Silicon CPV Badr 1+G2 User manual

Silicon CPV plc
Akhter House, Perry Road, Harlow, Essex, CM18 7PN, UK
Tel [phone] Email [email protected]
Solar Street Light
User Manual
Ver 1.5
Model
✔
Booster Panel
25W
34W
45W
60W
Badr 1+G2
Badr 2+G2
Kamr S+G2
Kamr 3+G2
Kamr 2+G2
Kamr 1+G2
Kamr 1L+G2
Kamr 2L+G2
Kamr 3L+G2
Kamr 4L+G2

Silicon CPV plc
Akhter House, Perry Road, Harlow, Essex, CM18 7PN, UK
Tel [phone] Email [e-mail]
Page 1 of 32
Contents
Document Revision Control ................................................................2
Disclaimer .......................................................................................3
Unpacking - Box Contents .................................................................3
Badr 1/2+G2.................................................................................3
Kamr+G2 Range ............................................................................3
Booster Pack....................................................................................4
Tools Required for Installation and Maintenance ...................................5
Key Solar Street Light Components.....................................................6
Kamr............................................................................................6
Badr.............................................................................................6
Available Model Numbers with Optical Lens Options ..............................7
Theory of Operation..........................................................................8
Installation Instructions for Kamr –Part 1 ......................................... 10
Mode selection............................................................................. 10
Antenna Installation ..................................................................... 11
Installation Instructions for Kamr –Part 2 ......................................... 12
Fixing the Solar Street Light to the Pole .......................................... 12
Pole Sizing and Spacing for Kamr ..................................................... 13
Installation Instructions for Badr –Part 1 .......................................... 14
Battery Bank and Controller Access ................................................ 14
Installation Instructions for Badr –Part 2 .......................................... 15
Mode selection............................................................................. 15
Installation Instructions for Badr –Part 3 .......................................... 16
Fixing the Solar Street Light to the Pole .......................................... 16
Pole Sizing and Spacing for Badr ...................................................... 17
Optical Lens and Distribution Patterns ............................................... 18
Network Management and Monitoring ............................................... 20
Maintenance and Care of Solar Lights................................................ 21
Troubleshooting ............................................................................. 22

Silicon CPV plc
Akhter House, Perry Road, Harlow, Essex, CM18 7PN, UK
Tel [phone] Email [e-mail]
Page 2 of 32
Battery and Controller Pack Replacement for Kamr ............................. 23
Battery Bank and Controller Removal ............................................. 23
Battery and Controller Pack Replacement for Badr ........................... 25
Battery Bank and Controller Removal ............................................. 25
Insertion and removal of Battery and Controller Pack ....................... 26
Warranty ....................................................................................... 27
Warranty Terms and Conditions ..................................................... 27
Technical Specifications - Kamr ........................................................ 28
Technical Specifications - Badr ......................................................... 29
Technical Specifications –Badr / Kamr .............................................. 30
Installation details........................................................................ 30
Mechanical data ........................................................................... 30
Environmental conditions .............................................................. 30
Contact Information........................................................................ 31
Disposal Information....................................................................... 32
Document Revision Control
Revision
Date
Comments
1.4
25th May 2016
Update XL G2

Silicon CPV plc
Akhter House, Perry Road, Harlow, Essex, CM18 7PN, UK
Tel [phone] Email [e-mail]
Page 3 of 32
Disclaimer
This document is the property of Silicon CPV and therefore cannot be
copied or edited in any way without the prior and written permission of
Silicon CPV.
Unpacking - Box Contents
Please take care as one of the key components of the Solar Street Light is
the Solar Panel that is protected via a toughened glass panel.
Please unbox the Solar Street Light and very carefully inspect the light to
check that there has been no damage to the Light during transportation.
Badr 1/2+G2
Description
Silicon CPV Part No
Qty
Main Light Unit - Badr
Badr 1/2+G2
1
Pole adaptor –Badr
TBC
1
Pole adaptor fixings –3 x M8 x 12mm
taptite hex washer head stainless
SCREW0013
3
Installation Guide including Warranty
Certificate
GUIDE001
1
Kamr+G2 Range
Description
Silicon CPV Part No
Qty
Main Light Unit - Kamr
Kamr
S+,3+,2+,1+,1L+,2L+,3L+,4L+
1
Pole adaptor - fitted
ALUM0030
1
Pole adaptor fixings –Security
Self Tappers Pin Torx BH - 10 x
3/4" (4.8 x 19mm)
SCREW0039
3

