Hali-Brite SPS Series Manual

Installation and Maintenance Manual
SPS
Solar Power Supply
Hali-Brite®Inc.
1119 Madison St
Brainerd, MN 56401
Tel: [phone]
Fax: [phone]
www.halibrite.com
Copyright © 2020 Hali-Brite®Inc., Brainerd, MN, U.S.A. Printed in U.S.A. Rev. 6

2SPS Installation and Maintenance Manual

SPS Installation and Maintenance Manual 3
Table of Contents
1Introduction................................................................................................................. 4
1.1 About this Manual............................................................................................... 4
1.2 Model Configurations......................................................................................... 4
1.3 Warranty ............................................................................................................. 4
1.4 Disclaimers ......................................................................................................... 5
2Safety Precautions....................................................................................................... 6
2.1 Safety Statements................................................................................................ 6
2.2 General Practices ................................................................................................ 6
2.3 Electrical Practices.............................................................................................. 7
2.4 Qualified Personnel............................................................................................. 8
2.5 Proper Usage....................................................................................................... 8
3Specifications.............................................................................................................. 9
3.1 Electrical Specifications...................................................................................... 9
3.2 Physical Specifications ....................................................................................... 9
3.3 Environmental Specifications............................................................................. 9
4Installation................................................................................................................. 10
4.1 Unpacking......................................................................................................... 10
4.2 Tools and Supplies Needed............................................................................... 10
4.3 Installation......................................................................................................... 11
5Maintenance.............................................................................................................. 19
5.1 Maintenance Schedule ...................................................................................... 19
6Repair........................................................................................................................ 20
6.1 Battery Replacement......................................................................................... 20
6.2 Fuse Replacement............................................................................................. 20
6.3 Solar Panel Replacement .................................................................................. 21
6.4 Charge Controller Replacement........................................................................ 22
6.5 Frangible Coupling Replacement ..................................................................... 23
6.6 Solar Panel Angle Adjustment.......................................................................... 25
6.7 Photocell Replacement...................................................................................... 25
7Replacement Parts..................................................................................................... 26

4SPS Installation and Maintenance Manual
1 Introduction
1.1 About this Manual
The information in this manual is provided to assist installation and maintenance
personnel in the proper installation, upkeep, and maintenance of the SPS Solar
Power Supply.
1.2 Model Configurations
SPS-135-2-12: 135 watt panel, 2 batteries, short legs
SPS-135-2-30: 135 watt panel, 2 batteries, tall legs
SPS-135-3-12: 135 watt panel, 3 batteries, short legs
SPS-135-3-30: 135 watt panel, 3 batteries, tall legs
SPS-50-2-12: 50 watt panel, 2 batteries, short legs
1.3 Warranty
Solar Panel: The solar panel warranty is offered by the manufacturer, BP Solar.
Please refer to the warranty materials included with this manual, and contact the
manufacturer directly for warranty claims.
Batteries: The battery warranty is offered by the manufacturer, Concorde Battery
Corporation. Please refer to the warranty materials included with this manual,
and contact the manufacturer directly for warranty claims.
The warranty for the other components of the SPS is offered by Hali-Brite®as
follows:
Hali-Brite®products are guaranteed against mechanical, electrical, and physical
defects (excluding lamps) for a period of one year from the date of installation
or a maximum of two years from the date of shipment and are guaranteed to be
merchantable and fit for the ordinary purposes for which such products are
made. Hali-Brite®will correct by repair or replacement, at its option, equipment
or parts which fail because of mechanical, electrical or physical defects, provided
that the goods have been properly handled and stored prior to installation,
properly installed and properly operated after installation, and provided further
that Buyer gives Hali-Brite®written notice of such defects after delivery of the
goods to Buyer. Hali-Brite®reserves the right to examine goods upon which a
claim is made. Said goods must be presented in the same condition as when the
defect therein was discovered. Hali-Brite®further reserves the right to require the
return of such goods to establish any claim. Hali-Brite’s obligation under this
guarantee is limited to making repair or replacement within a reasonable time
after receipt of such written notice and does not include any other costs such as
the cost of removal of defective part, installation of repaired product, labor or
consequential damages of any kind, the exclusive remedy being to require such

