TECHNICAL INSTRUCTIONS 76-50213-00 Solar Charger Kit This kit provides the necessary parts and instructions to install an optional Battery Solar Charger Kit. The solar panel charging system will help maintain battery voltage during extended unit off cycles. KIT CONTENTS Item No. Quantity Part Number Part Description 1 1 22-50436-00 Solar Panel (79 x 14 ) 2 1 22-50426-00 Solar Charge Controller 3 1 22-50428-00 Harness, Wire (Panel) 4 1 22-50429-00 Harness, Wire (Battery) 5 2 62-90841-00 Label, Attention 6 3 34-00373-54 Clamp, Cushion (7/16 ) 7 3 34-50086-00 Screw, Self-Drilling/Tapping #8-18 x ½ L 8 3 34-50087-04 Screw, Self-Drilling/Tapping #1/4-14 x 1 L 9 1 34-00967-12 Screw M6 X 12mm 10 25 66-U---1--3882 Wire Tie 11 16 58-50157-00 Mount, Adhesive, Wire Tie 12 16 58-50158-00 Wire Tie ( 4 ¼ ) 13 1 98-50767-00 Instructions, Technical SAFETY PRES SAFETY Your Carrier Transicold unit has been designed with the safety of the operator in mind. During normal operation, all moving parts are fully enclosed to help prevent injury. During all pre-trip inspections, daily inspections, and problem troubleshooting, you may be exposed to moving parts. Please stay clear of all moving parts when the unit is in operation and when the unit main power switch is in the START/RUN position. Engine Coolant The engine is equipped with a pressurized cooling system. Under normal operating conditions, the coolant in the engine and radiator is under high pressure and is very hot. Contact with hot coolant can cause severe burns. Do not remove the cap from a hot radiator. If the cap must be removed, do so very slowly in order to release the pressure without spray. Battery This unit is equipped with a lead-acid type battery. The battery normally vents small amounts of flammable hydrogen gas. Do not smoke when checking the battery. A battery explosion can cause serious physical harm and/or blindness. 98-50767-00 Rev A Page 1 of 8
TECHNICAL INSTRUCTIONS SPECIFIC WARNING AND STATEMENTS To help identify the label hazards on the unit and explain the level of awareness each one carries, an explanation is given with the appropriate consequences: DANGER DANGER - warns against an immediate hazard which WILL result in severe personal injury or death. WARNING WARNING - warns against hazards or unsafe conditions which COULD result in severe personal injury or death. - warns against potential hazard or unsafe practice which could result in minor personal injury, or product or property damage. NOTE NOTE - gives helpful information that may help and avoid equipment and property damage. The statements listed below are specifically applicable to this unit and appear elsewhere in this manual. These recommended precautions must be understood and applied during operation and maintenance of the equipment covered herein. Be sure to secure wires away from moving components. Make sure connectors and wires are secure and do not contact sharp, hot or moving components. WARNING Ensure all technicians working on roofs are properly tethered or secured against falling off of the roof. Technicians should wear appropriate Personal Protective Equipment (PPE). 98-50767-00 Rev A Page 2 of 8
TECHNICAL INSTRUCTIONS CHARGE CONTROL & HARNESS INSTALLATION 1. Verify correct unit operation prior to beginning work. 2. Before performing any work on the unit, place the SROS in the OFF position and disconnect the negative battery cable from the battery. 3. Locate the charge controller IT#2 as close to the battery as possible on a back frame member or on the diagonal support beside the battery. Mark and drill the controller mounting holes using a 1/8 drill bit. Using self-tapping screws IT#7, secure the charge controller to the unit frame, making sure the wire leads are centered through the bottom opening of the control housing. (See Figures 1, 2 & 3) NOTE: The controller can also be located on the roadside of the unit if there is no space available in or near the battery area. INSTRUCTIONS Charge Controller IT #2 and Screws IT #7 Figure 3, Middle Roadside Access 4. Connect the battery wire harness IT#4 to the (+) positive and the (-) negative starter studs making sure the fuse holder lead is connected to the (+) positive stud. Torque the starter positive (+) connection to 6-8 FT LBS [8.1-10.8 Nm]. Route the battery harness along the battery cables, under the compressor along the main engine harness terminating connector to the charge controller. Secure the harness tightly with wire ties IT#10 every 6 inches. (See Figures 4, 5, 6 & 7) Battery Wire Harness IT#4 Figure 1, Middle Curbside Access Positive (+) Lead Torque connection to 6 8 FT LBS [8.1 10.8 Nm] Negative Lead (-) Figure 2, Lower Curbside Access Figure 4, Front Engine Access 98-50767-00 Rev A Page 3 of 8