Silicon CPV plc
Akhter House, Perry Road, Harlow, Essex, CM18 7PN, UK
Tel [phone] Email [e-mail]
Page 4 of 32
Installation Guide including
Warranty Certificate
GUIDE001
1
Antenna
1
Booster Pack
Description
Silicon CPV Part No
Qty
Booster Panels
25W SOLARPANEL0055
34W SOLARPANEL0045
45W SOLARPANEL0035
60W SOLARPANEL0060
2
Aluminium Fixing Bracket
ALUM1035
1
Pozi flange head self-tapping screws
SCREW0098
8
Hex Head Self Drilling Screw
TBC
2

Silicon CPV plc
Akhter House, Perry Road, Harlow, Essex, CM18 7PN, UK
Tel [phone] Email [e-mail]
Page 5 of 32
Tools Required for Installation and Maintenance
The table below details the key tools that will be needed to install a
Silicon CPV Solar Street Light. It is assumed that the appropriate height
pole has already been installed. (Please refer to pole sizing section for
pole details)
Item
Description
Qty
1
Small flat bladed screw driver for light switch selector
1
2
Mains Operated Electric or Battery Drill
1
3
Screwdriver set –pozi drive
1
4
Set of HSS Drill bits (must include 4.5mm for light
body to pole fixing)
1
5
Tape measure
1
6
Long nose pliers
1
7
Side Cutters
1
8
Sprit or laser Level
1
9
Cherry Picker or equivalent access platform for
installation of Solar Light
1
10
Appropriate Personal protective equipment (PPE) that
conforms to local health and safety legislation
1
11
Digital Multi-meter
1
12
Electrical insulation tape
1
13
Security Bit Screwdriver Set (Torx Button Head TX25)
1
Note: Please be aware that no tools are provided with the product

Silicon CPV plc
Akhter House, Perry Road, Harlow, Essex, CM18 7PN, UK
Tel [phone] Email [e-mail]
Page 6 of 32
Key Solar Street Light Components
Please see below for main Solar Light Components
Kamr
Badr
Battery Pack & Controller
Solar Panel
Light Head
Mounting Pole

Silicon CPV plc
Akhter House, Perry Road, Harlow, Essex, CM18 7PN, UK
Tel [phone] Email [e-mail]
Page 7 of 32
Available Model Numbers with Optical Lens Options
Please refer to the Optical Lens section for more details
Available Lens Options
T2
T3
T4
DN
AT
ME
DWC
DNW
Model
SiliconCPV- Badr 1+G2
√
√
√
√
√
√
√
√
SiliconCPV- Badr 2+G2
√
√
√
√
√
√
√
√
SiliconCPV- Kamr S+G2
√
√
√
√
√
√
√
√
SiliconCPV- Kamr 3+G2
√
√
√
√
√
√
√
√
SiliconCPV- Kamr 2+G2
√
√
√
√
√
√
√
√
SiliconCPV- Kamr 1+G2
√
√
√
√
√
√
√
√
SiliconCPV- Kamr 1L+G2
√
√
√
√
√
√
√
√
SiliconCPV- Kamr 2L+G2
√
√
√
√
√
√
√
√
SiliconCPV- Kamr 3L+G2
√
√
√
√
√
√
√
√
SiliconCPV- Kamr 4L+G2
√
√
√
√
√
√
√
√

Silicon CPV plc
Akhter House, Perry Road, Harlow, Essex, CM18 7PN, UK
Tel [phone] Email [e-mail]
Page 8 of 32
Theory of Operation
The Silicon CPV Solar Light is based on a pair of state-of-art embedded
ultra-low power processing units.
Using a highly adaptive and predictive algorithm, the first processing unit
looks after the Energy Management System (EMS). This unit is
responsible for extracting and storing the maximum amount of solar
energy available during daylight hours. Using the available stored energy
the unit then manages a custom user light output profile during the night
time period (Dusk to Dawn).
The second processing unit is the Communications Management
System (CMS). This unit provides all the necessary facilities for a meshed
local and wide area network communications. This unit then provides
users with local or remote wide area light cluster management and local
light-to-light connectivity for wide area network communications.
When the light is first switched on the system has to build a solar light
model and environmental profile. This process is fully automatic but takes
2-3 days to complete.
The system will need to discover a number of key parameters to
maximise performance, these will include the following;
Solar PV Panel Output Power
LED Light Output
Battery Capacity
Daylight Hours
Night-time Hours
Following switch on, the system will detect the “dusk” period and enter
the “First Night” period. During this period the LED light will be turned
onto maximum brightness for a period dependant on the current battery
“state of charge”.
The system will then automatically detect dawn on the “Second Day”; the
system can then start calculating additional parameters including PV
panel power, battery capacity and night and day time hours.

