Windy Nation Complete Off-Grid Solar Kit User Manual
Complete Off-Grid Solar Kit Manual
Revision 2.0
windynation
Complete Off-Grid Solar Kits
30 to 400 Watts
Installation Manual
Page 1 of 21
windynation
03/31/2014
Complete Off-Grid Solar Kit Manual
Revision 2.0
Table of Contents
1 Introduction ...................................................................................................................................................... 3
1.1 Safety Precautions .................................................................................................................................. 3
1.1.1 Wiring and Connections ...................................................................................................................... 3
1.1.2 Environment ........................................................................................................................................ 3
2 Product Overview ............................................................................................................................................. 3
2.1 Features .................................................................................................................................................. 3
2.2 Kit Components ....................................................................................................................................... 3
2.2.1 Solar Panel .......................................................................................................................................... 3
2.2.1.1 Monocrystalline – Polycrystalline ............................................................................................... 4
2.2.2 Solar Charge Controller ....................................................................................................................... 4
2.2.2.1 PWM – MPPT ............................................................................................................................. 4
2.2.2.2 Models ........................................................................................................................................ 4
2.2.3 MC4 Connectors .................................................................................................................................. 5
2.2.4 MC4 Branch Connectors ..................................................................................................................... 5
2.2.5 Solar Panel Cable................................................................................................................................ 5
2.2.6 Solar Panel Mounting Z-Brackets ........................................................................................................ 5
2.2.7 Inverter ................................................................................................................................................ 5
2.3 Required Tools ........................................................................................................................................ 6
3 Charge Controller Installation .......................................................................................................................... 6
3.1 Mounting .................................................................................................................................................. 6
3.2 Connect Controller To Battery ................................................................................................................. 6
3.3 Connect Load To Controller (Optional) ................................................................................................... 7
4 Solar Panel Installation .................................................................................................................................... 8
4.1 Location ................................................................................................................................................... 8
4.2 12 or 24 Volt Battery Charging ................................................................................................................ 8
4.2.1 Layout - Placement.............................................................................................................................. 9
4.3 MC4 Connectors...................................................................................................................................... 9
4.3.1 MC4 Connector Assembly Instructions ............................................................................................... 9
4.3.2 MC4 Connector Installation Instructions.............................................................................................. 9
4.3.3 MC4 Branch Connectors ..................................................................................................................... 9
4.4 Interconnect Panels ............................................................................................................................... 10
4.5 Connect Solar Panel(s) to Charge Controller ........................................................................................ 10
4.6 Mounting ................................................................................................................................................ 11
4.7 Fusing Your System .............................................................................................................................. 12
4.8 Grounding .............................................................................................................................................. 12
5 Panel Placement and Wiring .......................................................................................................................... 13
5.1 100W – 12 Volt System ......................................................................................................................... 13
5.2 200W (Two 100W Panels) – 12 Volt System ........................................................................................ 13
5.3 200W (Two 100W Panels) – 24 Volt System ........................................................................................ 14
5.4 300W (Three 100W Panels) – 12 Volt System ..................................................................................... 15
5.5 400W (Four 100W Panels) – 12 Volt System ....................................................................................... 16
5.5.1 1x4 Layout ......................................................................................................................................... 16
5.5.2 2x2 Layout ......................................................................................................................................... 16
5.6 400W (Four 100W Panels) – 24 Volt System ....................................................................................... 17
6 Batteries ......................................................................................................................................................... 17
6.1 Types ..................................................................................................................................................... 17
6.2 Sizing ..................................................................................................................................................... 17
6.3 Wiring Battery Banks ............................................................................................................................. 18
7 Troubleshooting and Support ......................................................................................................................... 18
7.1 Maintenance .......................................................................................................................................... 18
7.2 Frequently Asked Questions (FAQ) ...................................................................................................... 19
7.3 Support .................................................................................................................................................. 20
7.1 Limited Warranty ................................................................................................................................... 20
7.2 Restrictions ............................................................................................................................................ 20
7.3 Warranty Claims & Return Procedures ................................................................................................. 20
7.4 Disclaimer .............................................................................................................................................. 21
7.5 Limitation of Liability .............................................................................................................................. 21
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windynation
03/31/2014
Complete Off-Grid Solar Kit Manual
Revision 2.0
1 INTRODUCTION
Congratulations on purchasing a high quality renewable energy product where building your own off-grid solar
system has never been easier. Although installation is quick and professional using the materials included in
your kit, it is important to read this manual and understand all the mechanical and electrical requirements prior
to beginning installation. If there are questions or concerns of any sort, please contact us at
info@windynation.com
The installer must be familiar and conform to all the safety precautions cited in this manual as well as any local
jurisdictions that must be adhered to.
