dml america 0661 solar system installation manual 2010

8/6/2019 DML America 0661 Solar System Installation Manual 2010

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DML America Ltd.Digital Magnetic Lighting Energy Saving Systems

Technical documentation

LVD Solar street light installationCopyright DML America Ltd. 2010

Directory

I. Packing list

II. Parts names

III. Installation steps

IV. Adjustment of controller

V. How to deal with common problems

Notice:

Before installation, pleases read this description;

After reading, please keep this description well in case later use;

The manufacturer would not pay any duty if the user does not comply with the rule;

LVD solar street light ISO9001:2000 Quality Management System Certification

Operation instructions






Packing list

LVD solar street light

Parts Description Unit Picture

1 Solar panel Mono-silicon/140W 1 pcs

2 Storage battery colloid/80AH 2 pcs

3 Controller 24V/10A/single load 1 pcs

4 Lamp TX-40W 24V DC 2 Pcs

5 Fixture LVD-0661 1 pcs

6 Wire connector one ser ( 2 pcs ) 2 pcs

7 Wires

4 mm red 7 m

4 mm black 7 m

2.5 mm red 7 m

2.5 mm black 7 m

8 Battery blocks ABS Plastic 2 sets

9 Pole System including bellows: 1 set

Steel pole Hot galvanized and painting 1 pcs

Bracket Hot galvanized and painting 1 pcs

Pole arm Hot galvanized and painting 1 pcs

Turtleneck one tube 1 pcs

Brace one set ( 2 pcs ) 2 pcs

Anchor ear one set ( 2 pcs ) 2 pcs

Embedded parts steel reinforcement 1 pcs

Other small parts screws, bolts and others. plenty






Parts names






Installation Steps

Foundation excavation

1. Dig a square pit of 0.8m × 0.8m, 1~2 m deep, then dig another pit of 1m, 1.0×0.6m, 1m deep ,

at least, for storage batteries, which is 0.2m from the first one.

2. Put embedded parts into the first pit, let the protruded part 0.1m above the ground; At the

same time, put the battery into the battery box. Also, put a 60-80MM diameter hose into the

embedded parts, then pour into the first pit with concrete, at the same time, cover up the

batteries with soil.

3. 4-7 days later, after the concrete becomes solidified 100％, the pole can be erected up.

System connection

4. Put the LVD lamps into the fixture, then connect aid with output end of the ballast.

5. Begin to thread wire: thread a 2.5 mm （each for red and black ）wire from the hole, which

the arm lies, to the bottom of the pole, then thread the wire through the arm and connect

with the input end of the ballast.

6. Fix the arm, and then fix the fixture on with the arm.

7. Thread the 4.0 mm wire (one red and one black) through the top to the bottom of pole.

8. Put the turtleneck on the top of pole and fix it.

9. Connect the bracket with the turtleneck, and fix them with one bolt.

10. Connect the anchor ears with the bracket, the anchor ears with the braces, then move the

anchor ears up and down to adjust direction of the solar panels so that the angle between

panel and ground will be 10-15 degrees (refer to the local latitude angle ±5°~10°). Finally,

fix the anchor ears and the bracket.

11. Put the solar panel to the framework of bracket, then fix it with screws.

12. Put the batteries into box, wire will be out from the wired hose, then fix the bolts and wired

hose. Later, put the box into the second pit, and the wired hose will be out from the 80MM

diameter hose. The wired hose should be a little out of the ground, and cover it with soil.

13. Wiring of the controller：first storage battery, second solar panel, third lamps, connect with

the corresponding place of the controller (Note：first "-" then "+", preventing short-circuit)

14. Cover the solar panels with a piece of dark cloth for 1 minute or so, if the lamp can work, it

indicates the connection is right; otherwise, it is wrong. It needs to be checked. Finally, fixthe controller on the insulation board.

The erection of the pole

15. Lift the pole up with a crane, making the holes of flange right with embedded parts, and then

fix the flange with screws.

16. Adjust the direction of solar panels horizontally, making the plane towards the direction of

equator.

System check

17. Check whether connection of the controller is loosening. If it is right, then shut the door andfix it.






User manual about controller

Dear customer,

Thank you very much for buying this Suntech product. Please read the instructions

carefully and thoroughly before using the product.

Outstanding Features

Automatic 12V/24V volt detection

Controlled by timing and/or lighting

Fully electronic protected on over-charging, deep-discharging, misconnecting, lighting, and

light interferenceWaterproof and dustproof

Technical Data

Nominal Voltage: 12V/24V, Auto recognition

Max module current: 20 A

Max load current: 20 A

Over charging voltage: 14.5V/29.0V

Low voltage disconnect function: 11.3V/22.6V

Load reconnect voltage: 12.6V/25.2V

Self consumption: <10mAAmbient temperature range: -25℃ to 50℃

Dimensions(L×W×H): 195×105×45 (mm)

Mounting and Connecting

1. The controller is intended for street lamp use. The space where the controller is mounted

must be rain free and dry.

2. Connect the wires according to the polarity marks on the controller panel (See picture

below). Wrong polarity will cause the controller out of function.

i. The connecting sequence must be: Loads-------Solar Module-------Battery

The output from terminal LOAD 1 is controlled by timing, while terminal LOAD 2 is controlled by

lighting. Details will be described below.






Picture of controller panel

Display Functions in Normal Operation

Charge level display

The controller is equipped with 4 red LEDs ,1 green LED and a buzzer.