Silicon CPV plc
Akhter House, Perry Road, Harlow, Essex, CM18 7PN, UK
Tel [phone] Email [e-mail]
Page 9 of 32
After successful completion of this “Adaptive Learning Phase” the
system operation will stabilise and the light output will become predictive
based on weather conditions.
The system then automatically creates an energy storage reserve
providing 1 day of operational autonomy.

Silicon CPV plc
Akhter House, Perry Road, Harlow, Essex, CM18 7PN, UK
Tel [phone] Email [e-mail]
Page 10 of 32
Installation Instructions for Kamr –Part 1
When the Solar Street Light is delivered the controller will be sent in ‘ship
mode’, which prevents excessive battery discharging during transit. This
needs to be changed to the ‘on’ mode before installing the light.
The mode selection switch is located on the front panel of the battery
pack and controller module. During normal operation the mode switch is
hidden due to the insertion of a weather seal rubber plug. The plug can be
easily pulled out to show the mode switch (see fig 1). Please ensure the
rubber plug is re-inserted after inspection to prevent water ingress.
Change the switch to the following modes of operation using the switch
(fig 2):
Mode selection
1. On Mode –This is the normal operating position. Please ensure
that when the Street Light is installed the mode switch is ALWAYS
in this position.
2. Ship Mode –This position is selected when the unit is not in use.
This is typically when the unit is stored or packed and being
transported to site for installation. The controller automatically
enters a power down state to conserve battery power.
3. Test Mode –This position is used to check the operation of the
light under test conditions. This should not be selected for normal
light operation.
Fig 1

Silicon CPV plc
Akhter House, Perry Road, Harlow, Essex, CM18 7PN, UK
Tel [phone] Email [e-mail]
Page 11 of 32
Important Note:
We recommend that the change of switch selection is done by the
use of a small flat bladed screwdriver. Care must used to ensure
that the switch is in the correct position. Excessive force should
NOT be used during this operation.
Fig 2
Antenna Installation
To prevent damage during packing / unpacking of the solar street light
the antenna required for network communications is included in the
accessory bag. Please screw in place and hand tighten with pliers. Care
must be taken during this process and the Antenna should not be
overtightened.

Silicon CPV plc
Akhter House, Perry Road, Harlow, Essex, CM18 7PN, UK
Tel [phone] Email [e-mail]
Page 12 of 32
Installation Instructions for Kamr –Part 2
Fixing the Solar Street Light to the Pole
Warning: During the installation of the street light please observe safe
working practices when working at height.
Please complete the following steps below to correctly install the Kamr
Solar Street Light
1. For this task you will need a powered drill with a 4.5mm HSS drill
bit and the 3 off Security Self Tappers Pin Torx BH - 10 x 3/4" (4.8
x 19mm) supplied in the light carton
2. Mount the street light on the pole as shown below and correctly
align with the road
3. Drill three pilot holes equally spaced around the circumference of
the pole and approximately 80mm from the light head
4. With the screws supplied fix the light to the pole
5. Ensure the mode switch is set to “ON” and insert the rubber plug
Security Screw
Light with Pole
adaptor

Silicon CPV plc
Akhter House, Perry Road, Harlow, Essex, CM18 7PN, UK
Tel [phone] Email [e-mail]
Page 13 of 32
Pole Sizing and Spacing for Kamr
The values below are specified using T2 optics as per IESNA Type II and
III specifications
Solar Street Light Models
Kamr
1+G2
Kamr
2+G2
Kamr
3+G2
Kamr
S+G2
Pole Height (m)
7-8
6-7
5-6
4-5
This is dependent on
optics
Pole Spacing (m)
For T2 optics
25-30
20-25
15-20
10-15
Light Envelope (m²)
For T2 optics
240
180
120
80
Solar Street Light Models (L)
Kamr
1L+G2
Kamr
2L+G2
Kamr
3L+G2
Kamr
4L+G2
Pole Height (m)
8-9
9-10
10-11
11-12
This is dependent on
optics
Pole Spacing (m)
For T2 optics
30-35
35-40
50-55
55-60
Light Envelope (m²)
For T2 optics
300
400
600
700

Silicon CPV plc
Akhter House, Perry Road, Harlow, Essex, CM18 7PN, UK
Tel [phone] Email [e-mail]
Page 14 of 32
Installation Instructions for Badr –Part 1
When the Solar Street Light is delivered the
battery bank and controller is left in the “SHIP
MODE”. This will prevent excessive battery
discharge during transit.
Battery Bank and Controller Access
1. Remove the pan pozi screw that secures the battery pack and
controller to the main light body
Correct Screw Hole for the pozi screw
2. Carefully slide the battery and controller pack out of the main
moulding. A small amount of force may be required.