1.1 SAFETY PRECAUTIONS
CAUTION:
Working with and installing electrical equipment is dangerous. Potential hazards include, but are not limited to,
electrocution and electrical fires. Always consult a licensed electrician when installing any electrical equipment.
CAUTION:
When solar panels are placed in sunlight or other light sources, they produce electrical energy and a voltage will
appear on the output terminals. To avoid a shock hazard, keep the panel covered with a dark material during
installation and avoid contact with the output terminals. Before handling the solar panel, test the voltage output
of the solar panel with a voltmeter to confirm it is not outputting voltage.
1.1.1 Wiring and Connections
• Wiring size and installation must comply with the National Electrical Code (NEC).
• Observe correct polarity with all inter-connections between the solar panel, charge controller, and the
battery. Reverse polarity may cause damage.
• Make sure all wire connections are tight and secure, loose connections may cause sparks and
intermittent behavior.
1.1.2 Environment
• Do not perform installation in the presence of any flammable materials.
• Make sure you work in a well-ventilated area
• Use prop erl y insula ted too l s and remove metal items such as rings, bracelets, and watches.
for further assistance.
2 PRODUCT OVERVIEW
Windy Nation offers many varieties of preconfigured off-grid solar kits designed to be modular and easily
expandable. Each kit is capable of a wide variety of power production needs from simply trickle charging
batteries to fully supporting the power needs of a cabin or RV.
2.1 FEATURES
• Auxiliary power for RV’s and boats. Popular with commercial RV retrofitters
• Great for camping or remote cabins. Power devices in remote back country locations
• Easy way to provide power for sheds, light poles and gates without the need for trenching and laying
cables
• Two or more panels can provide back-up power for critical appliances like a refrigerator during a power
outage.
2.2 KIT COMPONENTS
IMPORTANT: Not all of the components listed are included with each kit. The quantity and exact model of each
item will vary depending on the kit ordered.
2.2.1 Solar Panel
The solar panel is a set of solar photovoltaic modules that generate electricity and are available in powers of
30W, 60W, and 100W; with either Monocrystalline or polycrystalline solar cells. For kits sized 200W and larger,
the use of multiple 100W panels is utilized.
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Complete Off-Grid Solar Kit Manual
SKU
DESCRIPTION
1
CHC-1224-10
10A PWM Solar Controller
2
CHC-1224-30
30A PWM Solar Controller
3
CHC-TRMX-40
TrakMax 40 MPPT Controller
4
CHC-LCD-30
P30L 30A LCD Controller
Revision 2.0
2.2.1.1 Monocrystalline – Polycrystalline
Monocrystalline solar cells are manufactured using a single crystal of silicon and are dark black in color.
Polycrystalline, on the other hand, are blue in color and are manufactured by using multiple silicon crystals that
are melted and poured into a cast.
2.2.2 Solar Charge Controller
The solar charge controller regulates the battery charge and prevents overcharging of the batteries thus
increasing battery performance and lifespan.
2.2.2.1 PWM – MPPT
PWM (Pulse Width Modulation) Controllers use a FET switch to rapidly connect a power source, to a battery.
The switch "opens" and "closes" many times a second, to control the charge.
MPPT (Maximum Power Point Tracking) Controllers dynamically convert the power source (PV panels) via an
efficient DC-DC conversion process, to a suitable charging voltage for the battery, with very low losses, and
about 95% efficiency.
MPPT controllers are more efficient than PWM and will produce roughly 20% more power than PWM by using
the Vmp of the solar panel (Voltage at Max Power) to create additional power.
2.2.2.2 Models
Windy Nation has several controllers available; please consult the individual manuals for the controller provided
with your kit.
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Revision 2.0
2.2.3 MC4 Connectors
Single-contact connector used to connect solar panels; See Section 4.3 for additional information
2.2.4 MC4 Branch Connectors
Splitter/Combiner connector used to easily interconnect solar panels
2.2.5 Solar Panel Cable
Assembly of copper electrical conductors available in 12AWG or 10AWG sizes
2.2.6 Solar Panel Mounting Z-Brackets
Mounting brackets used to secure panel to a flat surface. There are four (4) brackets used for each solar panel
and include the following fasteners used to secure the bracket to the panel:
a. 1/4" diameter stainless steel bolts (1/2" long)
b. Stainless Steel flat washers and lock washers
c. K-Lock stainless steel nuts (will not vibrate loose)
2.2.7 Inverter
An electronic device that converts the battery DC voltage (Direct Current) provided from the solar panel/battery
to an AC voltage (Alternating Current).
