Global Solar powerflex User manual

Global Solar Energy recommends having the
PowerFLEX™ MOBILE Solar Kit professionally installed.
Although the kit is relatively straightforward to install,
working with high current battery systems and working
on the roof of the RV can be dangerous.
Global Solar Energy will be happy to work directly with
your dealer or service center of choice to ensure a
proper, long lasting installation. Just send us their
contact information or have them contact us and we’ll
take care of the rest.
GSE Document: 1000564 Rev. E

PowerFLEX
TM
MOBILE
Solar Power for Your RV
READ THIS PRIOR TO INSTALLING
The PowerFLEXTM MOBILE Solar Charging Kit is intended for use on newer roofs
that are in good condition when using only the adhesive to secure the solar panel
to the roof.
Cleaning the roof is critical in obtaining a safe, secure and long-lasting
installation. Failure to follow the included instructions can result in loss of
adhesion, damage or loss of the product, and shortened product life.
Mechanical fasteners such as screws or rivets are recommended in any
installation where the quality of the roof is questionable or if the vehicle is to be
used in extreme environments.
Contact Global Solar Energy Technical Support if you have any questions,
concerns or would like to discuss you special application.
GSE Document: 1000564 Rev. E

PowerFLEXTM MOBILE
Installation Instructions
Solar Power for Your RV
Global Solar Energy, Inc.
8500 S. Rita Road
Tucson, AZ 85747
Technical Support
www.GlobalSolar.com
520-546-6313
DOCUMENT NO. 1000564 REV. E
www.GlobalSolar.com
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2
Contents:
INTRODUCTION & SAFETY INFORMATION.......................................................................................................3
KIT CONTENTS..................................................................................................................................................4
TOOLS REQUIRED FOR INSTALLATION.............................................................................................................4
OTHER ITEMS ...................................................................................................................................................4
STORAGE & HANDLING PRECAUTIONS............................................................................................................5
INSTALLATION OVERVIEW ...............................................................................................................................5
SOLAR PANEL LOCATON...................................................................................................................................6
ROOF SURFACE PREPARATION ........................................................................................................................6
INSTALLING THE SOLAR PANELS ......................................................................................................................8
INSTALLING THE EDGE TRIM............................................................................................................................9
SPECIAL ROOF TYPES......................................................................................................................................12
LOCATING THE SOLAR CHARGE CONTROLLER...............................................................................................12
ROUTING THE CABLE......................................................................................................................................13
CONNECTING THE WIRING ............................................................................................................................17
MAINTENANCE...............................................................................................................................................18
APPENDIX.......................................................................................................................................................20
Technical Support.......................................................................................................................................20
About The Solar Charge Controller............................................................................................................20
Charge Controller Specications: ...............................................................................................................21
Solar Panel Specications:.........................................................................................................................21
Installaon Summary Chart .......................................................................................................................22
WARRANTY REGISTRATION...............................................................................................................................................19
DOCUMENT NO. 1000564 REV. E
Global Solar® PowerFLEX™ Mobile Limited Warranty................................................................................ 23

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INTRODUCTION & SAFETY INFORMATION
The PowerFLEXTM MOBILE Kit product line, the premier solar solution for RV’s , has been
specically developed for use on recreational vehicles and will provide years of reliable service
when properly installed.
IMPORTANT
READ THESE INSTRUCTIONS COMPLETELY BEFORE BEGINNING INSTALLATION
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN DAMAGED PRODUCT, DAMAGE TO THE RV, AND/OR
PERSONAL INJURY
GLOBAL SOLAR ENERGYHIGHLY RECOMMENDS HAVING THIS SYSTEM INSTALLED BY A PROFESSIONAL RV
TECHNICIAN
THE INSTALLER SHOULD BE FAMILIAR WITH:
DC electrical systems and wiring in RVs
Working with high capacity battery systems
ADDITIONAL PRECAUTIONS
NEVER MIX SOLAR PANELS OF DIFFERING BRANDS, PART NUMBERS OR POWER RATINGS IN THE SAME SYSTEM.
DOING SO WILL RESULT IN POOR PERFORMANCE AND MAY DAMAGE COMPONENTS
WORKING WITH ELECTRICITY AND LEAD ACID BATTERIES CAN BE DANGEROUS
INSTALLATION OF THE SOLAR PANELS REQUIRES WORKING ON THE ROOF OF THE RV WHERE THERE IS A RISK OF
FALLING
WARNING!
SOLAR PANELS PRODUCE ELECTRICITY WHEN EXPOSED TO LIGHT
EVEN WHEN NOT CONNECTED TO THE SYSTEM. THE SOLAR PANELS
SHOULD BE COVERED WHENEVER WORKING ON THE SOLAR POWER
SYSTEM IN ORDER TO AVOID ELECTRICAL SHOCK AND/OR ARCING.
DOCUMENT NO. 1000564 REV. E

