Purkeys SOLAR BOLT User manual

SOLAR BOLT CHARGING SYSTEM
INSTALLATION GUIDE
INST168 Doc 2.00

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CONTENTS
General Information ..........................................................................................2
Solar Panel Installation......................................................................................3
Installation Preparation ...........................................................................4
Solar Panel Install Process .......................................................................5
Solar Bolt Main Harness Installation...............................................................8
Cable Routing ...................................................................................................10
Solar Bolt Controller Installation ...................................................................11
Solar Panel Congurations..............................................................................13
200 Watt (2 Solar Panel).........................................................................13
300 Watt (3 Solar Panel).........................................................................14
400 Watt (4 Solar Panel).........................................................................15
LED Logic..........................................................................................................16
Part List..............................................................................................................17
Limited Commercial Warranty Policy...........................................................21

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e Solar Bolt™ Charging System is a Pulse Width Modulated (PWM) charge
controller with automatic temperature compensation for up to 400 watt
solar application. e Solar Bolt charge controller utilizes patent-pending
technology that is designed to work in conjunction with the electrical system
on a vehicle or trailer. e Solar Bolt provides three-stage charging for the
batteries when the vehicle’s primary charging system is not active. It senses
when the primary charging system is active and matches the charge voltage.
is enables the solar panel to deliver up to its full output capability to the
batteries when the vehicle is running. e module’s technology allows the
Solar Bolt to provide power to the electrical system of the vehicle, which
reduces the electrical load on the alternator and, in turn, reduces the
mechanical load on the engine, thereby realizing fuel savings.
GENERAL INFORMATION

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SOLAR BOLT INSTALLATION GUIDE
SOLAR PANEL INSTALLATION
Place the solar panel 4 inches from the side edge of the trailer and 24 inches
from the front edge of the trailer. is will leave sucient room so that more
panels can be added in the future (see the Solar Panel Congurations section
for instructions on mounting more than one panel).
Do not adhere panel to trailer! Leave the panel sitting in place until the
Solar Bolt main harness has been installed (see Step 5 in the Solar Bolt Main
Harness section), in case slight adjustment to panel placement is needed.
Double check the length of wiring and placement of panel to ensure that the
provided wire length is sucient for the intended panel placement.

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If the bond surface is wet or dirty, the solar panel may not completely bond.
We do not recommend solar panel installations in weather below 40 degrees
Fahrenheit or where there is moisture on the bond surface. Any installs
completed during the winter should be done in a heated shop where the
bonding surface is warm and dry.
Purkeys is not responsible for failures caused from installs completed in non-
recommended conditions.
Tools and Equipment Needed:
• 220 grit abrading block or paper
• Scotch-Brite pad (Maroon or Green)
• Isopropyl alcohol
• Eternabond RoofSeal 2” bonding tape
• Optional: Sikaex 221 or 291
• Rags
• Zip ties
• Rubber gloves
INSTALLATION PREPARATION
Step 1: Remove all loose material and clean the area where you are preparing
to place the solar panel(s).
Step 2: Abrade the surface with Scotch-Brite to remove surface impurities.
Step 3: Set the panel(s) in the desired location and use a permanent marker to
mark the location of each panel.
Step 4: Clean the area by applying isopropyl alcohol to the surface and wiping
clean. Repeat this process until the area is clean and no additional residue is
found on the rag or on the bonding surface.
Step 5: Let the area dry completely before bonding (10-15 minutes).

