SolarMate SOLAR POWERED MAINS FREE LIGHTING User manual

a. If a battery capacity of less than 35Ah or 70Ah will be used with Solar Mate
I and II respectively, the solar panel must be disconnected from the battery
during long periods of system inactivity (e.g when on holiday or in the
summer etc) or overcharging may occur and the battery could be permanently
damaged.Alternatively contact Solar Technology International who can supply
a voltage regulator (at a small extra charge).
b. We recommend the use of a standard leisure (caravan) battery or auto
battery. These can typically be found in most car / caravan accessory stores
and are typically 75Ah to 85Ah capacity. If the battery location could cause a
spillage form the battery then we would recommend using a Solar Technology
International sealed deep cycle battery - see www.solartechnology.co.uk
c. When routing cables & fittings, care must be taken that cables & fittings
cannot become damaged in the normal course of use by machinery or
livestock, & care must be taken to protect cables & fittings from damage,
where necessary, from any external influences. Care must also be taken near
any gas supplies, as arcing from switches & appliances may be a hazard.
d. If an existing electrical installation is already in place or in service, the 12v
DC Solar installation and sub circuits, including battery, must be kept totally
separate & isolated, and in no way integrated, or made part of the original
existing system. 12 volt DC & 240AC cables cannot be run in the same
conduits & trunking.
e. Run times may vary and will be dependent on weather conditions, the solar
panel will produce energy even in cloud conditions, but winter production will
be less primarily because of the position of the sun in relation to the solar
panel. Less power is produced when the sun is low in the sky.
f. Increased run times can be achieved in spring/summer months when the sun
is much higher in the sky.
g. Normal battery maintenance applies: check fluid levels on a regular basis,
top up as necessary.
h. Extra cable can be purchased by the metre from Solar Technology International.
i. Many 12v accessories can added: lighting, audio equipment, visual
equipment, water pumps etc, to make a comprehensive installation.
j. Both SolarMate systems can be expanded to power more appliances by ‘daisy
chaining’ more solar panels to the original installation. Please contact Solar
Technology on 01684 774000 for advice on your specific requirements.
Solar Technology International Ltd.
Unit 6, Station Drive, Bredon, Nr. Tewkesbury, Gloucestershire GL20 7HH
Tel: [phone] • Fax: [phone] • Email: [e-mail] • Web: www.solartechnology.co.uk
STEP 3a Connecting the
Voltage Regulator
SolarMate III (ES), IV (ES) and V (ES) require a voltage
regulator to protect the battey from overcharging and to
ensure the panel does not discharge the battery at night.
3.1 Position the Solar voltage regulator as close as possible
to the battery (must be a dry location).
3.2 Measure the distance between your battery terminals
and the Solar voltage regulator.
3.3 Cut the measured distance from the end of the cable.
3.4 Prepare as described in 3.1 & 3.2 the end of the cable
from the inline connector (if fitted) and attach to the two
terminals (G) on the Solar voltage regulator.
3.5 Take one end of the remaining cable, prepare as
above and attach to the centre terminals (H) on the
Solar voltage regulator by using the same procedure as
described in 1.6.
NOTE: RED = POSITIVE (+); BLACK = NEGATIVE (-)
STEP 4 Connect the Cable to the
Wall Switch and Battery
NOTE - if SolarMate III. IV or V has been purchased each
fluorescent fitting is individually switched, therefore ignore this
section and go straight to Connect Cable to Battery.
Remove the knockouts at the top & bottom of the wall switch
mounting box to allow cable access & secure to the wall at the
desired location.
The wall switch (10Amp max) will control & switch the light
fittings. The main supply from the battery will run through
the wall switch via the in-line fuse. The positive cable is the
wire that must be switched, the Negative wire must remain
unbroken. It may be necessary to join the Negative wire with
the single connector block supplied in the switch housing
to complete the circuit. Do not connect the battery until the
installation is complete.
Connect Cable to Wall Switch
4.1 Measure & cut to length the cable that will run from the
battery to the Wall Switch.