SPS Installation and Maintenance Manual 5
new parts to be furnished. Hali-Brite’s liability under no circumstances will exceed
the contract price of goods claimed to be defective. Any returns under this
guarantee are to be on a transportation charges prepaid basis. For products not
manufactured by, but sold by Hali-Brite®, warranty is limited to that extended by
the original manufacturer. This is Hali-Brite’s sole guarantee and warranty with
respect to the goods; there are no express warranties or warranties of fitness for
any particular purpose or any implied warranties of fitness for any particular
purpose or any implied warranties other than those made expressly herein. All
such warranties being expressly disclaimed. Details and values given in this
manual are average values and have been compiled with care. They are not
binding, however, and Hali-Brite®disclaims any liability for damages or
detriments suffered as a result of reliance on the information given herein or the
use of products, processes or equipment to which this manual refers. No
warranty is made that the use of the information or of the products, processes or
equipment to which this manual refers will not infringe any third party’s patents or
rights. The information given does not release the buyers from making their own
experiments and tests.
1.4 Disclaimers
This manual is published for informational purposes only and the information
provided should not be considered as all-inclusive or covering all contingencies.
If further information is required, Hali-Brite®Inc. should be contacted. Sale of the
product shown in this manual is subject to Hali-Brite’s terms and conditions
including, but not limited to, the Hali-Brite®Warranty. Such terms and conditions
are available upon request. Hali-Brite’s warranty will not apply to any products
which have been “so repaired or altered outside the manufacturer’s plants as, in
the manufacturer’s judgment, to affect its reliability and performance.”
No warranties, express or implied, including warranties of fitness for a particular
purpose or merchantability, or warranties arising from course or dealing or
usage of trade, are made regarding the information, recommendations, and
descriptions contained herein. The manufacturer is not responsible and will not
be held liable in contract or in tort (including negligence) for any special, indirect
or consequential damages, including injury or damage caused to vehicles,
contents or persons, by reason of the installation of any Hali-Brite®product or
its mechanical or electrical failure.

6SPS Installation and Maintenance Manual
2 Safety Precautions
To help you install and maintain this equipment safely and efficiently make sure
you read and understand all safety information in this manual prior to performing
any procedure. Failure to do so may result in personal injury, property damage,
or possible death.
2.1 Safety Statements
The following safety statements are used throughout this manual. They will alert
you to possible safety hazards and conditions that could result in personal injury,
death, or property and equipment damage.
CAUTION: Indicates hazards or unsafe practices that could result in minor
personal injury, product, or property damage.
WARNING: Indicates hazards or unsafe practices that could result in
severe personal injury or death.
DANGER: Indicates immediate hazards that will result in severe personal
injury or death.
2.2 General Practices
Read and become familiar with the general safety instructions provided in this
section of the manual before installing, operating, maintaining, or repairing this
equipment.
• Do not attempt to assemble or install this equipment if it has been damaged
from shipping.
• Do not attempt to install or maintain this equipment if you or the equipment is
standing in water.
• Only qualified personnel should perform maintenance on this equipment.
• Always use proper tools (as mentioned in this manual) to perform installation
and maintenance.
• Use proper hand and eye protection as needed when installing or maintaining
this equipment.
• Make sure you have adequate first aid supplies available when installing this
equipment.

SPS Installation and Maintenance Manual 7
• Do not modify this equipment as this could create a safety hazard and void your
Hali-Brite®warranty.
• Use only Hali-Brite®replacement parts.
• Read and carefully follow the instructions given throughout this manual for
performing specific tasks and working with specific equipment.
• Follow all applicable safety procedures required by your company, industry
standards, and government or other regulatory agencies.
• Make sure all equipment is rated and approved for the environment in which
you are using it.
• Follow all instructions for installing components and accessories.
• Protect components from damage, wear, and harsh environment conditions.
• Allow ample room for maintenance, wiring accessibility, and cover removal.
2.3 Electrical Practices
• Do not attempt to make electrical connections with the power on.
• Disconnect and lock out electrical power before touching any electrical
connections.
• Install all electrical connections to local code.
• Use only electrical wire of sufficient gauge and insulation to handle the rated
current demand. All wiring must meet local codes.
• Route electrical wiring along a protected path. Make sure moving equipment will
not damage it.
• Protect equipment with safety devices as specified by applicable safety
regulations.
• If safety devices must be removed for installation, install them immediately after
the work is completed and check them for proper functioning.
• Always use rated electrical tools when performing electrical work.
• Always make sure electrical connections are tight.
• Make sure electrical covers are in place after installation.