The 4 red LEDs displays the charge level in terms of battery voltage as below.

Red LEDs

stateBattery charge level Remark

○○○◎≤11.3V（22.6V） Buzzer alarm, load off

○○○● 11.3V（22.6V）to 12.6V（25.2V）

○○●● 12.6V（25.2V）to 13.7V（27.4V） Load re-connected

○●●● 13.7V（27.4V）to 14.5V（29.0V）

●●●● ≥14.5V（29.0V）

（Remarks：◎LED flashing ○ LED off ● LED on）

Under charging status, the first lighting red LED will be flushing and indicate charge level as below.

Red LEDs

stateBattery charge level Remark

○○◎● 11.3V（22.6V）to 12.6V（25.2V）

○◎●● 12.6V（25.2V）to 13.7V（27.4V） Solar module

reconnected

◎●●● 13.7V（27.4V）to 14.5V（29.0V）

●●●● ≥14.5V（29.0V） Solar module

disconnected

（Remarks：◎LED flashing ○ LED off ● LED on）






Load status display

The green LED displays the state of load as follows:

● LED on indicates Load is on○ LED off indicates Load is off

For the reason of saving battery energy, all RED LEDs are off during normal operation and will be

taken up by a short press on the button SET. This status will last for 30 seconds for your

observation.

Low Voltage Disconnect Function (LVD)

The controller has the Low Voltage Function to protect the battery from being

deeply discharged. It will disconnect the load at 11.3V (22.6V), and reconnect whenthe voltage goes up to 12.6V (25.2V) in the same day.

Over Charging Protection

The controller will stop the charging when the battery voltage reaches 14.5.V

（29.0V），and start charging again when the battery voltage down to 13.7V

（27.4V）.

Settings

The controlled has 2 different modes to control the loads.

1. Lighting mode (for the load connected to terminal LOAD 2 )

When the voltage of solar module goes down to 3.0V (6.0V), night is coming, the load will be

turned on in 5 seconds. The 5 seconds delay is designed for avoiding light (dark)

interference.

When the voltage of solar module goes up to 5.0V (10.0V), day is coming, the load will be

turned off in 30 seconds. The delay is designed for avoiding light interference.

2. Timing mode (for the load connected to terminal LOAD 1 )

The controller can switch on the loads only by lighting, but switch off the loads by timing

preset.

The time is set by keeping pressing button SET and clicking the button ADJ (adjustment)

according to the table below.






Red LEDs state Load switch off time after switched on by light control

○○○● 1 h

○○●○ 2 h

○○●● 3 h○●○○ 4 h

○●○● 5 h

○●●○ 6 h

○●●● 7 h

●○○○ 8 h

●○○● 9 h

●○●○ 10 h

●○●● 11 h

●●○○ 12 h

●●○● Goes to lighting control mode

Connection Guide for Controller

Order of connections:

1. 2-4-3-1

2. 6-5

3. 8-7

1. 1, 2: Connect with the anode and the cathode of the ballast respectively;

3, 4: Connect with the anode and the cathode of the ballast respectively;

2. 5: Connect with anode of the storage battery;

6: Connect with cathode of the storage battery;

3. 7: Connect with anode of the solar panel;

8: Connect with cathode of the solar panel;

Notice:

Storage battery: connect in parallel, then join with controller;

Solar panel: connect in series, then join with controller

Load 1: used for light control;Load 2: used for time control;






How to deal with common problems?

On the Stage of system debug：

1. Series flicking happens：if the lamp switches on and off continuously，this shows that the

controller connects wrong. The current flows from solar panel into lamp, not through

controller.

As the current from solar panel is not stable.

Note：Lamps must be supplied by the storage batteries indirectly through the controller.

2. Lamps cannot work ：Generally speaking, the power of storage batteries is very ample at

the beginning of the system (storage batteries are charged fully when produced ). When

lamps, solar panel and storage batteries are connected right, lamps cannot work properly,

the main problem lies poor contact of wire connector. It is easy to solve it by getting rid of the connectors and connecting the wires directly, then binding up the interface by 3M

insulating tape.

3. If the connections as stated above are right, but the lamps cannot work yet , you can

check the connection between lamp and ballast. Note the lamp should connect with input

end of ballast.

4. if all connections are all right, but the lamp cannot light up, the problem must lie on

controller. You can change a good controller to test it.

The condition of Years later:

1. The working time obviously becomes short ：the ability of charging and discharging

becomes weak, in this case, as for fixture with two lamps, we can adjust the timing

controlling lamp to less hours in order to assure the lighting controlling one to be longer.

When the lighting time(hours) is under the requirement, we should consider to replace the

storage batteries. Usually, as for Gel batteries, the life time is 3-5 years under suitable

working condition.

2. Lighting source cannot work at all：there may be wrong with lamp or ballast, so we pull

down it to make a check. Whether there are showings of crack, mechanism, steam leakage or

cold check on the lighting tube. If yes, it needs to be replaced; if no, the ballast is wrong and

needed to be replaced.

3. Lamp can be work, but brightness lowers much：this indicates that the depreciation is

very serious and lamp should be replaced. In this case, you`d better replace the lamp and the

ballast together.( such phenomenon would happen 3 years later at least )

4. If the lamp is normal in previous days, but it cannot light up for a few lasting days,

including sunny days among those. It indicates that the controller is wrong and needs to be

replaced.

dml america 0661 solar system installation manual 2010

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