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SOLAR BOLT INSTALLATION GUIDE
SOLAR PANEL INSTALL PROCESS
Note: If completing an install in temperatures lower than room
temperature, keep the panel and EternaBond RoofSeal at room
temperature until just before the installation.
Step 1: Partially remove the backing material from the mastic of the panel and
place panel according to the alignment marks.
Step 2: Pull the backing o the mastic as the panel is laid down on the surface.
e panel should be laid down by rolling the panel onto the bond surface;
this will ensure there are no air bubbles under the panel.
Step 3: Apply pressure by rubbing the panel by hand, making sure the mastic
meets the bond surface. Some trailer and box truck surfaces are not very
at, and you will need to take caution to make sure the panel is bonded
down as the panel is rolled out.
Step 4: Aer the panel mastic is bonded to the surface suciently, prepare for
the edge seal by lightly abrading the edge 1” of the solar panel and 1” of the
adjacent metal surface with Scotch-Brite.
Step 5: Clean the edge by adding isopropyl alcohol to the cleaning rag, wiping
the edge bonding surface. Make sure all loose material and residue from
sanding prep is removed. Be careful not to oversaturate the edge of the
solar panel where the mastic is exposed. Allow the isopropyl alcohol to
completely dry (10-15 minutes) before applying the edge seal.
Step 6: Apply the edge seal by applying the Eternabond RoofSeal 2” tape.
Apply by overlapping the panel (1” and bond surface 1”) and bond surface
to seal the edge. e tape seal should be applied from back to front of the
trailer to allow overlapping edges to be covered and not be exposed to the
wind as much as possible. e front edge will be applied last and two layers
should be applied to assure the wind will not pry up the edges of the front
of the panel. Apply with good pressure from hands or a rubbing tool per
EternaBond Installation Instructions.
Note: for extra edge seal and bonding the 4” wide Eternabond RoofSeal
may be used.

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Step 7: An alternate edge seal is to use Sikaex 221 or 291 by applying a liberal
bead around the edge of the panel to seal from moisture and keep the wind
from pulling the edges of the panel up. If this method is used, the Sikaex
will need at minimum 24 hours at room temperature (70 F) to cure before
service. It is the responsibility of the customer to verify the edge seal is
suciently cured before putting the trailer or box truck in service.
NOTE: Purkeys is not responsible for solar panel failure if the truck was put
into service before Sikaex edge seal is cured.
Step 8: Install cables and properly attach wires per customer requirement. It
is recommended that panel wires are installed running o the back of the
trailer if possible. Keep in mind that cables are exposed to potentially harsh
conditions such as being hit by tree limbs, snow, rain etc.

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SOLAR BOLT INSTALLATION GUIDE
SOLAR BOLT MAIN HARNESS INSTALLATION
Step 1: Connect the Solar Bolt main
harness to 100 watt solar panel.
e solar connectors on the main
harness are already installed and
ready to attach to the solar panel
positive and negative wires.
Step 2: Route the main harness
along the front edge of the trailer
and over to the right side of the
trailer. Secure the harness by using
the supplied nylon clamps and #12
x ¾” hex tek screws.
Step 3: Route the main harness over
the front of the trailer and use the
supplied E chain to protect the
cable. Secure the harness by using
the supplied rubber washers and
#12 x 1” roong screws.
Important: Do not screw into the roof of the trailer. Make sure to screw into
the framing of the trailer to prevent water intrusion.
Important: Do not screw into the roof of the trailer. Make sure to screw into
the framing of the trailer to prevent water intrusion.

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Installation Complete
Step 4: Route the main harness
down the trailer wall and secure it
using the supplied nylon clamps
and #12 x ¾” hex tek screws.
Important: Place the supplied cable clamps along the 2-conductor jacketed
main harness every 6 inches to ensure proper support for the cable. Avoid
sharp edges and possible chang points.
Step 5: Peel the adhesive lining o the back of the panel and press rmly on
the panel to ensure it adheres to the trailer. Applying heat to the trailer top
is recommended to help the adhesive stick.

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SOLAR BOLT INSTALLATION GUIDE
Step 1: Route main harness back
toward the ligate batteries.
Secure with wire ties or cable
clamps as you go.
Step 2: Once the cable is routed to
the battery box, feed the Solar Bolt
main harness into the battery box
through a dome nut or a grommet.
DO NOT cut the harness until the
mounting location for the Solar
Bolt controller is determined.
CABLE ROUTING
Installation Complete
Important: Place the supplied cable clamps along the 2-conductor jacketed
cable every 18 inches to ensure proper support for the cable. Avoid sharp
edges and possible chang points.

