Service and Troubleshooting Procedures Rev07_12

8/17/2019 Service and Troubleshooting Procedures Rev07_12

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Service and Troubleshooting Procedures

Sol® products may appear different but all have similar components and purpose. Thefollowing guide will help troubleshoot issues with all of Sol’s outdoor lighting products. In orderto troubleshoot properly, first you must familiarize yourself with the various components. Themain components are:

1. Battery or Battery Array 2. Solar Controller3. Solar Panel or Array 4. Light or other Load

Most if not all cases items #1 and #2 are located in the battery enclosure or close to it.

Typical Sol

®

Solar Lighting Products

20/20™ 10/10™ Models (TT Series) Top of Pole Mount (TP Series) GreenWay (GY Series)

Side of Pole Mount (SP Series) Flat Mount Models (AL/TL/SH Series)

Battery

Enclosure

with Batteries

Controller

Solar Panels

Battery Enclosure

with Batteries

Controller

LED Fixture

Solar Panels

Battery

Enclosure

with Batte

ControllerLED Fixture

LED Fixture

Solar Panel



TSP-01 REV: 7/12

What to Bring

1. Digital Volt Meter (DVM) able to measure 20 amps (Preferred)2. Spare Controller (if needed/ordered from Sol) and Fuse,3. Spare Gel Cell Batteries4.

Cleaning Supplies for Solar Array and Fixture5. Optional Equipment – Battery Load Tester

Check for Shading and Proper Sun Path

Sun path and obstructions should not be overlooked, systems installed years ago may have

been fine but local changes may have caused shading issues. Examples are trees growing, tall

buildings built or overhead power lines installed.

Solar powered equipment needs sun to operate correctly so Weather plays an important part

of how the system works. If weather has been bad, low sun or cloudy, you may encounter low

battery voltages, any testing should be on days with bright sunshine.

For proper operation, a solar system cannot

have any objects blocking its sun path from the

9am – 3pm sun position. Consider the east

horizon is 9:00, the sun’s highest position is

12:00, and the west horizon is 3:00. As seen in

the side example, the system receives

afternoon shading Approx. 1pm). The lower

example shows shading at 12 noon during the

winter months, but none during the summer,

spring or fall. In both cases the units will

function correctly until the winter months. Then

the system will start turning off early and not

operate well during cloudy/rainy periods.

If shading is a potential problem, here are a few

alternatives:

1.

Place system in another location to avoid

shading.

2. Raise mounting height.

3. If shading is caused by trees, trim or cut them

back.



TSP-01 REV: 7/12

Where to Start

1. Start with the condition of the battery and status of the charge controller. Visually

inspect for signs of corrosion or fault!2. Check fuse!3. Check the charge controller, charge light on? Is the unit in LVD mode? If LVD light is lit

you should find the battery voltage on the low side. Controller tests will not be 100%accurate in LVD mode.

4. Measure battery voltage, voltage should be between 11.9 vdc to 13.2 vdc for a 12-voltsystem and 23.8 vdc to 26.4 vdc for a 24-volt system.

During daylight the charge led should be lit, if the charge led is turning on and off aboutevery 10 seconds or so, check the fuse. If the fuse is good, then check battery voltage. Ifbattery voltage is over 13 volts, then the controller is functioning properly in the charge

mode; if under 10 volts then battery needs replacement. These con ditions will cause the

controller to cycle on and o ff

The controller is the brain of the system, most problems are a result of the controller workingcorrectly but the technicians do not know how it works. To explain it simply; it regulates howmuch energy is absorbed from the sun and stored in the batteries, it also monitors howmuch power is removed from the batteries. When the system has the proper amount of suneveryday (about 10% more then was used by the light at night) the batteries will rechargefully in about 4 hours. On days where the sun’s input is less then the amount used by thelight at night the system starts to use it’s battery backup. If the weather stays bad, more and

more backup is used until the system reaches a preset voltage (LVD = 10.8vdc) 21.6 vdc for24 volt systems , low voltage disconnect and shuts the system off. The system will remain offuntil the voltage of the batteries reaches a preset voltage (LVD Reconnect =12.8vdc ) 25.6 vdcfor 24 volt systems . Example: If the system reaches LVD, takes approximately 2 -3 days torecharge the batteries, and the technician arrives to check it out after day 1, he will find thesystem looks fine. The battery voltage is 12vdc (24 vdc for 24 volt systems) but does notrealize it needs to reach 12.8vdc (25.6 vdc for 24 volt systems) before the controller will allowthe system to operate.

Technicians must be trained in order to properly understand and diagnose the system



TSP-01 REV: 7/12

Testing Sol EternO® Controllers

Fig 3.

