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SOLAR BOLT CHARGING SYSTEM

INSTALLATION GUIDE

INST168 Doc 2.00

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Summary of Contents for SOLAR BOLT

Page 1: ...SOLAR BOLT CHARGING SYSTEM INSTALLATION GUIDE INST168 Doc 2 00 ...

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Page 3: ...ation Preparation 4 Solar Panel Install Process 5 Solar Bolt Main Harness Installation 8 Cable Routing 10 Solar Bolt Controller Installation 11 Solar Panel Configurations 13 200 Watt 2 Solar Panel 13 300 Watt 3 Solar Panel 14 400 Watt 4 Solar Panel 15 LED Logic 16 Part List 17 Limited Commercial Warranty Policy 21 ...

Page 4: ...tage 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 This enables the solar panel to deliver up to its full output capability to the batteries when the vehicle is running The module s technology allows the Solar Bolt to provide power to the electrical system of the vehicle which ...

Page 5: ...added in the future see the Solar Panel Configurations section for instructions on mounting more than one panel 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...

Page 6: ...ad Maroon or Green Isopropyl alcohol Eternabond RoofSeal 2 bonding tape Optional Sikaflex 221 or 291 Rags Zip ties Rubber gloves INSTALLATION PREPARATION 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 Scotch Brite to remove surface impurities Step 3 Set the panel s in the desired location and use a permanent mar...

Page 7: ...ficiently prepare for the edge seal by lightly abrading the edge 1 of the solar panel and 1 of the adjacent metal surface with Scotch Brite 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 A...

Page 8: ...ibility of the customer to verify the edge seal is sufficiently cured before putting the trailer or box truck in service NOTE Purkeys is not responsible for solar panel failure if the truck was put into service before Sikaflex edge seal is cured Step 8 Install cables and properly attach wires per customer requirement It is recommended that panel wires are installed running off the back of the trai...

Page 9: ...ler and over to the right side of the trailer Secure the harness by using the supplied nylon clamps and 12 x hex tek screws Step 3 Route the main harness over the front of the trailer and use the supplied E chain to protect the cable Secure the harness by using the supplied rubber washers and 12 x 1 roofing screws Important Do not screw into the roof of the trailer Make sure to screw into the fram...

Page 10: ... 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 chaffing points Step 5 Peel the adhesive lining off the back of the panel and press firmly on the panel to ensure it adheres to the trailer Applying heat to the trailer top is recommended to help the adhesive stick ...

Page 11: ...d 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 Installation Complete 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 possib...

Page 12: ... the connections to the Solar Bolt controller then cut excess cable Strip off jacketed insulation from the Solar Bolt main harness to approximately 2 inches Strip the insulation on both wires Step 3 Connect the blue wire from the Solar Bolt main harness to the wire on the Solar Bolt controller labeled SOLAR POSITIVE Solder and heat shrink SOLAR BOLT CONTROLLER INSTALLATION ...

Page 13: ...olt main harness to the white wire located on the Solar Bolt controller Solder and heat shrink Step 5 Connect the ground wire from the Solar Bolt controller to the liftgate battery negative terminal Step 6 Connect the positive wire from the Solar Bolt controller to the liftgate battery positive terminal Installation Complete ...

Page 14: ...on for details on installing the first panel 200 Watt 2 Solar Panels 1 Place the second solar panel no more than 4 inches away from the first 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 B...

Page 15: ... inches away from the second solar panel 2 Connect the second Solar Bolt Y Splitter input side to the longest output from the first 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 ...

Page 16: ...olar panel 2 Connect the third Solar Bolt Y Splitter input side to the longest output of the second splitter Positive Positive Negative Negative 3 Connect the outputs of the third Solar Bolt Y Splitter to the third and fourth solar panels 4 Clamp the Solar Bolt Y Splitter to the edge of the trailer ...

Page 17: ...19 4800 F 479 419 4801 www purkeys net SOLAR BOLT INSTALLATION GUIDE LED LOGIC LED Status Blinking Red Battery below 12 4 V above 16 V or fault Blinking Green Battery above 12 4 V Solid Green Battery above 13 2 V ...

Page 18: ...BOLT 03 WI Solar Bolt Charging System 300 W Three Panels No Indicator Part SLRBOLT 02 WI Solar Bolt Charging System 200 W Two Panels No Indicator Part SLRBOLT 01 WI Solar Bolt Charging System 100 W Single Panel No Indicator ...

Page 19: ...F 479 419 4801 www purkeys net SOLAR BOLT INSTALLATION GUIDE Part SLRBOLT 04 WI Solar Bolt Charging System 400 W Four Panels No Indicator Part MOD00083 Solar Bolt Controller Part MOD00083 K Solar Bolt Controller Assembly ...

Page 20: ...18 Part CHRG 006 Solar Panel Flexible 100 W Watt Solar Panel Part H 00383 Harness Solar Main 50 Part H 00382 Harness Solar Bolt Y Splitter ...

Page 21: ...19 P 479 419 4800 F 479 419 4801 www purkeys net SOLAR BOLT INSTALLATION GUIDE Part BK 1062 Bag Kit Solar Bolt Hardware Part INST168 Guide Installation Solar Bolt Without Indicate ...

Page 22: ...y if any Purkeys product is used for a purpose for which it is not designed or is in any way altered without the specific prior written consent of Purkeys ANY Product alleged by a Customer to be defective must be inspected by Purkeys as a part of the warranty claims process in order to confirm that the part has failed as a result of a defect in material or workmanship Transportation for products a...

Page 23: ...21 P 479 419 4800 F 479 419 4801 www purkeys net SOLAR BOLT INSTALLATION GUIDE ...

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