Purkeys SOLAR BOLT User manual
A MISSION CRITICAL ELECTRONICS BRAN
D
SOLAR BOLT
INSTALLATION GUIDE
300-52 R2.00
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P: 479.419.4800 | F: 479.419.4801 | www.purkeys.net
CONTENTS
General Information ..........................................................................................2
Solar Panel Placement........................................................................................3
Installation Preparation.....................................................................................4
Solar Bolt Main Harness Installation...............................................................6
Solar Panel Installation ......................................................................................8
Mechanical Fastening...............................................................................8
Bonding Solar Panels................................................................................8
Metal Roofs............................................................................................8
Translucent Roofs ...............................................................................10
Cable Routing ...................................................................................................12
Solar Bolt Controller Installation...................................................................13
Solar Panel Congurations..............................................................................15
200 Watt (2 Solar Panels).......................................................................15
300 Watt (3 Solar Panels).......................................................................16
LED Logic..........................................................................................................17
Limited Commercial Warranty Policy...........................................................20
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e Solar Bolt™ Charging System is an MPPT charge controller with
automatic temperature compensation. One and two panel systems use a 15
amp controller and three panel systems use a 20 amp controller.
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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P: 479.419.4800 | F: 479.419.4801 | www.purkeys.net
SOLAR BOLT INSTALLATION GUIDE
SOLAR PANEL PLACEMENT
Place the solar panel a minimum of 4 inches from the side edge of the trailer
and 4 inches from the front or rear edge of the trailer, allowing enough room
for the edge tape to be applied. Avoid placing edge tape over trailer roof rivets
to prevent water intrusion under the edge tape. Placement of panels in this
manner will leave sucient room so that more panels can be added in the
future.
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 sucient 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 when surface temperatures
are 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
INSTALLATION PREPARATION
Translucent Roofs
• 220 grit sand paper or Scotch-
Brite pad (Maroon or Green)
• Isopropyl alcohol
• 3M 94 primer or equivalent
• Roof seal 4” bonding tape
• 3M VHB tape or equivalent
• Optional: Sikaex 221 or 291
• Rags
• Zip ties
• Rubber gloves
Metal Roofs
• 220 grit sand paper or Scotch-
Brite pad (Maroon or Green)
• Isopropyl alcohol
• Roof seal 4” bonding tape
• Optional: Sikaex 221 or 291
• Rags
• Zip ties
• Rubber gloves
Note: Use proper Personal Protective Equipment (PPE), as needed.
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P: 479.419.4800 | F: 479.419.4801 | www.purkeys.net
SOLAR BOLT INSTALLATION GUIDE
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 220
grit sand paper or Scotch-Brite
to remove surface impurities
(example of scued roof shown
here).
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).
Note: When working on a translucent or berglass roof, apply 3M 94
primer or equivalent aer area is dry.
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SOLAR BOLT MAIN HARNESS INSTALLATION
Step 1: Connect the Solar Bolt main
harness to the 100 watt solar
panel(s). 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 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.
Important: Do not screw into the roof of the trailer. Make sure to screw into
the framing of the trailer to prevent water intrusion.
If mounting on the front edge of the trailer, keep the wire secure on the roof
edge. E chain or conduit is recommended to be placed over the wire at the
roof edge, not provided in the kit.
If mounting panel(s) at rear of trailer, use the hollow door post. is is the
same side that the wiring going to the top rear clearance lights is routed
through.
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P: 479.419.4800 | F: 479.419.4801 | www.purkeys.net
SOLAR BOLT INSTALLATION GUIDE
Step 4: If mounting on the rear,
route the main harness through
the channel for trailer light wiring
in the door frame, if possible, or
route the main harness down the
trailer wall. 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 chang points.
Step 5: Refer to the “Bonding Solar Panels” section for details on panel
installation.
Step 3: If mounting on the front,
route the main harness over the
edge of the trailer. Secure the
harness by using the supplied #12
x 1” washer head hex tek 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.
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BONDING SOLAR PANELS
Note: If completing an install in temperatures lower than room
temperature, keep the panel and roof seal tape 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: Aer the panel mastic is bonded to the surface suciently, prepare for
the edge seal by lightly abrading the edge of the solar panel and the adjacent
metal surface with Scotch-Brite. Do NOT abrade any of the actual solar
cells.
Metal Roofs
SOLAR PANEL INSTALLATION
Panels have six mounting grommets to provide mechanical fastening
capabilities. If mechanical fastening will be used, please refer to the trailer or
box OEM practices in regards to mechanically fastening to the roof.
MECHANICAL FASTENING
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