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KIT CONTENTS
Your PowerFLEXTM MOBILE Solar Power Kit includes the following items:
ITEM PFM-2K PFM-1K PFM-1E
PowerFLEX Solar Panel 2 1 1
Solar Charge Controller Kit
1. Charge Controller, 1ea.
2. StandoffBlocks, 2ea.
3. Ring Terminals, 2ea.
4. #6 x 1” Screws, 2ea.
5. #6 x 2” Screws, 2ea.
1 1 -
Edge Trim Set (7 pieces)
2
1
1
Top right, top le, boom, (4) sides
Structural Adhesive Caulking 300 ml-310 ml 1 1 1
Cable with PV connector (1 Pos, 1 Neg) 20’ 20’ 0
Cable, 10 AWG/2-Conductor 20’ 20’ 0
Y-Connector Set (1 Pos, 1 Neg) 1 0 1
Inline ATC Fuse Holder w/20A Fuses
2
2
-
Ring Terminal, 10 AWG (Large)
2
2
-
Cable Tie Mounts
10
4
10
Cable Ties 14 6 14
TOOLS REQUIRED FOR INSTALLATION
Safety glasses suitable for use around liquid chemicals
Phillips screw driver
Wire cuers and strippers
Caulking gun
Crimping tool for 10 AWG connectors (ratcheng type preferred)
Ulity knife
OTHER ITEMS
Roof cleaning supplies appropriate for roof type
Medium Synthec Bristle Brush (E.g. deck scrub brush)
Mild Liquid Dish Soap or RV-dealer-recommended wash
Warm Water
Isopropyl Alcohol >70%
DOCUMENT NO. 1000564 REV. E

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Pressure Washer / Hose With Spray Nozzle
Tape measure
STORAGE & HANDLING PRECAUTIONS
Failure to follow these Storage and Handling guidelines can lead to product damage and premature failure
and violate the PowerFLEXTM MOBILE Limited Warranty.
For the protecon of PowerFLEXTM MOBILE kits, the kit contents and sealed boxes must always be
stored between temperatures of 60°F (15°C) and 85°F (30°C).
Do not use screws, nails, staples or otherwise puncture any part of the solar panel.
The PowerFLEXTM solar panel must not be rolled to a diameter smaller than 20”. Doing so may
result in permanent internal damage and lead to immediate or premature failure. Do not fold or
crease the solar panel.
Scratches on the panel surface can occur if walked on improperly. Guidelines to avoid such
damage include:
oKeep walking on the solar panel to an absolute minimum.
oDo not walk on the solar panel with hard soled shoes.
oInspect shoe tread for rocks or debris before stepping on the panel.
oBe careful not to drop objects on the solar panel.
The solar panel surface is slippery. Use extreme cauon.
Do not aempt to open the solar panel’s juncon box. The juncon box contains no user
serviceable parts.
Do not aempt to open the solar charge controller. The controller contains no user serviceable
parts.
The solar panel can become very hot when le in direct Sun light. Gloves may be required in
hoer climates.
INSTALLATION OVERVIEW
The installaon of the PowerFLEXTM MOBILE solar kit is fairly simple and straight forward with a lile
planning. The key installaon steps are:
1. Choose a suitable locaon for the solar panel(s).
2. Prepare roof surface.
3. Install the solar panels, edge adhesive, and edge trim.
4. Choose the internal RV locaon for the charge controller.
5. Route the cable from the solar panels to the charge controller and then to the baeries.
6. Connect the wiring.
DOCUMENT NO. 1000564 REV. E