4.2 Remove 3.5cm of the outer black cable sheathing.
4.3 Strip back approx. 5mm of insulation from the red &
black wires.
4.4 Feed cable into the bottom of the switch mounting box.
4.5 Connect the red wire to the bottom of the switch.
4.6 Connect the black wire to the single connector block
supplied.
Connect Cable to Battery
4.7 Strip back 20cm of the black outer sheath of the cable
end to be connected to the battery.
4.8 Repeat Step 3.2.
4.9 Follow step 3.3 and connect the cable ends to the same
crocodile clips as the cable running from the solar panel.
Do not connect the battery until the installation is
complete.
STEP 5 Measure & cut Cable to
run from the Wall Switch
to the Lamp Holder
5.1 Repeat steps 4.2 & 4.3.
5.2 Feed cable into top of switch mounting box.
5.3 Connect the red wire to the top of the switch,
marked TOP (See picture left).
5.4 Repeat step 4.6.
5.5 Secure the switch plate to the mounting box.
STEP 6 Connecting the
Lamp Holder
6.1 It will be necessary to remove or cut away a small
portion of plastic at the lamp holder base to allow cable
entry. The cut outs can be seen at the base and can be
removed with a sharp knife. The lamp holder will need
to be connected up electrically before finally fixing in
position.
6.2 At the cable end to be connected to the lamp holder,
remove 4cm of outer sheathing.
6.3 Strip back approx. 5mm of insulation from the red and
black wires.
6.4 Connect red wire by pushing the wiretip into Lamp
Holder's positive terminal (D) located at the 3 o’clock
position (See picture left).
6.5 Connect the black wire by pushing the wiretip into the
Lamp Holder's negative Terminal (E) located at 9 o’clock.
(See photograph left)
6.6 Secure the Lamp Holder at the desired location.
6.7 SolarMate II, III (ES) and V (ES) have more than one lamp
holder to fit. Simply connect all subsequent lamp holders
to the first by connecting red to red
and black to black (parallel connection). This also applies
to connecting the fluorescent light fitting on SolarMate III,
IV and V.
+ve
from
Battery
+ve to
Lamp
Holder
Connect Wall Switch
STEPS 4 & 5
Connect In-Line Fuse
STEPS 3 & 4
C
INSTRUCTIONS
SOLAR POWERED MAINS FREE LIGHTING
SolarMate®
TECHNICAL HELPLINE 01684 774000
TECHNOLOGY INTERNATIONAL
Solar
Notes
Auxilliary connections
Solar Panel
connections
Battery
connections
VOLTAGE
REGULATOR
Connecting the Voltage Regulator to
a battery and Solar panel
Connect Voltage Regulator
STEP 3a
G H
Connect Lamp Holder
STEP 6
EPlace a flat screwdriver
in here to release the
grip of the wire
–ve
BLACK
wire
D
+ve
RED
wire
D
+ve
RED
wire
E
–ve
BLACK
wire

Connect cable to crocodile clips
STEP 3
Cable
Attach here
A
B
STEP 1
Connect Terminal Box
STEP 2
Feed Cable Ties through holes
in panel before securing to
Roof Mounting Blocks
SolarMate I:
1 x 5wp Solar Panel (a)
1 x Long Life Bulb
(40-45W equivalent) (b)
1 x Bulb holder (c)
1 x Wall switch (d)
5m Cabling (e)
4 x Cable ties (f)
2 x Crocodile clips (g)
2 x In-line fuses (h)
6 x Ring terminals (i)
1 x Single connection block (j)
4 x Roof/wall mounting blocks (k)
4 x Mounting screws (l)
8 x Cable Clips (not pictured)
Fixing screws for items (c) & (d)
SolarMate I LED:
As above but with 1 x LED Bulb
instead of Long Life Bulb
TECHNICAL HELPLINE 01684 774000 TECHNICAL HELPLINE 01684 774000
Please read all instructions carefully before any
installation work begins.
