Xantrex SOLAR Max Flex 784-0140-01 User manual
Installation Guide
140W Xantrex Solar Max Flex Panel Kit
Model Number: 784-0140-01
NOTE: Actualproduct may be different from what isshown.
Thank you for purchasing the 140W Xantrex Solar Max Flex Panel Kit. The 140W Xantrex Solar Max
Flex Panel Kit is a high quality, carbon emissions-free, and sustainable power source for your vehicle
such as, recreational vehicle (RV), truck, or boat. It is designed to take solar energy and quietly
produce power for your vehicle's DC appliances and store energy to a battery during daylight hours.
The 140W Xantrex Solar Max Flex Panel Kit package
includes the following items:
none pair of Solar Max Flex Panel kit
none 30A solar charge controller with Inline Fuse
none pair of Battery Cables with Deutsch
Connector/Ring Terminals
none pair of Jacketed Home Run Cables with
Staubli MC4 Connectors
none Mounting Hardware Kit - screw, cable clamp,
flange adapter, warning label, wire tie, edge tape
(2x), filling foam (4x)
none Product Notice with a link to this Installation
Guide
NOTE: If any of the accessories, materials, and other
items are missing, contact Xantrex or any authorized
Xantrex dealer for replacement. See Contact Information
on the back cover.
Safety Information
Important Information
READ AND SAVE THIS INSTALLATION GUIDE FOR FUTURE REFERENCE.
Read these instructions carefully and look at the equipment to become familiar with the device before
installing, operating, configuring, maintaining, and troubleshooting it. The following special messages
may appear throughout this documentation or on the equipment to warn of potential hazards or to call
attention to information that clarifies or simplifies a procedure.
The addition of either symbol to a “Danger” or “Warning” safety label indicates that an
electrical hazard exists which will result in personal injury if the instructions are not followed.
This is the safety alert symbol. It is used to alert you to potential personal injury hazards.
Obey all safety messages that follow this symbol to avoid possible injury or death.
Product Safety Information
cBefore using the 140W Solar Max Flex Panel Kit, read all instructions and cautionary markings
on the 140W Solar Max Flex Panel Kit's components, the batteries, and all appropriate
sections of this guide.
cUse of accessories not recommended or sold by the manufacturer may result in injury to
persons, a risk of electric shock, or a risk of fire.
cThe 140W Solar Max Flex Panel Kit is designed to be connected to your DC electrical systems.
The manufacturer recommends that all wiring be done by a certified PV technician or
electrician to ensure adherence to the local and national electrical codes applicable in your
jurisdiction.
cTo avoid a risk of fire and electric shock, make sure that existing wiring is in good condition and
that wire is not undersized. Do not operate the 140W Solar Max Flex Panel Kit with damaged or
substandard wiring.
cDo not operate the 140W Solar Max Flex Panel Kit if it has been damaged in any way.
cThis 140W Solar Max Flex Panel Kit does not have any user-serviceable parts. Do not
disassemble the 140W Solar Max Flex Panel Kit except where noted for connecting wiring and
cabling. See your warranty for instructions on obtaining service. Attempting to service the
140W Solar Max Flex Panel Kit yourself may result in a risk of electrical shock or fire.
cTo reduce the risk of electrical shock, disconnect the 140W Solar Max Flex Panel Kit from all
devices and or components before attempting any maintenance or cleaning on the 140W Solar
Max Flex Panel Kit.
cTo reduce the chance of short-circuits, always use insulated tools when installing or working
with this equipment.
cRemove personal metal items such as rings, bracelets, necklaces, and watches when working
with electrical equipment.
cDo not ground any PV conductors.
cDo not install the solar panel on top of a residential structure.
Copy right© 2023 X antrex LLC. All Rights Res erved. All trademarks are owned by Xantrex LLC and its affiliates .
Exclusion for Documentation
UNLE SS S PE CIFICA LLY A GRE ED TO IN WRITING,SE LLER
(A ) MAK ES NO WARRANTY AS TOTHE ACCURACY , SUFFICIENCY OR SUITABILITY OF A NY TECHNICAL OR OTHE R INFORMATION PROVIDED IN ITS MA NUA LS OR OTHER
DOCUMENTATION;
(B ) A SSUMES NO RES PONSIBILITY OR LIABILITY FOR LOS SES, DA MAGES ,COSTS OR EX P ENS ES, WHETHER SP ECIAL, DIRECT,INDIRECT,CONSE QUE NTIAL OR INCIDENTAL,
WHICH MIGHT A RIS E OUT OF THE US E OF SUCH INFORMATION. THE US E OF A NY S UCH INFORMA TION WILL B E ENTIRE LY A T THE US ER ’S RISK ;A ND
(C) RE MINDS Y OU THAT IF THIS MANUA L IS IN ANY LA NGUAGE OTHER THAN ENGLISH,A LTHOUGH STEPS HAV E BE EN TAK E N TOMAINTAIN THE A CCURA CY OF THE TRANS LATION,
THE A CCURACY CANNOT BE GUARA NTEE D. APPROVED CONTENT IS CONTAINED WITH THE E NGLIS H LA NGUAGE V ERS ION WHICH IS P OSTED AT http://www.xantrex.com.