8SPS Installation and Maintenance Manual
• Do not touch hot lamps with bare hands.
2.4 Qualified Personnel
Qualified personnel are those that are trained and experienced with installing or
maintaining Hali-Brite®equipment. Only qualified personnel should install or
maintain Hali-Brite®equipment and auxiliary features.
No one should:
• Attempt to install or perform maintenance on this or any Hali-Brite®equipment
if they are physically impaired or under the influence of alcohol or non-
prescription drugs.
• Maintain or install this equipment without correct training, supervision or
experience in mechanical or electrical equipment.
• Attempt to maintain or install this equipment without the correct tools as
specified in this manual.
2.5 Proper Usage
Always use this equipment as specified in this manual. Improper usage may
result in serious personal injury, property damage, or possible death.
• Do not make any modifications that have not been recommended by Hali-
Brite®.
• Do not use any replacement parts that are not purchased from Hali-Brite®.
• Hali-Brite®cannot be responsible for injuries or damages resulting from
nonstandard, unintended applications of its equipment. This equipment is
designed and intended only for the purpose described in this manual. Uses not
described in this manual are considered unintended uses and may result in
serious personal injury, death, or property damage.

SPS Installation and Maintenance Manual 9
3 Specifications
3.1 Electrical Specifications
Batteries….................................................(2) or (3) 12 VDC, 100 A-hr
Type……………………..……………AGM
Life……………..………………….….4000 charge/discharge cycles, typical
Charge Controller......................................Temperature compensated, maximum
power point tracking
Status Indicators…………………….………Battery state of charge, charging,
system status
Light Control…………................................Photocell, ETL certified
Photovoltaic Panel.....................................50 or 135 watt
Load….......................................................8-13 watts
Autonomy..................................................10 days typical
3.2 Physical Specifications
Dimensions
Height............................................37-55 inches (94-140 cm)
Width…………………………………59 or 33 inches (150 or 84 cm)
Mounting .................................................(2) frangible couplings and flanges
to a 6 x 32 inch anchor assembly with
(4) 5/8 inch mounting bolts.
Product Weight........................................196-278 lb. (87-126 kg)
Shipping Weight .....................................276-398 lb. (125-180 kg)
3.3 Environmental Specifications
Operating Temperature .................................-40C (-40F) to +55C (+131F)
Humidity .........................................................0% to 100%
Altitude .......................................... ................Sea level to 10,000 feet (3000 m)
Wind................................................................120 mph minimum

10 SPS Installation and Maintenance Manual
4 Installation
WARNING: Allow only qualified personnel to perform the following tasks.
Observe and follow the safety instructions in this document and all other
related documentation.
4.1 Unpacking
Handle the equipment very carefully to prevent component damage. Note any
exterior damage to the carton/crate that might lead to detection of equipment
damage. If you note any damage to any equipment, file a claim with the carrier
immediately. The carrier may need to inspect the equipment. A typical shipping
crate (including an L-806 wind cone) is shown below:
Figure 1
Note: To prevent damage to the equipment, transport the pallet to the
installation site before removing the SPS components from the pallet. The
anchor assembly may be removed earlier for preparing the mounting base.
4.2 Tools and Supplies Needed
Equipment Required But Not Supplied
Wrenches
Set of Screwdrivers
Set of Pliers

