GreenWay® SolarLEDPathandTrailLightingSystem

InstallationandOwner’sManual

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InstallationManual|Greenway®SolarLEDPathandTrailLightingSystem

ImportantNotesandWarnings

Thisinstallationandinstructionmanualprovidesinstallation,operation,andmaintenanceinstructionsfortheSolGreenWaysolarLEDlightingsystem.Theentirecontentsofthismanualshouldbethoroughlyreviewedandunderstoodpriortoinstallingthisequipment.Donotdiscardthismanual,asitcontainscompletemaintenanceinstructions,atroubleshootingchart,andasparepartslist.Toinsureproperoperationofthisequipment,itisimportantthattheequipmentbeutilizedforitsintendeduse.Anyuseofthisequipmentforpurposesotherthanthoseintendedwillvoidallwarranties.

Installationand/ortroubleshootingshouldbeperformedonlybyqualifiedpersonnel.FollowlocalcodesatalltimesduringinstallationoftheGreenWaysystem.

Beverycarefulwhenworkingwithbatteries.

Donotallowbareendsofthewirestotoucheachotherorgroundedmetalpartswhileconnectedtothecontroller.Thiswilldamagethecontroller.

ThismanualcontainsimportantinstructionsfortheSolGreenWaySeriesthatshallbefollowedduringinstallationandmaintenanceofthechargecontroller.

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InstallationManual|Greenway®SolarLEDPathandTrailLightingSystem

1.0SystemOverview

FIGURE1: SolGreenwaySystemHardwareComponents

SolarPanelPan

ArmAssembly

Pole

FixtureAssembly

SolarPanelMount

BatteryBox(singleordual) Battery(1or2)

Controller

HolesforFixtureInstallationMust

FaceDown

DriveRivets(bottom-3)

SolarPanelAssembly

BatteryBoxChannel

FixtureMountingScrews

DriveRivets(top-3)

SolarPanelMountingScrews&Washers(4sets)

BatteryBoxMountingScrews(4)

BatteryBoxChannel-suppliedonlywhenusingadualbatterybox

BatteryCable(1perbattery)

BatteryHarness(SingleorDual)

FixtureHarness

PVHarnesss

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InstallationManual|Greenway®SolarLEDPathandTrailLightingSystem

1.0PositioningtheLight

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InstallationManual|Greenway®SolarLEDPathandTrailLightingSystem

2.2RoutingtheLoadCableThroughtheArmAssembly

LEDFixtureConnector

HolesforMountingLEDFixtureMustFaceDown

FixtureHarness

ConnectortoController

2.0Assembling

2.1 PolePreparationFourholesmustbedrilledatthetopofthepole.Thisshouldbedonebeforethepoleissetandanchored.

1. Drilltwoequally-spaced0.125-inch(3.2mm)pilotholes1inch(2.5cm)belowthetopofthepole,asshowninFigure3.

2. Drilltwoadditionalequally-spaced0.125-inch(3.2mm)pilotholes4inches(10.2cm)belowthetopofthepole,asshowninFigure3.Positiontheholes90degreesfromtheholesdrilledinStep1.

Itisimperativethatthepoleisproperlyanchored.Standardpoleanchoringmethodsmaybeused,providingtheymeettheengineeringrequirementsforEPAandweightofthesystemyouhavepurchased.

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2.3DrillingHolesintheSolarPanelMount1. Drilltwoequally-spaced0.125-inch(3.2mm)pilotholes1inch(2.5cm)below

theendofthepipe,asshowninFigure5.

2. Drilltwoadditionalequally-spaced0.125-inch(3.2mm)pilotholes4inches(10.2cm)belowtheendofthepipe,asshowninFigure5.Positiontheholes90degreesfromtheholesdrilledinthepreviousStep.