NOTE:Visithttp://www.xantrex.c om ,click P roducts, select a Product category, select a Product,and s earch the Product Documents panel for a translation of the English guide, if available.
Contact Information
Telephone: +1-800-670-0707 / +1-408-987-6030 Web: http://www.xantrex.com
Email: customerservice@xantrex.com,
https://xantrex.com/support/get-customer-support/
2 975-1172-01-01 Rev A
August 2023
Basic Installation Steps
Safety Instructions
Before beginning your installation:
nRead this entire Installation section so you can plan the installation from beginning to end.
nAssemble all the tools and materials you require for the installation.
nBe aware of all safety and electrical codes which must be met.
WARNING
ELECTRICAL SHOCK AND FIRE HAZARD
nThe power system must be designed by a certified vehicle solar system designer and installed
by a certified solar system technician.
nAll wiring should be done by qualified personnel to ensure compliance with all applicable
installation codes and regulations.
nDisconnect all power sources.
nDisable and secure disconnect devices.
Failure to follow these instructions can result in death, serious injury, or equipment
damage
Tools and Materials
You may need the following tools to install the Solar Max Flex Panel kit:
nScrewdriver
nSocket wrenches
nUtility knife
nDC clamp-on multimeter
nMeasuring tape
nPliers
nWire cutter
nSafety gloves and eye protection
nRubber roller
nPrimer
nZip ties (provided as strain-relief devices)
nFlange adapters (provided as needed in mounting)
n30A solar charge controller (provided)
Installation Instructions
1.Plan the power system and prior to installing, check that the panel is producing power.
a. Prepare the multimeter.
b. Check out the weather to see if it is sunny.
c. Partially unpack the solar panel, expose the cells to the sun and
test the output voltage using the multimeter's probes on the
solar panel's connectors.
d. If the solar panel is functioning properly, the voltage reading
should be above 3VDC.
e. Draw your power system on paper similar to Figure 1 on page
5.
4 975-1172-01-01 Rev A
August 2023
Figure 1 Complete cable schematic of a 2-solar panel power system
1
2
5
6
78
4
3
1Solar panels connected in series (+–+–) 5Inline fuse on red, POS+ cable
230A solar charge controller 6Battery (12V or 24V)
3PV jacketed home run cable (red,
POS+)
7Battery cable (red, POS+)
4PV jacketed home run cable (black,
NEG–)
8Battery cable (black, NEG–)
975-1172-01-01 Rev A
August 2023
5
2.Plan and prepare where you would install the solar panels.
PROTIP: Place end of module aligned to
marked line. Peeloff around 12 inchesof liner
from below module, making sure it isaligned.
Partiallyremove and stickthe module on in 1
foot increments, making sure module
conforms to the surface.Roll out the module
with rubber roller ormicrofiber rag.
NOTICE
GENERAL PRECAUTIONS
lSelect a mounting surface on the roof of your vehicle that is
firm, thick, rigid, and able to support the solar panel and
mounting hardware.
lSurface must be at least 60°F (15°C).
lDo not select a roof location within 1m (3 ft) of the front of the
vehicle to reduce wind lift forces during motion.
lDo not mount the solar panel near other roof fixtures that can
obstruct direct exposure to sunlight.
Failure to follow these instructions can result in physical
damage to vehicles and property.
a. Unpack the solar panels and prepare all installation tools and
materials.
b. Prepare the mounting surface by removing dust, dirt, and
debris.
lObserve and measure surface obstructions on the
installation surface, if any.
lDetermine which areas need extensive cleaning.
lUse the filling foams (provided in the kit), if the
installation surface is ridged and not flat. Contact your
dealer for further suggestions.
c. Apply a cleaner to the mounting surface.
lSoak a microfiber rag with the chosen cleaner.
lChoose isopropyl alcohol, acetone, or a residue-free
industrial surface cleaner/degreaser.
lRemove any substance that could hinder adhesion.
lIf needed, apply the cleaner directly to the surface.
lEnsure there is no residue left on the mounting surface.
d. Mark mounting location of panel.
6 975-1172-01-01 Rev A
August 2023
3.Mount the solar panel.
a. Hold module in place, then remove several inches of liner from
one end.
b. Apply even pressure only on top of the areas where there is the
3M VHB tape underneath the solar panel for proper bonding of
the 3M VHB tape to the mounting surface. It is ideal to use a
roller or the palm of your hands to apply pressure.
c. Be careful not to apply hard pressure on the solar cells that may
lead to damage.