SPS Installation and Maintenance Manual 11
Level
2 Pipe Wrenches
Liquid Glass Cleaner
1 inch conduit, as needed to connect the wind cone to the SPS
Concrete and materials to construct the mounting base
4.3 Installation
The following procedure describes the site preparation, construction of the
mounting base, and final wiring and checkout of the SPS.
4.3.1 Site Planning
The wind cone and SPS locations and mounting bases must be properly planned
prior to construction. Full sun exposure is critical to proper operation of the SPS.
Therefore, the SPS must be located on the south side of the wind cone in the
northern hemisphere, and on the north side of the wind cone in the southern
hemisphere. The front of the solar panel must face the equator.
The SPS shall be located 8 to 15 feet from an L806 or L807 Size 1 wind
cone, and 12 to 15 feet from an L807 Size 2 wind cone.
Electrical cable to connect the wind cone to the SPS is supplied with the wind
cone (additional cable may be required). This cable is not suitable for direct
burial. The following instructions assume this cable is contained in 1 inch conduit
between the wind cone and the SPS, with 1 inch conduit elbows at each end.
Refer to the Installation Manual supplied with the wind cone for wind cone
installation procedures.
4.3.2 Construct the Mounting Base
Figure 2 illustrates the completed SPS installation, mounted on a concrete slab.
Figure 2. Completed Installation
Conduit Entrance must be on right-
hand side, when facing the solar panel
direction
Solar
Panel
Direction
Left Side

12 SPS Installation and Maintenance Manual
Note the location of the conduit entrance in Figures 2 and 3. If the conduit is
installed on the wrong side, the solar panel will be facing the wrong
direction.
Refer to Figure 3 to guide construction of the SPS mounting base. Perform the
following steps:
1. Locate the anchor assembly included with the SPS.
2. Orient the anchor assembly as shown in Figure 3.
3. Trench and bury the 1 inch conduit from the wind cone location to the SPS
location.
4. Construct concrete forms as shown in Figure 3. The concrete base should
be a minimum of 40 inches square, and at least 3 ½ inches thick.
5. Orient the SPS anchor assembly in the center of the base, with the
conduit entrance as shown. Place blocks under anchor assembly as
needed to ensure the anchor bolts will protrude about 4 inches above the
top of the finished concrete surface. Make sure the 2 mounting nuts and
washer on each anchor bolt will be above the top surface of the concrete.
6. Ensure the conduit will protrude 2-3 inches above the top of the finished
concrete surface.
7. Pour the concrete, allow it to cure, and remove the forms.
Figure 3. Mounting Base Layout
4.3.3 Install the SPS to the Mounting Base
Proceed as follows to install the SPS to the mounting base:
Solar
Panel
Direction
Conduit Entrance must be on
right-hand side, when facing
the solar panel direction

SPS Installation and Maintenance Manual 13
1. Pull the electrical cable from the wind cone, through the conduit, and
through the conduit elbow in the SPS mounting base.
2. Bring the SPS, on its shipping pallet, to the installation site.
3. Remove the top boards from the pallet, and position the pallet next to the
mounting base, as shown in Figure 4.
4. On some SPS models the 2 mounting legs are factory installed, and on
some models these legs are installed in the field. If this unit does not have
mounting legs installed, locate and install them. Tighten them securely
with pipe wrenches.
Figure 4. Cable Installation
5. Note: Do not remove the protective cover from the solar panel until
instructed to do so.
6. Remove the cover from the SPS battery enclosure.
7. Feed the electrical cable through the mounting leg of the SPS, and into
the battery enclosure.
8. Remove the top nut and lock washer from each of the 4 anchor bolts. One
nut should remain on each of the 4 bolts.
9. Caution: The following step should be performed by 2 people: Lift the
SPS from the pallet, and guide the mounting legs on to the 4 mounting
bolts. Install a lock washer and nut on to each of the 4 mounting bolts.
10.The bottom nuts on the mounting bolts are used to level the SPS. Place a
level on the top surface of the battery compartment, and adjust the 4
bottom nuts until the battery compartment is level in all directions.
11.Tighten the top nut on each of the 4 mounting bolts to secure the SPS to
the mounting base.
4.3.4 Connect the Power Cable from the Wind Cone to the SPS
Proceed as follows to connect the wind cone power cable to the SPS:
1. Locate the power cable from the wind cone, inside the battery enclosure,
as shown in Figure 5.
2. Locate the red and black wires with wire nuts attached to each end.