Please refer to circuit diagram, please observe correct polarity
at all times: Positive = Red; Negative = Black
Positioning your Solar Panel
Position your solar panel, ideally on a sloping roof facing
south, at an angle of 50-70 degrees to the horizontal. If this
is not possible, remote positioning may be required to give
maximum performance, although west or southwest will still
provide good power generation. Avoid shaded areas.
Solar Panel
Bulb
Bulb
Holder
Switch
Battery
Fuse
Positive Negative
Single
connector
block
Connecting your
SolarMate Kit
STEP 1 Fitting the Cable to
the Solar Panel
1.1 Before fitting the cable to the solar panel, decide on
the panel location and cut the appropriate length of
cable ensuring it will reach from the solar panel to the
battery.
1.2 Remove the cover from the terminal box on the rear of
the solar panel.
1.3 Unscrew & remove the cable clamp (A). Loosen (do
not remove) the two terminal screws (B)
1.4 Take one end of the cable & strip back the black outer
sheath 4.5cm. Strip back the insulation of the red &
black inner cables 1.5cm to expose bare conductor.
1.5 Feed the cable through the hole in the terminal box.
1.6 Twist the bare conductor ends tightly & wrap clockwise
around the loosened terminal screws. Alternatively
two ring terminals (supplied) can be crimped onto the
bare conductor ends.
RED (POSITIVE); BLACK (NEGATIVE)
As marked on the inside of the
terminal box
1.7 Tighten terminal screws, refit the cable clamp and
replace the terminal box cover.
Note: The cable clamp will give best results
with low profile cable is fitted with the bulge
facing (touching) the cable.
STEP 2 Mounting the
Solar Panel
2.1 Drill an 8mm access hole, ideally positioned close to
or underneath where the solar panel will be located.
2.2 Fix the mounting blocks to the outer surface of the
roof or wall as shown in ‘STEP 2’ picture on left.
2.3 Thread the cable ties through both loops on the
mounting blocks.
2.4 Insert the loose end of the cable from the solar panel
into the access hole and lower the panel onto the
fixing surface, ensuring the pre-drilled holes on the
back of the panel frame line up with the mounting
blocks.
SolarMate II:
1 x 10wp Powered Solar Panel
2 x Long Life Bulbs
(40-45W equivalent)
2 x Bulb holders
1 x Wall switch
7m Cabling
4 x Cable ties
2 x Crocodile clips
2 x In-line fuses
6 x Ring terminals
1 x Single connection block
4 x Roof/wall mounting blocks
4 x Mounting screws
8 x Cable Clips (not pictured)
Fixing screws for items (c) & (d)
SolarMate II LED:
As above but with 2 x LED Bulbs
instead of Long Life Bulbs
STEP 2
Screw Roof Mounting Blocks
to roof
Roof
2.5 Thread the pointed end of each cable tie through each
panel frame hole and then through the square end of
the tie. Now pull the pointed end of the tie tight to lock
off.
2.6 Cut of the loose end of the cable tie.
2.7 The access hole can now be filled to prevent leakage
with a suitable sealant or adhesive.
STEP 3 Connecting Solar Panel
to the system Battery
(Recommended battery size 35Ah to 85Ah - see
notes, section A.) Site the battery in a well-ventilated
& dry area; protect from frost. Always start with a
fully charged battery. If the battery is flat at the time
of installation of the SolarMate kit, allow the fully
connected system a period of between 8 to 14 days
to fully charge the battery before first use.
SolarMate I & SolarMate II solar panels can be connected
direct to the battery using the cable supplied. A reverse feed
diode is fitted to prevent discharge through the solar panel
at night time. SolarMate III/ES, IV/ES and V/ES do not have
a reverse feed diode fitted. This function is performed by the
voltage regulator supplied in these kits - see section 3a. All
SolarMate kits require a fuse (supplied) to be fitted on the
positive (red) cable.
3.1 Strip back 20cm of the black outer sheath of the cable
end to be connected to the battery.