Press the TEST button until a distinct click is heard and felt.This button performs two functions:

a. Confirm rotary switch selection

To verify that the rotary digital switch is set at the desired position, press the TEST button.The red LED will flash once per second. Count these LED flashes to confirm the correctswitch setting. Each of the 10 LIGHTING CONTROL positions has a unique number offlashes. These are as follows:

Switch Setting # of Flashes Switch Setting # of FlashesOFF 0 12 55 1 3/2 66 2 4/2 77 3 6/2 88 4 D/D 9

NOTE: Rotate the rotary switch one full cycle if there is an incorrect or no LED flash (exceptfor OFF setting).

b. Turn system lights on Pressing the TEST button will turn the system lights on to verify correct installation or fortroubleshooting a system problem.The lights can be turned on anytime (day or night) for 5 minute intervals. The lights can beturned on repeatedly with the TEST button except when the system is in LVD (loaddisconnect/red LED on). In LVD the TEST button will only work 3 times to avoid damaging

the battery. If pressing the TEST button causes a load disconnect (LVD), the lights will turnoff. Wait 5 minutes and press TEST again to turn the lights on in LVD.



TSP-01 REV: 7/12

Testing Sol EternO® 4 Controllers

After the battery is installed and the components are connected, press the test button(Figure 4). When the test button is pressed the three LEDs will flash sequentially green,yellow then red. Count the number of flashes for each led. This represents the three digit

SW code. The test button can be pressed as many times as necessary to get an accuratecount.

Fig. 4

Sol EternO4 LED indicator definitions:

Green LED: Lamp is on or the controller is attempting to turn the lamp on.

Yellow LED: The battery charger is active.

Flashing Red LED: The Red LED will flash if the battery becomes disconnected or batteryvoltage is inadequate(below 10.5V).

Red LED: Low Voltage Disconnect. In the event of a low voltage disconnect, the lamp isturned off for the remainder of the night. The Red LED will remain illuminated throughoutthe following day as a diagnostic aid regardless of battery voltage.

Yellow & Red LED: Charger is on. The system was in LVD during the previous night. The

Red LED will remain illuminated throughout the following day as a diagnostic aid regardlessof battery voltage.

Green & Red LED: Lamp Fault. If the green and red LEDs are illuminated simultaneously,the controller cannot start the lamp. This can be caused by high wiring resistance betweenthe controller and the lamp, a short circuit, open circuit, or a problem with the lamp itself.

Flashing Green, Red, and Yellow: Indicates test code is installed.

Diagnostic

Indicators

Test Button



TSP-01 REV: 7/12

* If the battery voltage is too low, contact Sol Customer Service at +1-772-286-9461.After the lighting system is tested and found to be satisfactory, secure the battery box coverto the battery box, using the 1/4”-20 x 1/2” hex head bolts and lock key (optional).

Testing the Batteries

Testing the batteries can be done in various ways.To get a simple status condition of the battery, do the following:

1. Measure and record battery voltage.2. Do system test as described earlier.3. Measure and record voltage after 15 – 20 minutes. Voltage should be approximately

the starting voltage minus one or two hundredths. If voltage is dropping sharply,batteries need replacing. To get a better status condition of the battery, have the

battery load-tested by an automotive repair shop or with a hand held tester as shownin fig. 5

Fig 5



TSP-01 REV: 7/12

Troubleshooting G uidelines

The system may need a full day of peak sun to reset all of its circuits after installation. If the system isinstalled during a period of inclement weather or late in the day, it may not operate the first night.

PROBLEM POSSIBLE CAUSE SOLUTION

The light does not turnon at all.

1. The batteries are discharged. 1. Charge the batteries.

2. The batteries are bad. 2. Replace the batteries

3. The LED fixture is bad. 3. Replace the LED fixture

4. A fuse is blown. 4. Replace the fuse

5. Controller is bad. 5. Check the controller

The light does not stayon for the expected

period of time.

1. The run time is incorrectly set. 1. Contact Sol for assistance.

The light turns on atdusk but does not turnon again at dawn (splitrun time).

2. The run time exceeds themaximum run time for yourmodel and location.

2. Contact Sol for assistance.

3. Low battery voltage caused byinclement weather.

3. Allow for two to three days ofconsecutive sunny weather tocharge the battery pack.

4. Low battery voltage caused byshading of the PV panel.

4. Clear tree branches and otherobstructions from the vicinity of

the PV panel.5. The batteries are bad. 5. Replace the batteries

The red LED on thecontroller remainsilluminated.

1. Low battery voltage caused byinclement weather.

1. Allow for two to three days ofconsecutive sunny weather tocharge the battery pack.

The light does notoperate every day.

2. Low battery voltage caused byshading of the PV panel.

2. Clear tree branches and otherobstructions from the vicinity ofthe PV panel.


The fuse blowsrepeatedly. 1. There is a short circuit in thewiring. 1. Check all system wiring for a shortcircuit.