14 SPS Installation and Maintenance Manual
3. Remove the wire nut from the black wire, and use this wire nut to connect
this black wire to the black wire from the wind cone power cable.
4. Remove the wire nut from the red wire, and use this wire nut to connect
this red wire to the white wire from the wind cone power cable.
Figure 5. Power Cable Wiring
4.3.5 Install the Batteries
Proceed as follows to install the batteries:
1. Locate the battery connection wires and fuses (packed with this manual).
2. Caution-The fuses are not installed in the inline fuseholders. Do not
install the fuses until instructed to do so.
3. Unpack the batteries from their packing materials. Locate the battery
terminal bolts and washers, shipped with each battery.
4. Place the batteries in the battery enclosure, with the battery connection
posts towards the charge controller, as shown in Figure 6. The batteries
are installed as close as possible to the charge controller, snugly against
the battery stop in the floor of the battery enclosure.
5. The batteries are wired to the charge controller as described in the
following steps. Use the bolts supplied with the batteries, and loosely
hand-tighten the bolts as you make the connections. The battery bolts will
be tightened with a wrench after all the connections are in place.
RTS
Wire nuts connecting
wind cone power
cable to the SPS

SPS Installation and Maintenance Manual 15
Figure 6. Battery Installation
6. Locate the orange wire with the inline fuseholder connected to the charge
controller. Connect this wire to the positive terminal of the first (closest)
battery.
7. Connect another orange wire with fuseholder from the positive terminal of
the first battery to the positive terminal of the second battery.
8. If a third battery is supplied with the product, connect another orange wire
with fuseholder from the positive terminal of the second battery to the
positive terminal of the third battery.
9. Locate the black battery wire. One end is connected to the charge
controller.
10.Connect this black wire to the negative terminal of the first battery.
11.Connect another black wire to the negative terminal of the first battery.
12.Connect the black wire from the first battery to the negative terminal of the
second battery, as shown in Figure 6.
13.If a third battery is supplied with the product, connect another black wire
from the negative terminal of the second battery to the negative terminal of
the third battery.
14.Inspect all battery connections for proper wiring. Tighten each battery
terminal bolt securely with a wrench.
4.3.6 Install the Fuses and Photocell
Proceed as follows to install the fuses:
1. This product has one 30 ampere fuse for each battery. Locate the fuses
(shipped with this manual).
Charge Controller

16 SPS Installation and Maintenance Manual
2. Figure 7a illustrates a typical inline fuseholder. Install a fuse in each
fuseholder. Note: When the fuse is installed for the battery closest to the
charge controller, the system will start to operate, and some of the LEDs
on the charge controller will illuminate.
Figure 7a. Fuse Installation
3. Be sure to install 1 fuse for each battery. If fuses are not installed for
every battery, the unit will operate, but will not have full battery
capacity.
4. Snap the fuseholder cover over each fuse.
Proceed as follows to install the photocell:
1. Refer to Figure 7b. The photocell is installed in a receptacle.
Figure 7b. Photocell
2. Position the photocell near the receptacle, with the photocell window
facing away from the solar panel.
3. Insert the photocell into the receptacle, and turn it clockwise 1/8 turn.
4.3.7 Electrical Checkout
Inspect the SPS for proper electrical operation, as follows:
Fuseholder
Charge Controller