Silicon CPV plc
Akhter House, Perry Road, Harlow, Essex, CM18 7PN, UK
Tel [phone] Email [e-mail]
Page 15 of 32
Installation Instructions for Badr –Part 2
The mode selection switch is located on the PCB moulding on the battery
pack. During normal operation the mode switch is hidden due to the
insertion of a weather seal rubber plug. The plug can be easily pulled out
to show the mode switch (see fig 1). Please ensure the rubber plug is re-
inserted after inspection to prevent water ingress. Using a small flat
bladed screw driver (fig 2), change the switch to the following modes of
operation (fig 3):
Mode selection
1. On Mode –This is the normal operating position. Please ensure
that when the Street Light is installed the mode switch is ALWAYS in
this position.
2. Ship Mode –This position is selected when the unit is not in use.
This is typically when the unit is stored or packed and being
transported to site for installation. The controller automatically
enters a power down state to conserve battery power
3. Test Mode - This position is used to check the operation of the light
under test conditions. This should not be selected for normal light
operation.

Silicon CPV plc
Akhter House, Perry Road, Harlow, Essex, CM18 7PN, UK
Tel [phone] Email [e-mail]
Page 16 of 32
Installation Instructions for Badr –Part 3
Fixing the Solar Street Light to the Pole
Warning: During the installation of the street light please observe safe
working practices when working at height.
Set the street light mode to ‘on mode’. Secure the battery and controller
pack into the Street Light using the pozi screw and install as instructed
below.
1. For this task you will need a powered drill with a 4.5mm HSS drill
bit and the 3 off Security Self Tappers Pin Torx BH - 10 x 3/4" (4.8
x 19mm) supplied in the light carton
2. Mount the street light on the pole as shown below and correctly
align with the road
3. Drill three pilot holes equally spaced around the circumference of
the pole and approximately 80mm from the light head
4. With the screws supplied fix the light to the pole
Pole Mounted Badr Street Light
Light with Pole
adaptor
Security Screw

Silicon CPV plc
Akhter House, Perry Road, Harlow, Essex, CM18 7PN, UK
Tel [phone] Email [e-mail]
Page 17 of 32
Pole Sizing and Spacing for Badr
The values below are specified using T2 optics as per IESNA Type II and
III specification
Solar Street Light Models
Badr 1+G2 / Badr 2+G2
Pole Height (m)
9-10
This is dependent on
optics
Pole Spacing (m)
For T2 optics
35-40
Light Envelope (m²)
For T2 optics
400

Silicon CPV plc
Akhter House, Perry Road, Harlow, Essex, CM18 7PN, UK
Tel [phone] Email [e-mail]
Page 18 of 32
Optical Lens and Distribution Patterns
SiliconCPV -T2 is classified as
IESNA type II, with a great mix
of luminance and illuminance
uniformity. It is also applicable
to European S-standard
pedestrian lighting.
SiliconCPV -T3 is classified as
IESNA type III, with a great mix
of luminance and illuminance
uniformity.
SiliconCPV -T4 is classified as
IESNA type IV, being best suited
for wider roads. It is also an
excellent choice for wide area
lighting, for example parking lots
and yards.
SiliconCPV -DN is a 2X2 array of
asymmetric lenses suitable for
area lighting. It has asymmetric
forward tilted beam and wider
light distribution than -FN.

Silicon CPV plc
Akhter House, Perry Road, Harlow, Essex, CM18 7PN, UK
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Page 19 of 32
SiliconCPV -A-T has similar
light distribution as SCPVSQ-A-T
and is designed to work on roads
that are narrower than the
height of the pole and when the
spacing is four times the height
of the pole.
SiliconCPV -ME is the best of
the class. Typical ME4a
installations are possible with the
ratio of pole distance and height
up to 5.5. SCPV-ME is designed
to fulfil ME-classes on a road
whose width is equal to pole
height or less.
SiliconCPV -DWC is designed
for roads with longer pole
distances. It can be used in
street lighting setups where the
pole distance is six times the
pole height.
SiliconCPV -DNW is designed
for roads where the pole height
and the roadway width are
similar.