3.2 Cut the red cable at the halfway point & strip 5mm
of the red insulation from both the cut ends. Twist the
bare wire ends tightly. Fit into the screw terminals C on
each of the fuse holder pieces (See picture left).
3.3 For both SolarMate I and SolarMate II, connect
the cable to your battery. Strip red and black insulation
from the inner cable. Twist the bare conductor ends
tightly & wrap clockwise around the loosened terminal
screws. Alternatively two ring terminals (supplied) can
be crimped onto the bare conductor ends.
Do not connect the battery until the installation is
complete.
For step 3a, 4, 5 and 6 please see overleaf
SolarMate III:
1 x 18wp Solar Panel
1 x 4Ah Voltage regulator (not pictured)
2 x Flourescent light tubes and
fittings -self switched
(40-45W equivalent)
7m Cabling
4 x Cable ties
2 x Crocodile clips
2 x In-line fuses
10 x Ring terminals
1 x Single connection block
4 x Roof/wall mounting blocks
4 x Mounting screws
8 x Cable Clips (not pictured)
Fixing screws for items (c) & (d)
SolarMate III ES:
1 x 18wp Powered Solar Panel
1 x 4Ah Voltage regulator
4 x Long Life Bulbs (40-45W equivalent)
4 x Bulb holders
1 x Wall switch
7m Cabling
4 x Cable ties
2 x Crocodile clips
2 x In-line fuses
10 x Ring terminals
1 x Single connection block
4 x Roof/wall mounting blocks
4 x Mounting screws
8 x Cable Clips (not pictured)
Fixing screws for items (c) & (d)
SolarMate III ES LED:
As above but with 4 x LED Bulbs
instead of Long Life Bulbs
SolarMate IV:
1 x 28wp Solar Panel
1 x 4Ah Voltage regulator
4 x Flourescent light tubes and
fittings -self switched
(40-45W equivalent)
10m Cabling
4 x Cable ties
2 x Crocodile clips
2 x In-line fuses
12 x Ring terminals
1 x Single connection block
4 x Roof/wall mounting blocks
4 x Mounting screws
14 x Cable Clips (not pictured)
Fixing screws for items (c) & (d)
SolarMate IV ES:
1 x 28wp Powered Solar Panel
1 x 4Ah Voltage regulator
6 x Long Life Bulbs (40-45W equivalent)
6 x Bulb holders
2 x Wall switches
10m Cabling
4 x Cable ties
2 x Crocodile clips
2 x In-line fuses
12 x Ring terminals
1 x Single connection block
4 x Roof/wall mounting blocks
4 x Mounting screws
14 x Cable Clips (not pictured)
Fixing screws for items (c) & (d)
SolarMate IV ES LED:
As above but with 6 x LED Bulbs
instead of Long Life Bulbs
SolarMate V:
1 x 43wp Solar Panel
1 x 4Ah Voltage regulator
6 x Flourescent light tubes and
fittings -self switched
(40-45W equivalent)
10m Cabling
4 x Cable ties
2 x Crocodile clips
2 x In-line fuses
12 x Ring terminals
1 x Single connection block
4 x Roof/wall mounting blocks
4 x Mounting screws
14 x Cable Clips (not pictured)
Fixing screws for items (c) & (d)
SolarMate V ES:
1 x 43wp Powered Solar Panel
1 x 4Ah Voltage regulator
8 x Long Life Bulbs (40-45W equivalent)
8 x Bulb holders
2 x Wall switches
10m Cabling
4 x Cable ties
2 x Crocodile clips
2 x In-line fuses
12 x Ring terminals
1 x Single connection block
4 x Roof/wall mounting blocks
4 x Mounting screws
14 x Cable Clips (not pictured)
Fixing screws for items (c) & (d)
SolarMate V ES LED:
As above but with 8 x LED Bulbs
instead of Long Life Bulbs
(a) (b)
(c)
(d)
(g)
(h)
(i)
(j)
(e)
(f)
(l)
(k)
(SolarMate I contents shown)
SolarMate Kit Contents
LED light
bulboption
Flourescent light
tube option