Be sure to secure wires away from moving components. 5. Connect solar panel wire harness IT#3 to charge controller IT#2, routing the harness along main unit harness up the diagonal frame member to upper frame area. Secure the harness tightly with wire ties IT#10 every 6 inches. (See Figures 7 & 8) Battery Wire Harness IT#4 Charge Controller Connectors IT#2 Figure 7, Middle Curbside Access Battery & Solar Panel Wire Harness IT S #3 & 4 Figure 5, Front Compressor Access Solar Panel Wire Harness IT#3 Battery Wire Harness IT#4 Figure 8, Upper Curbside Access SOLAR PANEL INSTALLATION Figure 6, Front Compressor Access Make sure connectors and wires are secure and do not contact sharp, hot or moving components. WARNING Ensure all technicians working on roofs are properly tethered or secured against falling off of the roof. Technicians should wear appropriate Personal Protective Equipment (PPE). Before you begin panel installation: Prior to permanently installing the solar panel, verify with a digital volt meter on DC scale, the voltage from the solar panel when it is exposed to sunlight is above 17VDC (see SOLAR PANEL VOLTAGE OUTPUT). 98-50767-00 Rev A Page 4 of 8
NOTE: DO NOT FOLD OR CREASE SOLAR PANEL. Panels can be rolled with the dark side facing out. DO NOT roll to tight. Rolling the panel to tightly will likely reduce the effectiveness of the solar panel. The inner roll should measure at least 3 across. NOTE: It is recommended to install the panel out of direct sunlight. The solar panel uses an industrial Butyl adhesive to ensure a permanent installation. If the adhesive is too cold, the panel will not bond properly. If the adhesive is too hot, the release liner covering the adhesive will become difficult to remove and installation can become messy. For best results, install the solar panel when the ambient temperature is between 40 F and 80 F (4 C to 27 C). For optimum adhesive performance, the recommended installation temperature is 50 F (10 C) or above. In lower temperatures the solar panel and mounting surface can be warmed to this temperature prior to installation. NOTE: Before exposing the permanent adhesive, position the solar panel on top of the trailer/boxcar roof to ensure proper fitting, mark the roof with a pencil to ease alignment if necessary. Do not install the solar panel on a roof where the roof sags and water may pool. The solar panel should be positioned on the roof as far forward as possible to insure connectors can be terminated in the TRU frame. While the solar panel is very lightweight, best alignment of the panel to the roof will be achieved by having two people involved. Figure 9, Front Curbside of Trailer Roof 6. Clean the roof surface, all oxidation, dust and dirt particles must be removed for proper bonding. If required, pressure wash or mechanically clean area where the panel will be installed. 7. Clean the panel area with alcohol-based cleaning solution removing any oils - mix equal parts rubbing alcohol and water to yield suitable cleaning liquid. 8. Wait until the roof surface has dried BEFORE applying the solar panel. 9. Position the solar panel so the wires on the panel are on the battery side of the unit. (See Figure 9 & 10) Figure 10, Front center of Trailer Roof 10. Starting from the front of the trailer roof remove 1-2 inches of the release liner exposing the adhesive and apply to the roof (aligning with previously marked guide marks). Before continuing, make any alignment adjustments needed for proper installation. (See Figure 11) NOTE: The solar panel can be mounted on either side of the trailer/car depending on the location mounting of the charge controller as long as the panel connectors can be terminated in the frame area of the TRU. 98-50767-00 Rev A Page 5 of 8
13. For rail installation, secure the solar panel wire harness to the rooftop as needed very six inches using adhesive tie-wrap mount (item 11) and wire tie (item 12). Clean the tie-wrap mount location as outlined in step # 6 then clean area with rubbing alcohol. Note: The tie-wrap mount requires 24 hours to cure for maximum strength. 14. Secure the solar panel wiring harness to the rooftop front extrusion using (2) cushion clamps IT#6 and self-tapping screws IT#8 to remove any strain from the harness pulling on the panel. Note: Pre-drill clamp mounting holes with a 9/64 drill bit if necessary. (See Figure 13) NOTE: Do not drill or install clamps into roof liner. Figure 11, Rail Car Roof NOTE: Do not let the solar module stick to itself at any time, as it is very difficult to separate the butyl adhesive once joined. Clamps IT#6 & Self-Tapping Screws IT#8 Moving from the front of the roof to the rear, continue to remove the release liner, adhering the panel to the roof until all the release liner has been removed. (See Figure 11) 11. Apply light pressure with your hand or a j-roller (available from most hardware stores in the laminate counter top department) to ensure that the entire solar panel is firmly joined to the roof. NOTE: It is recommended to work from the center of the panel out to the edges and avoid bubbles from occurring between the adhesive and the top. 12. Apply LocTite 5512 or Carrier P/N 02-0067-01 (not provided) around the entire perimeter of the panel (See Figure 12). Figure 13, Top Front Trailer Roof 15. Terminate solar panel connectors to solar panel wire harness and secure to TRU frame using cushion clamp IT#6 and M6 screw IT#9. Secure the connectors and the harness tightly with wire ties IT#10 every 6 inches. (See Figure 14) Clamp IT#6 & Screw IT#9 Figure 14, Inside Top Trailer Unit Figure 12, Trailer roof Make sure connectors and wires are secure and do not contact sharp, hot or moving components. 98-50767-00 Rev A Page 6 of 8