SPS Installation and Maintenance Manual 17
1. The SPS should now be operating. Locate the charge controller, as shown
in Figure 7.
2. On the top surface of the charge controller, locate the three “Battery
Status” LEDs.
3. The Battery Status green LED will illuminate, indicating a full battery
charge, or the yellow LED will illuminate, indicating a partial charge. (A
partial charge is OK.)
4. Locate the “Charging Status” LED on the top surface of the charge
controller.
5. The Charging Status LED should flash green briefly every 5 seconds. This
indicates the charging system is in Night Mode, since the solar panel is
still covered.
6. Inspect the wind cone light. If this installation is being done during the day,
with sufficient sunlight, the wind cone light should be off. If the wind cone
light is off, proceed to Step 8.
7. Note: If the wind cone light is on, it may be dark enough to cause the
system to be in Night Mode. Locate the green photocell on the side of the
battery enclosure. Shine a flashlight beam in the photocell light entrance,
to simulate normal daylight. If this causes the wind cone light to turn off, it
is too dark to perform these tests. Stop this test, and repeat it in normal
daylight.
8. Remove the protective cover from the solar panel. Assuming daylight is
available, the Charging Status LED will become steady green, and flash
off briefly every 5 seconds. This indicates the charging system is in Day
Mode, and the solar panel is charging the batteries.
9. Locate the green photocell mounted on the side of the battery enclosure.
10.The photocell has a light entrance opening in the side. Cover this entrance
to block light from entering the photocell. The wind cone light should turn
on.
11.Uncover the light entrance on the photocell. After a few seconds, the wind
cone light should turn off.
12.Check to be sure 1 fuse is installed for each battery, and that each
fuse is not blown. If good fuses are not installed for every battery,
the unit will operate, but will not have full battery capacity.
13.If the product performs as stated above, it is functioning correctly. If any of
the Status LEDs are red, or if the wind cone light does not function
correctly, contact Hali-Brite®for assistance.
4.3.8 Install Battery Enclosure Cover
Install the battery enclosure cover as follows:
1. Inspect the black weather seal around the top edge of the battery
enclosure, to make sure it was not damaged during this installation
process.

18 SPS Installation and Maintenance Manual
2. Locate the enclosure cover vent, as shown in Figure 8a. Orient the
enclosure cover as shown, positioning the vent next to the enclosure wall
opposite the photocell.
Figure 8a. Cover Installation
3. Place the cover on the enclosure, as shown in Figure 8a, aligning the
mounting holes in the cover with the holes in the enclosure.
4. Install the 10 mounting screws in the cover, but do not tighten.
5. Tighten the screws evenly and equally around the cover, until the weather
seal is compressed to about half of its original height.
6. Install the shade to the 4 mounting posts on the enclosure cover, as
shown in Figure 8b, using the 4 bolts provided. Tighten each bolt securely.
7. Clean the glass on the face of the solar panel.
8. Installation of the SPS is now complete.
Figure 8b Shade Installation
Vent
Photocell

SPS Installation and Maintenance Manual 19
5 Maintenance
5.1 Maintenance Schedule
Interval Task
Daily Inspect the wind cone for proper lamp operation.
As Needed Clean the solar panel glass. Make sure vegetation is not
obstructing the solar panel.
Annually Remove the battery enclosure cover, and inspect all
electrical connections.

20 SPS Installation and Maintenance Manual
6 Repair
Note: Be sure you have correctly identified the faulty component prior to
making any repairs. Troubleshooting SPS problems can be complex.
Contact Hali-Brite®for troubleshooting assistance.
6.1 Battery Replacement
Batteries are replaced as follows:
1. Install a temporary cover on the solar panel, to prevent battery charging.
2. Remove the battery enclosure cover, by reversing the procedure
described in Section 4.3.8.
3. Remove the battery fuses, by reversing the procedure described in
Section 4.3.6.
4. Remove the batteries, by reversing the procedure described in Section
4.3.5.
5. Install the new batteries, using the procedure described in Section 4.3.5.
6. Note: The new batteries must be the same model as the original, to
ensure adequate performance. All batteries must be replaced at the
same time.
7. Install the fuses, using the procedure described in Section 4.3.6.
8. Remove the temporary cover from the solar panel.
9. Perform the electrical checkout as described in Section 4.3.7.
10.Install the battery enclosure cover, using the procedure described in
Section 4.3.8.
6.2 Fuse Replacement
The fuses are replaced as follows:
1. Install a temporary cover on the solar panel, to prevent battery charging.
2. Remove the battery enclosure cover, by reversing the procedure
described in Section 4.3.8.
3. Remove the battery fuses, by reversing the procedure described in
Section 4.3.6.
4. Acquire the proper replacement fuses.
5. Install the fuses, using the procedure described in Section 4.3.6.
6. Remove the temporary cover from the solar panel.
7. Perform the electrical checkout as described in Section 4.3.7.
8. Install the battery enclosure cover, using the procedure described in
Section 4.3.8.