The inverter, if included, will connect directly to the 12V battery and will provide three 120VAC outlets used to
power typical household items.
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windynation
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Complete Off-Grid Solar Kit Manual
Revision 2.0
2.3 REQUIRED TOOLS
• Two adjustable wrenches
• Wire crimping tool
• Wire stripper
• Philips head screwdriver
• Bolt to secure Z-Bracket to mounting surface (4x per panel); e.g.: l ag bo lt, carriage bolt, etc.
• Batteries (Deep Cycle preferred)
• Fuses
3 CHARGE CONTROLLER INSTALLATION
NOTE: The charge controller you receive depends on the kit ordered. Please refer to the controller instructions
specific to the model you received.
Insure all terminating connections are clean and tight to prevent arcing and overheating.
The controller must be installed in an area that satisfies all of the following conditions:
1. Dry: Avoid any location where water can contact the controller
2. Cool: Ambient air temperature between 30°F and 105°F (0°C and 40°C)
3. Ventilated: Allow at least 2 in (50 mm) of clearance above and below and at least 1 in (25 mm) on
each side for proper air flow.
CAUTION: All electronic circuits may be damaged by static electricity. To minimize the likelihood of electrostatic
damage, discharge yourself by touching an electrical ground (e.g.: copper pipe) prior to handling the unit.
3.1 MOUNTING
Mounting is optional but for best results, locate the charge controller as close as possible to the batteries and
the batteries and charge controller as close to the panels as practical. The controller can be mounted on a
vertical or horizontal surface. Be sure to orient the controller so that any open end of the controller (if applicable)
is at the top. This will prevent foreign material from settling into the unit.
Securely fasten the controller to ensure it cannot slide in any direction.
IMPORTANT: Loose connectors result in excessive voltage drop and may cause over heated wires and melted
insulation, which can lead to solar system failure and electrical fires.
3.2 CONNECT CONTROLLER TO BATTERY
The wire included in your kit is to be used primarily to connect the solar panels to the controller. It is important to
adequately size your battery cable according to your system size, taking into account any future expansion that
may be implemented. For additional information regarding wire size, please refer to the Windy Nation website or
contact us directly. Two lengths of cable will be required, a positive (+) and a negative (-). It is recommended to
identify each cable or use a different colored cable for each connection (eg: black and red). Connect the wire
designated as positive (+), usually red, to the BATTERY terminals on the charge controller labeled ‘BAT +’ and
tighten the terminal with a screwdriver . Connec t the wire designated as negative (-), usually black, to the
BATTERY terminals on the charge controller labeled ‘BAT -’ and tighten the terminal with a screwdriver.
NOTE: The polarity should be identified on the screw-down terminals of the charge controller; however, the
naming convention of the terminals may differ slightly, depending on the model of the solar controller that came
with your Kit.
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Revision 2.0
Once the connections are made to the battery terminals on the charge controller, make sure the battery post
terminals are clean and free from corrosion.
IMPORTANT: A properly sized fuse needs to be placed in the positive wire connecting the charge controller to
the battery; See Section 4.4.4 for assistance.
It is recommended to use a battery cable lug appropriately sized to fit the post of your battery. Connect the
remaining loose end of the wire designated as positive (+), to the positive post/terminal of the BATTERY.
Connect the remaining loose end of wire designated as negative (-), to the negative post/terminal of the
BATTERY.
As soon as the battery is connected to the charge controller, the controller will power automatically and should
indicate a battery voltage is applied (eg: green LED).
The diagram below shows the connection for controller to battery
3.3 CONNECT LOAD TO CONTROLLER (OPTIONAL)
The connection of a DC load is optional and most applications will not utilize this connection. It is designed to be
used with 12VDC lighting or sm all 12VDC appli ances.
CAUTION: A Power Inverter (if used) should never be connected to the LOAD terminals of the controller. The
inverter will be connected directly to the BATTERY posts.
If desired, connect your small 12VDC light or appliance to the LOAD terminals on the controller. For most light
bulbs the polarity doesn’t matter. Howe ver, if your Bulb or small appliance has Positive (+) and Negative (-)
leads, make sure to connect them to the corresponding terminals on the charge controller.
IMPORTANT: A properly sized fuse needs to be placed in the positive wire connecting the load (e.g. light, etc)
to the charge controller.
The diagram below shows the connection for controller to load
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