WARNING
ELECTRIC SHOCK AND FIRE HAZARD
Do not ground any PV conductors.
Failure to follow these instructions can result in death,
serious injury, or equipment damage.
TIP: Once applied to a surface, the 3M™
VHB™ tape, which isa high-strength, double-
sided acrylicadhesive tape, cannot be easily
removed without damaging both the solar
paneland the mounting surface. For more
information, visit the 3M website.
IMPORTANT: Follow the recommendations
illustrated in Figure 2 and succeeding Figures.
Figure 2 Precautions
NOTICE
GENERAL PRECAUTIONS
lDo not bend more than 30° when handling and mounting the
solar panel.
lDo not step on the solar panel.
lDo not mount the solar panel near other roof fixtures that can
obstruct direct exposure to sunlight.
lSelect the mounting area carefully and mark the exact and
intended location of the solar panel.
Failure to follow these instructions can result in physical
damage to vehicles and property.
Figure 3 Adhesive strips on the panel's backside
all sides adhesive
all surface adhesive
The backside of the Solar Max Flex Panelkit has3M VHBtape strips already applied around the perimeter of the
panel.
c. Use the edge tape (provided in the kit) to apply all around the
perimeter edge of the panel for a tighter seal. See Figure 4 for
an illustration.
975-1172-01-01 Rev A
August 2023
7
Figure 4 Adhesive placement depending on surface
sealing tape
For illustration purposes. The solar cellsare shown as perspective only. Do not apply the adhesive tape on top of
the solar cells. The adhesive tape must be applied on the backside of the paneland onto the mounting surface.
8 975-1172-01-01 Rev A
August 2023
4.Mount the Charge Controller.
The charge controller is best mounted in a location away from direct
heat, water, salt, snow, ice, and debris.
a. Mount the unit.
b. Ensure the heat fins have sufficient air flow.
c. Use the charge controller flange to create a hole template so
you can pre-drill the mounting holes.
Figure 5 Charge Controller
3
2
4
1
5
1Communication port (do not
cut or remove)
4LED lights
2Battery cables (Power
output) positive (+)with fuse
& negative (-)
5Thermistor probe (do not
cut or remove)
3PV cables (Solar Input)
positive (+) & negative (-)
Make sure the in-line fuse (in item 2 above) is connected on the (+)
side of the battery side of the charge controller. If you have a busman
disconnect, make sure it is not near an area where it can disconnect by
touching other cables or components.
975-1172-01-01 Rev A
August 2023
9
d. Use an appropriately sized self-tapping screw (4x) to attach the
solar charge controller to the wall.
NOTICE
MOUNTING TO A WALL WITH NO BACK ACCESS
If drilling to a wall is not possible, use flange adapters to secure the
solar charger to the wall.
Failure to follow these instructions can result in equipment
damage.
Figure 6 Flange adapter
e. Use the provided flange adapters (4x) to clamp the solar
charge controller to the wall.
10 975-1172-01-01 Rev A
August 2023
5.Connect the DC cables.
NOTICE
REVERSE POLARITY
Check polarity at all terminals before making the final DC
connection. POS(+) (red) must connect to charge controller POS
(+) (red); NEG(–) (black) must connect to charge controller NEG
(–) (black).
Failure to follow these instructions can result in
equipment damage.
a. Cover the solar panel with a blanket (or the packaging box) to
de-energize it.
b. Before connecting the cables, be sure to review the
information below regarding where to place strain-relief
devices.
NOTICE
STRAIN-RELIEF REQUIREMENT
Using the diagram below, when you start inter-connecting the
cables make sure to install a strain-relief device (a zip tie) on the
points indicated.
Failure to follow these instructions can result in
equipment damage.
Figure 7 Strain-relief points
1
2
3
4
5
1Install approximately 2 to 4 inches from the
solar charger to tie the battery cables
together.
4Install approximately 5 to 7 inches from the
solar charger to tie the battery cables
together.
2Install approximately 5 inches from the solar
charger to tie the negative (-) battery cable
with the communication cable.
5Install approximately 8 to 10 inches from the
solar charger to tie the connecting PV
cables together.
3Install approximately 4 inches from the solar
charger to tie the PV cables together.
cDo not tie the BTS cable to any of the DC
cables.
975-1172-01-01 Rev A
August 2023
11
c. Connect the red pos (+) and black neg (–) battery cables to the
charge controller.
d. Route the battery cable inside the vehicle and connect the red
pos (+) and black neg (–) battery cables to the respective
battery terminals.
e. Secure all cables with clamps (and/or cable ties) and additional
strain-relief as necessary.
f. Connect the red pos (+) and black neg (–) PV cables to the
solar panel using the MC4-type connectors.
g. Route the PV cables through the roof entry point and connect
the red pos (+) and black neg (–) PV cables to the charge
controller.
h. Clear the roof and the cable routes of tools and other debris
that may have been left during installation.