2.4AttachingtheSolarPanelAssemblytotheSolarPanelMount

PVHarness

BottomView

HoleandGrommet

JunctionBox

PanelPan

PVMountScrews,LockWasher&washers(4)

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InstallationManual|Greenway®SolarLEDPathandTrailLightingSystem

2.5AssemblingtheComponentsPlacingtheArmAssemblyandSolarPanelMountAssemblyonthePole

FixtureHarness

ArmAssembly

Pole

ArmAssembly

a

b c

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InstallationManual|Greenway®SolarLEDPathandTrailLightingSystem

2.6 PositioningtheArmAssemblyandPVMountAssembly

TowardsEquator(DueSouthinthe

NorthernHemisphere)

SolarPanelAssembly

ArmAssembly

Pathway Parking Lot

b

a

c

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InstallationManual|Greenway®SolarLEDPathandTrailLightingSystem

2.7 RivetingtheArmAssemblyandPVAssemblytothePole1. Verifythatthearmispositionedsothatthelightfixture(whichwillbeattachedto

theendofthearm)isinthedesiredorientation.

2. Usingoneofthepilotholesattheupperendofthepoleasaguide,drillonerivetholeusingaU.S.“W”gauge(0.386-inch)drillbit.

Whendrillingarivethole,drillthroughthepilotholeandthenthroughthearmassemblystockbeneaththepilothole.

Drillandrivetonepilotholeatatime.Donotdrillanotherholeuntilthepreviousrivetissecured.Ifa“W”gauge(0.386-inch)drillbitisnotavailable,usea25/64-inchdrillbit.

3. Placeadriverivetintherivetholeandpoundthedriverivetintotheholeuntiltheheadofthedriverivetistightagainstthesideofthepole.

4. Repeatforremainingdriverivets.

c

ba

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InstallationManual|Greenway®SolarLEDPathandTrailLightingSystem

2.8 AttachingBatteryBoxtotheSolarPanelMount

StandardBatteryBox:

1. RouteendsofFixtureandPVHarnessthroughholeinbackofthebatterybox.

2. Looselyfastenthebracketsofthebatteryboxtomount,usingfour1/4”–20x1/2”hexheadboltsandtighteneachbolttoatorqueof15ft-lbs(20N-m).

Avoidstrippingthethreadedholesonthesolarpanelassembly.Donotover-tightenthebolts.

DoubleBatteryBox:

1. UsingBatteryBoxChannelasguide,drillthreeholesandmountchannel.

2. Looselyfastenthebracketsofthebatteryboxtomount,usingfour1/4”–20x1/2”hexheadboltsandtighteneachbolttoatorqueof15ft-lbs(20N-m).

Battery Box Channel location when using Double Battery Box

(a) Routing the Cables Into the Battery Box

(b) Securing the Battery Box to the PV Mount

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InstallationManual|Greenway®SolarLEDPathandTrailLightingSystem

4x1/4”–20x1/2”hexheadbolts

b

BatteryEnclosureChannelMountSet

2x3/4-11x12”

4.25”below

AccessholeforHarnesses.Drillthruoneside@1.25”Dia.

ChannelMountholes:Drillthru@.87”Dia.

28”

a

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InstallationManual|Greenway®SolarLEDPathandTrailLightingSystem

2.9 AttachingtheControllertoBatteryBoxCover

StandardBatteryBox:

DoubleBatteryBox:

a

b

MountingStudsforController

MountingStudsforController

c

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InstallationManual|Greenway®SolarLEDPathandTrailLightingSystem

2.10 AttachingtheLEDFixturetotheArmAttachingtheAscotFixturetotheArm

1. PlugtheAscotfixtureconnectorintotheharnessconnector.

2. SlidetheAscotfixtureintothearm.FeedanyexcesscablebackintothearmwhileslidingtheLEDfixtureontothearm.

3. Adjustforthedesiredtiltandsecurefixturetothearmusingthesocketheadbolts.

AttachingtheShoeboxFixturetotheArm

1. LoosenthetwosetscrewsontheShoeboxfixture.

2. PlugtheShoeboxfixtureconnectorintotheharnessconnector.

3. SlidetheShoeboxfixtureoverthearm.Feedanyexcesscablebackintothearmwhileslidingthefixtureoverthearm.

4. Removethecircularcover(usingaPhillipsscrewdriver)andloosenthebolt(usingasocketwrench)tochangetheangleofthefixture.Tightentheboltandreplacethecoverwhencompleted.