16. Install new labels IT#5 on TRU frame, one near the charge controller and the other near the unit serial / model number label. (See Figures 15 & 16) SOLAR PANEL VOLTAGE OUTPUT The minimum open circuit voltage defining functional output is 17VDC. This is the voltage required to assure proper battery charging operation, the testing procedure is as follows: NOTE: Open circuit voltage is to be measured while the panel is in direct sunlight with the sun at no more than a 45 degree angle from perpendicular. Figure 15, Roadside Access Figure 16, Curbside Access Label IT#5 Label IT#5 1. Clean panel surface with soap and water. 2) Verify unit SROS is in the OFF position and disconnect unit negative battery cable from the battery. 3) Disconnect the panel wire harness (22-50428-00) from the charge controller (22-50426-00). 4) Measure the voltage at the solar panels connectors the minimum voltage should be 17 volts DC or greater. FIELD TESTING THE SOLAR CONTROLLER P/N 22-50426-00 NOTE: The controller is powered from the battery, not the solar input. A battery is required for operation to power the controller. This testing procedure was developed for use in field conditions where no external power sources are available. Due to the construction of the controller, it is possible only to determine whether the unit is functioning properly. It is not always apparent what component has failed or the cause for the failure. It is left up to the technician to determine the cause for the controllers failure based on evidence present at the site (i.e. burned leads, excessive loads, evidence of short circuits on system wiring, etc) The procedures outlined below assume a basic knowledge of electrical circuits and the necessary safety precautions to be used when working with live circuits present in solar energy systems. You will need a Digital multi-meter (frequency and duty cycle measurements are helpful) for this procedure. CHECK SOLAR PANEL OPERATION 1. Reconnect the negative battery cable to the battery. 2. Remove the 5 amp fuse from the battery harness that attaches to the starter. 3. Measure the battery voltage with the SROS in the OFF position. 4. Re-install the fuse and check the battery voltage. The battery voltage should be higher depending on the amount of direct sunlight. 5. Connect a DC Amp clamp around the wire with the fuse installed. Depending on the battery voltage and the amount of sunlight, the current will vary from 0-4 amps. TESTING PROCEDURE 1) No power connected to the controller a) With no power connected to the controller, check for short to ground between the following leads: i) Solar (+) and Solar (-) ii) Battery(+) and Battery(-) If short exists controller is damaged and not operational. b) Check for continuity between the ground connections on the Solar (-) and Battery (-) leads. If an open circuit exists the controller has a damaged ground trace or a wire is broken and not operational. 2) Battery power connected to the controller battery leads only. 98-50767-00 Rev A Page 7 of 8
a) Measure the voltage at the battery leads b) Measure the voltage at the solar leads. The voltage should be less than 1.5 V DC (negative due to the diode drop across the input circuit). If battery voltage is measured, the input circuit is damaged and the controller will not operate properly. 3) Solar and battery power applied to the controller. a) With both solar and battery connected to the controller the solar and battery voltages should be the same UNTIL the battery voltage has reached the controllers regulated set-point (14.1 V @ 25C) b) If the battery is charged, there will be a voltage difference between the battery (+) lead and the solar (+) lead. If your DVM has a frequency measuring option, a 300 Hz AC signal should be measured between battery (+) and solar (+). The duty cycle of this signal can also be measured to give a rough indication of the battery state of charge. The lower the duty cycle, the more charged the battery. SCHEMATIC: FINAL SYSTEM CHECKS 1. Ensure that all connections are secure and weather-protected and that the controller is housed from the elements. 2. Check the condition of the 5 amp fuse. 3. Verify the panel & controller wiring is correct. 4. Check all connections and terminals for good electrical contact. INSPECTION & PREVENTATIVE MAINTENANCE 1) Inspect wire harness on rooftop and correct any issues found within first 30 days, Semi Annual thereafter. 2) Inspect solar panel adhesion to rooftop and panel edge caulking for cracks, repair as needed within first 30 days, Semi Annual thereafter. 3) Clean solar panel surface with soap and water every 90 days for optimal performance. 98-50767-00 Rev A Page 8 of 8