6.Operate and maintain the system.
a. Remove the blanket (or the packaging box) covering the solar
panel to start energizing the solar panel.
b. Refer to Solar Panel Maintenance and Care on page 13 for
best practices.
12 975-1172-01-01 Rev A
August 2023
Solar Panel Maintenance and Care
Although a well designed vehicle-mounted solar system requires minimal maintenance, it is highly
recommended to perform an inspection and cleaning of the solar panels during the warranty period.
This helps to ensure optimal system performance and reliability through a few simple steps.
Visual
Inspection
Perform a visual inspection of the solar system on a monthly basis to identify if there are
any visual defects or improper connections.
nCheck for any sharp objects on the solar panel surface.
nCheck for any signs of corrosion or burnt hotspots around the solar cell and
backsheet area.
nCheck that the solar panel is clear of any shading by any foreign material or
unwanted obstacles. Just a small amount of shade on the solar panel surface can
cause significant power output loss.
nIf the solar panel has slight discoloration over a period of usage, this is considered
normal for solar panels that use an anti-reflection coating laminate.
Cleaning
Solar
Panels
The power output of a solar panel is proportional to the amount of sunlight that reaches
the solar cells. Therefore, any build-up of dust or dirt on the surface of the solar panel will
result in a loss of power. This is a trade-off between the maximizing the power output of
the solar panel versus the cost and time to perform regular cleaning.
cDo not clean solar panels if there is broken plastic material or exposed wiring because
this creates a risk for electric shock.
cDo not step or kneel on the solar panel during cleaning.
nCheck the solar panel periodically during seasons that the vehicle is in-use. If
there is a build-up of dust or dirt on the surface of the solar panel, it is
recommended to clean it.
nClean the solar panel in the early morning or early evening when the solar panel
is cooler, especially in hot regions. This will reduce the risk for electrical and
thermal shock.
nClean using a soft cloth together with clean water and mild detergent or soap.
lMake sure there is no soap residue remaining after cleaning.
lAvoid using water with high mineral content that may leave deposits on
the solar panel surface.
lDo not use abrasive materials to clean the solar panel.
lDo not use chemicals to clean the solar panel.
lDo not pressure wash the solar panel.
975-1172-01-01 Rev A
August 2023
13
Troubleshooting
WARNING
ELECTRICAL SHOCK HAZARD
If the in-line fuse on the 10AWG positive (+) battery cable blows, replace with a 30A/32V green ATC
blade fuse.
Failure to follow these instructions can result in death, serious injury, or equipment
damage.
NOTE: To obtain service go to Contact Information on page 1.
Problem Possible Cause Solution
Battery does not get charged
even when sunlight is
present.
Solar panel is partially shaded
or there is insufficient sunlight.
Move the vehicle or vessel so the whole
solar panel is exposed to direct sunlight.
Loose or no DC cable
connections.
Connect DC cables to the battery and
solar panel and tighten terminal
connections.
Fuse is blown. Replace the blown fuse with a 30A/32V
green ATC blade fuse.
14 975-1172-01-01 Rev A
August 2023
Specifications
NOTE: Specifications are subject to change without prior notice.
140W Xantrex Solar Max Flex Panel Kit
Part number 784-0140-01
Dimensions 47.01 x 14.69 in
(1194 x 373 mm)
Cell type Monocrystalline PERC
Top layer ETFE
Junction box IP67
Connector MC4
Maximum power at STC* 140W
Maximum power voltage 65V
Maximum power current 2.2A
Open circuit voltage 72.8V
Short circuit current 2.4A
Maximum system voltage 600VDC
Operating temperature -40 °C to +85 °C
Temperature coefficients of Pmax -0.39%/ °C
Temperature coefficients of Voc -0.30%/ °C
Temperature coefficients of Isc +0.06%/ °C
*Standard Test Conditions(STC): Irradiance: 1000W/m2, Cell Temperature: 25°C, Air Mass: 1.5
MPPT Charge Controller
Battery Norminal Voltage 12/24VDC
Rated Charge Current 30A
Nominal PV Power 195W @ 12V
390W @ 24V
Enclosure IP68
Cable Terminal 14AWG/2.5mm2
Dimensions 5.91 x 3.68 x 1.23 in
(150 x 93.5 x 32.7 mm)
Unit weight 1.6 lbs.(740 g)
975-1172-01-01 Rev A
August 2023
15
+1-800-670-0707
+1-408-987-6030
customerservice@xantrex.com
https://xantrex.com/support/get-customer-support/
http://www.xantrex.com
975-1172-01-01 Rev A
August 2023
Printed in USA.
Table of contents
Other Xantrex Solar Panel manuals