SetScrews

ba

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InstallationManual|Greenway®SolarLEDPathandTrailLightingSystem

LEDFixturePrecautions

TheAscotandShoeboxfixturescontainthefollowingwarninglabel:

This lamp (LED) is in excess of the Exempt Risk Group defined in IEC 62471:2006-07. This lamp (LED) has been found to be in the Risk Group 2 classification at an exposure distance of 20 cm or less from the glass surface of the lamp. Care should be taken to avoid exposure when operating and installing this lamp.

CAUTION: Possible Hazardous LED Radiation Emitted From This Product. Do Not Stare Directly Into Beam. Disconnect Power Before Servicing.

2.11 InstalltheBatteryCablesandBattery(s)

a

IfusingDeka®BrandBatteries,seeenclosedAddendum.

b

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InstallationManual|Greenway®SolarLEDPathandTrailLightingSystem

2.12 ConnecttheCables

Batteries(1or2)

GreenWire(toGround)

BatteryHarness

SolarPanel

LEDLuminaire

EternO4Controller

BatteryCable(1perbattery)

PVHarness

LuminaireHarness

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InstallationManual|Greenway®SolarLEDPathandTrailLightingSystem

2.10 Test

2.11 CloseBatteryEnclosureCover

a

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InstallationManual|Greenway®SolarLEDPathandTrailLightingSystem

3.0 OperationandMaintenance

3.1 ExpectedPerformanceTheGreenway™lightingsystemisdesignedtoprovidereliableoperationandilluminationallyear.ThesolarpanelprovidesenoughenergyduringanormaldaytochargethebatteryforoperationoftheLEDfixtureforthefollowingnight.Thesystemisdesignedwithafive-dayreservecharge.Asaresult,extendedperiodsoflowsunmaydepletethefive-dayreserveandaffectperformanceofthesystem.ThefollowingconditionsmaycauseyourGreenway™lightingsystemtooperateoutofspecification:

1. Prolonged Bad Weather.Aseriesofdayswithlowlevelsofsunlightmaydepletethebatteryreserve.Dependingontheseverityofthecondition,thenightlyilluminationperiodcouldbereduceduntilasunnydayre-establishesthereservebatterycharge.Pleasenotethatthesystemmayneedanywherefromtwodays(insummer)totendays(inwinter)ofgoodsunnyweatherbeforethefullfive-daybatteryreserveiscompletelyachieved.

2. Shading.InstallationoftheGreenway™lightingsysteminalocationwherethesolarpanelisshadedduringpartofthedaywillinhibittheabilityofthesolarpaneltofullychargethebatteryandmayseverelydamagethebattery.Thehoursofnighttimeilluminationwillbereducedbythecontrollerifthesolarpanelcannotfullychargethebattery.

IfyoubelievethatyourGreenway™lightingsystemisnotperformingasexpectedandtheaboveconditionsdonotapply,pleasecontactSolCustomerServiceat1.772.286.9461.

3.2 PreventiveMaintenanceandServiceObstructions

Obstructions(includingtreebranches)mustnotshadethesolarpanel(s).Checkforandremoveanyobstructionsinthevicinityofthesolarpanel(s)onceeverythreemonths.

SolarPanelCleaning

Thesolarpanel(s)shouldbecleanedperiodicallytoinsureoptimumperformance.

Solarpanelscangetveryhotwhenthesunisout.Itisadvisabletocleansolarpanelsduringtheearlymorninghours.

1. Usinganon-streakingwindowcleanerandasoftcloth,thoroughlywipedownthesolarpanel(s)toremoveanydirtandgrimethatmayhaveaccumulate.Aplasticscrapermayalsobeneededforremovingbirddroppings.