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Step 1: Mount the Solar Bolt
controller to the ligate battery
box by using the supplied #12 ¾”
hex tek screws.
Step 2: Determine the appropriate
amount of cable needed to make
the connections to the Solar Bolt
controller, then cut excess cable.
Strip o jacketed insulation from
the Solar Bolt main harness to
approximately 2 inches. Strip the
insulation on both wires.
Step 3: Connect the blue wire from
the Solar Bolt main harness to the
wire on the Solar Bolt controller
labeled SOLAR POSITIVE. Solder
and heat shrink.
SOLAR BOLT CONTROLLER INSTALLATION

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SOLAR BOLT INSTALLATION GUIDE
Step 4: Connect the white wire from
the Solar Bolt main harness to the
white wire located on the Solar
Bolt controller. Solder and heat
shrink.
Step 5: Connect the ground wire
from the Solar Bolt controller
to the ligate battery negative
terminal.
Step 6: Connect the positive wire
from the Solar Bolt controller
to the ligate battery positive
terminal.
Installation Complete

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SOLAR PANEL CONFIGURATIONS
When adding additional panels, follow the following conguration
instructions:
e rst Solar Panel (100 Watt) should have been placed 4 inches from the
edge of the trailer (see the Solar Panel Installation section for details on
installing the rst panel).
200 Watt (2 Solar Panels)
1. Place the second solar panel no more than 4 inches away from the rst
solar panel.
2. Connect the supplied Solar Bolt Y Splitter input side to the Solar Bolt
main harness (Positive-Positive, Negative-Negative).
3. Connect the Solar Bolt Y Splitter outputs to the two solar panels
(Positive-Positive, Negative-Negative).
4. Clamp the Solar Bolt Y Splitter to the edge of the trailer.

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SOLAR BOLT INSTALLATION GUIDE
300 Watt (3 Solar Panels)
1. Place the third panel no more than four inches away from the second
solar panel.
2. Connect the second Solar Bolt Y Splitter input side to the longest
output from the rst Solar Bolt Y Splitter (Positive-Positive, Negative-
Negative).
3. Connect the outputs of the second Solar Bolt Y Splitter to the second
and third solar panels.
4. Clamp the Solar Bolt Y Splitter to the edge of the trailer.

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400 Watt (4 Solar Panels)
1. Place the fourth panel no more than four inches away from the third
solar panel.
2. Connect the third Solar Bolt Y Splitter input side to the longest output of
the second splitter (Positive-Positive, Negative-Negative).
3. Connect the outputs of the third Solar Bolt Y Splitter to the third and
fourth solar panels.
4. Clamp the Solar Bolt Y Splitter to the edge of the trailer.

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SOLAR BOLT INSTALLATION GUIDE
LED LOGIC
LED Status
Blinking Red Battery below 12.4 V, above 16 V, or fault
Blinking Green Battery above 12.4 V
Solid Green Battery above 13.2 V

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PART LIST
Part#: SLRBOLT-03-WI
Solar Bolt Charging System 300 W
(ree Panels), No Indicator
Part#: SLRBOLT-02-WI
Solar Bolt Charging System 200 W
(Two Panels), No Indicator
Part#: SLRBOLT-01-WI
Solar Bolt Charging System 100 W
(Single Panel), No Indicator

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SOLAR BOLT INSTALLATION GUIDE
Part#: SLRBOLT-04-WI
Solar Bolt Charging System 400 W
(Four Panels), No Indicator
Part#: MOD00083
Solar Bolt Controller
Part#: MOD00083-K
Solar Bolt Controller Assembly

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Part# CHRG-006
Solar Panel, Flexible, 100 W Watt
Solar Panel
Part# H-00383
Harness, Solar Main 50’
Part# H-00382
Harness, Solar Bolt Y Splitter