Purkeys SOLAR BOLT User manual

A MISSION CRITICAL ELECTRONICS BRAN
D
SOLAR BOLT
INSTALLATION GUIDE
300-52 R2.00


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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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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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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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SOLAR BOLT INSTALLATION GUIDE
Step 7: An alternate edge seal is to use Sikaex 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 Sikaex
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
suciently cured before putting the trailer or box truck in service.
NOTE: Purkeys is not responsible for solar panel failure if the truck or
trailer was put into service before Sikaex 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, using the supplied clamps if possible. Keep in mind that cables are
exposed to potentially harsh conditions such as being hit by tree limbs,
snow, rain etc.
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: Using the 4” roof seal edge tape, drape it over the panel about 1/2”
without covering any solar cells. Do NOT cover the actual solar cells with
the tape. 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.

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Step 1: Paint the location for the panels with 3M 94 primer, or equivalent, and
let dry.
NOTE: You may need to remark the panel location(s) aer the primer dries.
Step 2: Apply 3M VHB, or equivalent, double-sided tape to the back of the
panels around the perimeter of the panel, 2” in from the edge, with a strip
down the middle of the panel lengthwise.
Step 3: Place the panels in their previously marked locations.
Step 4: Press rmly on the panel to ensure the tape is adhered to the roof.
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: Using the 4” roof seal edge tape, drape it over the panel about 1/2”
without covering any solar cells. Do NOT cover the actual solar cells with
the tape. 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. Use a so roller to ensure the tape conforms to the roof.
Translucent Roofs

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SOLAR BOLT INSTALLATION GUIDE
NOTE: Purkeys is not responsible for solar panel failure if the truck or
trailer was put into service before Sikaex 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, using the supplied clamps if possible. Keep in mind that cables are
exposed to potentially harsh conditions such as being hit by tree limbs,
snow, rain etc.
Step 7: An alternate edge seal is to use Sikaex 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 Sikaex
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
suciently cured before putting the trailer or box truck in service.

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Step 1: Route main harness toward
the ligate 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
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 chang points.

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SOLAR BOLT INSTALLATION GUIDE
Step 1: Mount the Solar Bolt
controller to the ligate battery
box by using the supplied
hardware (hardware kit shown
here). A drop of blue Locktite can
be placed on the screw next to the
nut for added security.
Be sure to place the controller where
the LED lights can be easily seen
from the battery box opening.
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 3a: On the 15 amp controller,
connect the blue wires together
and the white wires together using
the supplied butt splices. Crimp,
solder, and heat shrink.
SOLAR BOLT CONTROLLER INSTALLATION
NOTE: DO NOT use screws to mount the controller. Only use supplied
hardware.
NOTE: ONLY mount the unit on a side or back wall. Mounting it in any
other location may result in damage to the unit.

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Step 4: Connect the white wire
from the Solar Bolt main harness
to the black negative wire with
butt connector on the Solar Bolt
controller. Crimp, solder and heat
shrink.
Step 6: Connect the ground wire
from the Solar Bolt controller
to the ligate battery negative
terminal.
Step 5: Connect the positive wire
from the Solar Bolt controller
to the ligate battery positive
terminal.
Step 3b: On 20 amp controller connect the blue wire from the main harness
to the red wire on the controller and the white wire from the harness to the
black wire on the controller. Crimp solder and heat shrink.

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SOLAR BOLT INSTALLATION GUIDE
SOLAR PANEL CONFIGURATIONS
When adding additional panels, follow the following conguration
instructions:
e rst solar panel (100 Watt) should be placed a minimum of 4 inches
from the side edge of the trailer and 4 inches from the front or rear edge of
the trailer.
200 Watt (2 Solar Panels)
1. Place the second solar panel no more than 3 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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1. Place the third panel no more than 3 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.
300 Watt (3 Solar Panels)

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SOLAR BOLT INSTALLATION GUIDE
LED LOGIC
LED Status Function
Le Red LED
Solar Indicator
O Solar voltage too low
On Solar panel voltage
good
Slow ash System is charging
Double ash Batteries fully charged
Fast ash Fault over temp or
current
Right Red LED
Battery Indicator
O Battery not connected
On Working correctly
Fast ash Battery discharged
Note: for additional assistance please contact our technical support at
479-419-4800.
Verify operation of the system by viewing the LED lights. Both lights should
be solid and not ashing.
Check the battery voltage. It should be increasing so that the voltage is higher
than it was before the Solar Bolt was connected.

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NOTES
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