltage Two Long Blinks followed by short blinks:... Internal Error The advantages of the Helios Solar Roof System: We offer the highest power and most sophisticated solar system on the market. With only the highest quality and 100% USA Made & Manufactured Products our solar system will provide power in almost all daytime conditions. Helios uses a Digital MPPT Charge Controller This type of charging system with a solar panel uses all available power from the solar panel to provide a charging current to your batteries. This is especially important under low light or cloudy days where your solar panel will output as much 7

8 energy as it can and our controller will work 100% to convert all usable sun energy to recharge your Golf / LSV / Electric / Utility Vehicle. SenDec Battery Gauge: The installed SenDec Battery Meter is essentially a battery fuel gauge. The SenDEC Battery Fuel Gauge is specifically designed to accurately monitor the charge capacity of lead acid batteries used in your electric car. Charge capacity is indicated using the 10 segment LED bar graph display from empty (left) to full (right). SenDec has a built in LED Flash Alert. It will flash the 2nd LED from the left as a warning that the battery has discharged 70%. At 80% discharge, LED Flash Alert flashes the 2 Left LED s to indicate very low capacity is remaining. The SenDec Battery Fuel Gauge calculates the amount of energy in reserve over a small period of time. It is normal to see the gauge fluctuate lower / less capacity after immediate driving. The gauge calculates and recalculates at an average of 6-10 minute increments for proper readings. Gauge Reading Example: Your car is fully charged and you begin driving for 10, 20, 30 minutes and now you have ceased driving because you gauge may show 50-70% capacity remaining. Please Do NOT Be Alarmed! It is normal for your gauge to not read a full 100% even though the car was just fully charged. There has been a considerable decrease in voltage as your car was in use and in motion driving but the voltage restores after the car is no longer in motion / driving use. *** Please allow about 6-10 minutes of time for your gauge to re-calculate the resting voltage of your batteries and properly display your battery capacity / amount of run time left. *** Many users have been concerned with this issue but electric stored energy is not as easy to calculate as a fuel source that has a float system to 8

9 constantly monitor fuel levels. Please allow a few minutes to pass to accurately read the SenDec Battery Fuel Gauge. WARRANTY: Helios Solar Chargers, Inc. products are guaranteed to be free from defects in material and/or workmanship and to perform as advertised when properly installed, used, and maintained in accordance with written instructions. Failure to adhere to and/or comply with operation manual instructions will void all associated warranty obligations. Should any part(s)/solar charging systems prove defective within two years from date of purchase, it(they) will be replaced F.O.B. our factory, or branch, without charge provided the defective part(s) is returned to our factory or branch transportation charges prepaid. PURCHASER MUST PROVIDE PROOF OF DATE OF PURCHASE WITH ANY WARRANTY CLAIM. EXCLUSIONS: Helios Solar Chargers, Inc. will not be responsible for labor charges, loss, or consequential damage of any kind or character caused by defective parts or for charges incurred in the replacement or repair of defective parts by Purchaser. This warranty does not apply when damage is caused by sand or abrasive materials, chemical deposits, collision, unreasonable/unintended use, improper installation, non-approved alteration/modification, corrosion, neglect and acts of god. Careless handling, including that by freight companies, and improper installation or use may void all warranties. SOLE REMEDY: Helios Solar Charger s liability under this limited warranty, or in any action whether based upon warranty, contract, negligence, strict product liability or otherwise, shall be the repair or replacement, at Helios Solar Charger s option, of the system or component thereof that Helios Solar Chargers, Inc. deems to be defective. Replacement shall mean furnishing, during the applicable limited warranty period, a new product or factory-reconditioned product or component thereof that is identical or reasonably equivalent to the warranted product or component at no cost to the purchaser. Repair shall mean remedying a defect in the product or component thereof at no cost to the purchaser during the applicable limited warranty period. If Helios Solar Chargers, Inc. elects to repair the product, it may provide factory-reconditioned parts or components. All parts and components replaced under warranty shall become the property of Helios Solar Chargers, Inc. DISCLAIMER: THIS LIMITED WARRANTY IS EXCLUSIVE. HELIOS SOLAR CHARGERS, INC. MAKES NO OTHER WARRANTY OF ANY KIND, EXPRESSED OR IMPLIED. ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS OR TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY HELIOS SOLAR CHARGERS, INC. AND EXCLUDED FROM THIS WARRANTY. THE PURCHASER AND HELIOS SOLAR CHARGERS, INC. EXPRESSLY AGREE THAT THE SOLE REMEDY OF THE REPLACEMENT OR REPAIR OF THE DEFECTIVE SOLAR CHARGING SYSTEM OR COMPONENT THEREOF IS THE SOLE REMEDY OF THE PURCHASER. HELIOS SOLAR CHARGERS, INC. MAKES NO OTHER REPRESENTATION OR WARRANTY OF ANY KIND, AND NO REPRESENTATIVE, EMPLOYEE, DISTRIBUTOR OR DEALER OF HELIOS SOLAR CHARGERS, INC. HAS THE AUTHORITY TO MAKE OR IMPLY ANY REPRESENTATION, PROMISE OR AGREEMENT, WHICH IN ANY WAY VARIES THE TERMS OF THIS WARRANTY. INFORMATION: For further information contact HELIOS SOLAR CHARGERS, INC., 1901 NW67th Place STE I, Gainesville, Florida 32653, U.S.A., NO CONSEQUENTIAL DAMAGES: IN NO EVENT SHALL HELIOS SOLAR CHARGERS, INC. BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING, BUT NOT LIMITED TO, LOSS RELATED TO PROPERTY OTHER THAN THE SOLAR SYSTEM, LOSS OF USE, LOSS OF TIME, INCONVENIENCE, OR ANY OTHER ECONOMIC LOSS. Some states allow neither limitation on the duration of an implied warranty nor exclusions or limitation of incidental or consequential damages. Therefore, the above limitations or exclusions may not apply to you. This warranty gives you specific legal rights, and you may also have other rights, which vary from state to state. 9

10 WARRANTY TRANSFER: The original owner shall have the right to transfer any remaining warranty coverage to one subsequent purchaser only. In order for the original owner to transfer any remaining warranty coverage to a subsequent purchaser, Helios Solar Chargers, Inc. must be notified of such transfer and it must take place within the first year of operation. No transfers of any remaining warranty coverage shall be permitted by any subsequent purchasers. RETURNS: A product may be returned within (2) weeks of delivery (prepaid shipping), provided it is returned in 100% original condition and unused. Our products are custom manufactured and a 20% restocking fee (unit invoice price) applies to all returned products WARNING: Any modification or alteration of any solar system beyond factory specifications, including those that affect the performance, structural integrity of the system or electric vehicle can cause serious personal injury or death. This product is built to withstand condensation, however it is not 100% water resistant. Long term exposure to heavy rain/water can damage/disable your unit. This is not covered under warranty. Helios Solar Chargers, Inc. s warranty terms and conditions are subject to change without notice. A current copy of our warranty and policies can be requested via mail or via our website. Compatibility is guaranteed with factory golf carts, we cannot guarantee our product s compatibility with aftermarket products and accessories, such as cabins, seat kits and other modifications to the stock configuration of the golf cart. We are committed to serving your solar transportation and portable battery charging needs. Feedback is always welcome on our products. For technical help or sales please contact your local dealer or Helios Solar Chargers Inc. at Please visit for additional support and to browse our continuous and expanding product line. DEALER INFO: 10

11 Helios Solar Chargers, Inc State Road 54 #205 Lutz, FL Phone 11