The battery voltage isless than 9.0 volts.

1. One (or both, if there are two)controller is bad.

1. Check the controller(s)


The abo ve table assume s the installation of the original equipment wa s to ma nufacturer’s

specifications .



TSP-01 REV: 7/12

Preventive M aintenance and Service

Be very careful when working with batteries. Short circuits can draw thousands of

amps from the battery, and gel batteries can generate explosive gases. Observe all precautions when working with energized circuitry.

Do not short circuit the PV array or load while it is connected to the controller. Thiswill damage the controller.

Tree Branch Clearing

Trim tree branches (and remove any other obstructions) in the vicinity of the solarpanel(s) once every three months.

Solar Panel Cleaning

The solar panel(s) should be cleaned once every 6+ months depending on rainfall in yourregion for optimumperformance.

1. Using a non-streaking window cleaner and a soft cloth, thoroughly wipe downthe solar panel(s) to remove any dirt and grime that may have accumulated.

A plastic scraper may also be needed for removing bird droppings.

2. Dry the solar panel(s) with a soft clean cloth.

3. Repeat Steps and 2 , if necessary, until all dirt and grime have been removed.

Solar panels can get very hot when the sun is out. It is advisable toclean solar panels during the early morning hours.

Fuse Replacement

Occasionally, the fuse that is used to protect the Top of Pole Mount system circuitry mayhave to be replaced. Be sure that the replacement fuse matches the specifications of theoriginal fuse. One spare fuse has been provided with your system.

The spare fuse is attached to the battery box cover. If the fuse needs tobe replaced, be sure to also check operation of the controller.

1.

Open the battery box.

2. Remove the fuse cover on the fuse holder.

3. Remove the existing fuse, insert the new fuse, and replace the fuse cover.

4. Test the system (see page19).

5. Close the battery box.

Preventive maintenance and service should be performed only by qualified personnel.



TSP-01 REV: 7/12

LED Fixture Replacement

1. Loosen the fasteners that secure the fixture to the mounting arm or pole.

2. Slide the light fixture off the arm or remove from mounting bolts if no arm.

3. Unplug the connection plugs and remove luminaire.

4.

Insert the new luminaire.The LED in the fixture is not serviceable. The entire LED fixtureassembly must be replaced.

5. Re-connect the luminaire plugs together.

6. Press TEST button on the controller until a distinct click is heard and felt. The LEDfixture will illuminate for five minutes.

7. Close the battery box, and replace or close the fixture cover.

Battery Replacement

1. Remove or open battery box cover.

2. Disconnect the battery harness from the controller.

3. Disconnect the ground wire from the battery.

4. Remove the battery/batteries from the battery box.

5. Disconnect the battery cables from each of the old battery/batteries and attachto the new battery/batteries.

6. Place the new battery in the battery box. Connect the ground wire to the battery.

7.

Re-connect the battery harness connector to the controller.8.

Replace the battery box cover.



TSP-01 REV: 7/12

Measure

Battery

0v

> 11v

< 11v

Press Test

State of

light

ON

Flickers

GOTO Check Battery

1

GOTO Light Flickers

GOTO Check Battery

heck Harness

and fuse

2

Light Turns Off early

GOTO Check Battery

3

Light Flickers

Frequency of

flicker

Fast SlowPossible large resistance in

connection to fixture.

Check harness.

OFF

Fixture is disconnected or

damaged. Check harness

from EternO4 to light

fixture for short circuits

and discontinuities. Check

light fixture for water

intrusion or other visual

signs of damage.

What type of fault is the system exhibiting? Choose the corresponding flowchart below.1.

Light does not come on.

2. Light turns off early

3. Li ht flickers

Light does not come

Troubleshooting Flowchart



TSP-01 REV: 7/12

Is Charge LED

ON?

Measure PV

Voltage

0 V

< 15v

16–22V

>0 V

Yes

No

Check PV

Harness

Wait 2 min

Is charge LED

On?

Replace

Charge

No

Yes

Measure PV

Voltage

Replace

Charge

Controller

Batteries are not being adequately charged.

Clean panels, trim trees, check that all panels

are connected, Check system sizing

Check Battery

Load Test

Batterieseplace Batteries

Fail

Pass

Troubleshooting Flowchart – cont.



Sol Inc. | 3210 SW 42nd Avenue | Palm City, Florida 34990

www.solarlighting.com

E-mail support: [email protected]

Phone: 1.772.286.9461 | 1-800-959-1329 (US /CANADA)

Fax: 1.772.286.9616

Office Hours: Monday - Friday: 8:30am to 5:00pm (EST)

© 2012 Sol Inc. All rights reserved.

Service and Troubleshooting Procedures Rev07_12

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