2. Drythesolarpanel(s)withasoftcleancloth.

3. RepeatSteps1and2,ifnecessary,untilalldirtandgrimehavebeenremoved.

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FuseReplacement

Ifthefuseneedstobereplaced,besuretoalsocheckoperationofthecontroller.

1. Openthebatteryboxandremovethefusecoveronthefuseholder.

2. Removetheexistingfuse,insertthenewfuse,andreplacethefusecover.

3. Testthesystemandclosethebatterybox.

LEDFixtureReplacement

1. RemovetheLEDfixturefromthearmanddisconnectplugs.

2. InstallthenewLEDfixture,followingtheinstallprocedure.

TheLEDinthefixtureisnotserviceable.TheentireLEDfixtureassemblymustbereplaced.

3. Testthesystem.

BatteryReplacement

1. Openbatteryboxcoveranddisconnectthesolarpanelharnessconnectorfromthecontroller,thendisconnectthebatterycablefromeachbattery.

2. Removethebattery(s)fromthebatterybox.

3. Placethenewbattery(s)andplugthebatterycableintoeachbattery,thenplugthesolarpanelintothecontrollerconnector.

4. Testthesystem,thenclosethebatteryboxcover.

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InstallationManual|Greenway®SolarLEDPathandTrailLightingSystem

3.3 TroubleshootingChart

Problem PossibleCause Solution

Lightdoesnotilluminate. 1.Thebatteryisdischarged.2.Thebatteryisbad.3.TheLEDfixtureisbad.4.Thefuseisblown.5.Thecontrollerisbad.

1.Chargethebattery.2.Replacethebattery.3.ReplacetheLEDfixture.4.Replacethefuse.5.Checkthecontroller.

1.Lightdoesnotstayonfortheexpectedperiodoftime.2.Lightturnsonatduskbutdoesnotturnonagainatdawn(splitruntime).3.Lightdoesnotoperateeveryday.

1.Lowbatteryvoltage,causedbyinclementweather.2.Lowbatteryvoltage,causedbyshadingofthesolarpanel.3.Thebatteryisbad.

1.Allowfortwotothreedaysofconsecutivesunnyweathertochargethebatterypack.2.Cleartreebranchesandotherobstructionsfromthevicinityofthesolarpanel.3.Replacethebattery.

Fuseblowsrepeatedly. 1.Thereisashortcircuitinthewiring.

1.Checkallsystemwiringforashortcircuit.

Batteryvoltageislessthan9.0volts.

1.Thecontrollerisbad.2.Thebatteryisbad.

1.Checkthecontroller.2.Replacethebattery.

In-WarrantyServiceInstructions

AReturnedMerchandiseAuthorization(RMA)numbermustbeobtainedfromSolInc.beforeequipmentcanbereturnedforrepairorreplacementunderwarranty.

WerequirethefollowinginformationbeforewecanissueanRMAnumber:

• ControllerNumberfortheproductbeingreturned • SerialNumberoftheproductbeingreturned • WorkOrderNumber(locatedinsidethebatterybox) • Adescriptionoftheproblem • Theaddresstowhichtherepairedorreplacedproductistobeshipped

Equipmentbeingreturnedmustbeproperlypackagedtoprotectitfromdamageduringshipment.ShippingcostsandinsurancetoSolInc.aretheresponsibilityofcustomer.

Uponverificationoffailureduetodefectsinmaterialsorworkmanship,wewilleitherrepairorreplacetheproductatourdiscretion.ThecustomerwillberesponsibleforallshippingandhandlingchargesforanyequipmentthatissenttoSolInc.inerror(nodefinableproblems).

SolInc.|3210SW42ndAvenue|PalmCity,Florida34990

www.solarlighting.com

E-mailsupport:support@solarlighting.com

Phone:+1.772.286.9461|Toll:800.959.1329(USA&Canada)

Fax:+1.772.286.9616

OfficeHours:Monday-Friday:8:30amto5:00pm(EST)

©2011SolInc.Allrightsreserved