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SOLAR PANEL LOCATON
The following recommendaons for locaon of the PowerFLEXTM solar panels are important to ensure
best performance and aesthecs. The PowerFLEXTM solar panels:
Need to be placed close enough to each other so that the pre-fabricated cables will reach. The
included “Y” cables in the two panel system will allow the panels to be placed 6’-7’ apart.
Route the cables such that they are not pulling or placing stress on the panel’s juncon box.
Bends or turns in the wiring should be gentle and as large as possible.
Can be posioned either in-line with the RV or across it.
Should be located in an area that is not shaded by the AC unit, satellite or TV antenna, roof vents,
etc…
Require a minimum of 21.5” x 81.5” area, including edging.
Note: It is a good idea to “dry fit” the solar panels and edge trim components prior to permanently
adhering them to the roof.
ROOF SURFACE PREPARATION
PROPER ROOF PREPARATIONIS PARAMOUNT TO ATTAIN THE NECESSARY LONG-TERM
ADHESION OF THE PANEL AND MOUNTING STRUCTURE
Follow all recommendaons in this secon for Roof Preparaon and associated precauons
Addional Precauons and Warnings
New EPDM roofing surfaces may contain a layer of mica or other nonsck layer. This layer must
be removed.
Citrus based cleaners, denatured alcohol, or mineral spirits are not recommended for use on
EPDM rubber roofing materials.
All roofing surfaces can be very slippery when wet. Extreme cauon should be taken and it is
recommended to navigate the roofing surface on your hands and knees. This will greatly reduce
the risk of falling.
Note: For older rubber (EPDM) roofs, the solar panels should be adhered to the roof with screws
as described in “SPECIAL ROOF TYPES” secon.
DOCUMENT NO. 1000564 REV. E

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Direcons forRoof Preparaon
A. Use a pressure washer or a hose witha spray nozzle toremove loose dirt and debris from the
enre roof.
B. Combine your mild liquid dish soap soluon with warm water in a bucket or spray bole.
a. A 20:1 rao of warm water and mild liquid dish soap cleaner should be sufficient for new
roofing surfaces (about 6oz of soap per gallon of water). Using cold or tepid water is not
recommended as this will reduce the strength of the adhesive bond.
b. Alwaysconsult withthe RV manufacturer for opmal cleaning methods.
C. Using a medium bristle brush and the cleaning soluon begin scrubbing the roofing surface in
small areas that are easily reachable on your hands and knees(E.g. arm’s length or 3’ X 3’ areas).
a. Beginning at one end of the roof and working toward the point of exit on the roof where
the solar panels will be placed.
b. Be sure toalso prepare the areas where the cable e mounts will be placed [See secon
for ROUTING THE CABLE].
D. Scrub the roofing surface ina circular moon applying a moderate amount of pressure unl any
visible evidence of dirt and debris is removed. Oen, aer surface dirt is removed, a light yellow
surface coloraon is observable. If such a yellow surface is visible, repeat the scrubbing step unl
the yellow disappears, leaving a clean white colored surface.
E. Rinse the roof with water thoroughly toavoid any residue buildup.
F. For EPDM roofs, wipe the area where the PowerFLEXTM panels will be adhered with Isopropyl
Alcohol.
G. Inthe case of Gel-coated Fiberglass roofs, the isopropyl alcohol wipe is not required. However, a
final surface wax removal step is required with an appropriate wax-remover or acetone is
required. All the other surface preparaon steps are idencal toEPDM roofs.
DOCUMENT NO. 1000564 REV. E

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INSTALLING THE SOLAR PANELS
WARNING!
SOLAR PANELS PRODUCE ELECTRICITY WHEN EXPOSED TO LIGHT
EVEN WHEN NOT CONNECTED TO THE SYSTEM. THE SOLAR PANELS
SHOULD BE COVERED WHENEVER WORKING ON THE SOLAR POWER
SYSTEM IN ORDER TO AVOID ELECTRICAL SHOCK AND/OR ARCING.
A. The PowerFLEXTM solar panels included a long piece of cardboard in the package. This piece of
cardboard should be cut to the length of the solar panel and used to shade it during the
installaon. Use tape to hold the cardboard in place.
B. Start by aligning the solar panel to the posion chosen when locang the panels. As shown below,
roll back one end of the panel about 2 feet and remove 10”-12” of the protecve paper liner to
expose the adhesive. Lay the panel back down and apply pressure to bond to the roof surface.
C. Next, as shown below, go to the other end of the panel and roll it back towards the end already
adhered. Pull the protecve paper liner offslowly in 2 foot increments, applying pressure
starng from the center and working towards the outer edges unl the enre panel is affixed to
the roof.
DOCUMENT NO. 1000564 REV. E
DOCUMENT NO. 1000564 REV. E