Solar-Flo™ INSTALLATION AND OPERATION MANUAL
Contents
1. 3 Badger Meter Europa GmbH Solar Flo Solar powered electromagnetic flow meter INSTALLATION AND OPERATION MANUAL November 2001 MID_SolarFlo Bedienungsanleitung 0701 e doc Contents Contents 1 Introduction 2 Uncrating and inspection 3 Tools required 4 Site preparation 5 Summary of installation options 6 Installation 6 1 Pipe mount attached array 0 2 Pipe or pole mount detached array 6 3 solar deployment 6 4 Antenna mounting 7 Power up 1 1 step 1 7 2 Step 2 Z Step 3 7 4 Step 4 7 5 Step 5 8 Operation co Fuse replacement MID SolarFlo Bedienungsanleitung 0701 e doc Page oo N N N N N 10 11 12 Battery replacement c cD C Cc CH CH CO N Let CD CD C co gt co e CD Fc gt oO co oD NJN ct Let CD CD Cc 1 co co c cD C co NN cn co D Step 9 Solar voltage regulator Maintenance MID_SolarFlo_Bedienungsanleitung_0701_e doc Ss D Qm Y CO Coco co co co co co co Introduction Page 1 12 1 Introduction The Badger Meter Solar Flo has specifically been designed to operate reliably year round in any kind of weather almost anywhere in the world The Solar Flo provides a viable solution to installation sites where conventional mains power is unavailable unreliable or too expensive to install2. During normal operation it should require little or no maintenance and should be inspected once or twice a year 2 Uncrating and inspection It is advisable to remove the protective cardboard cover on the sole panels and inspect them for damage before signing the delivery ticket or bill of lading You should also inspect the outside of the enclosure as well as the wire and cabling for shipping damage Although the Solar Flo is a very rugged package with a 30 year design life it can be damaged by a forklift or careless handling Look for signs that the pallet may have tipped over or had been used to push other cargo as well as the obvious signs of torn shrink wrap broken banding or punctured cardboard Any damage should be noted on the bill of lading or delivery ticket before signing and accepting Failure to do so will severely limit your rights to a damage claim against the freight company 3 Tools required Use a utility knife to cut the shrink wrap plastic tape and plastic banding A 9 16 wrench or socket is required to remove the pedestal from the plywood base or alternatively a Philips head screwdriver can be used to remove the plywood base from the pallet It is suggested that for maximum stability and safety the Solar Flo be left on the pallet until it arrives at the installation site Move the palletized Solar Flo with a forklift preferred or a pallet jack on LEVEL GROUND ONLY The top of the Solar Flo enclosure
3. 4 for 180 to 320 4 6 for 420 and 480 Wooden pole Recommended for low cost where soil is stable If theft and vandalism are an issue wooden pole allows elevated mounting of the enclosure and solar array Structural rack Works well on metal grating and sites where other flow control devices require mounting or higher elevation of the system is required when using concrete pad Frost line Recommended where annual frost can heave the foundation possibly causing instability and leaning creating solar and antenna problems among others MID SolarFlo Bedienungsanleitung 0701 e dor Installation Page 3 12 6 Installation If no lifting equipment is available at the installation site it is safe to remove the batteries for ease of handling If you elect the muscle to unit into place try to position the pallet as close to the concrete pad as possible lit is not advisable to muscle the system into place if it is on a pole or pipe unless the pedestal is resting on a base Unscrew the 4 3 8 anchor bolts down gently until they drop out Grasping the top of the enclosure firmly walk the Solar Flo across the pallet to the pad Place several 2x4 pieces on the pad so you will clear the anchor bolts when you walk the Solar Flo across the pad Position the mounting holes over the anchor bolts then carefully tilt the unit to remove the 2x4 s one side at a time letting the unit down over the anchor bolts When mountin
4. during the daytime as the cold water may shatter the hot glass A wet sponge is okay rinse with clean water If perching birds are a problem they tend to face North in winter time placing their posterior over the solar panels humane bird deterrents are available Any corrosion on the battery terminals should be cleaned with a stainless steel wire brush again WEAR GOGGLES AND GLOVES Clean the terminal and ring lug on the cables reassemble coat with marine grade battery terminal sealant such as CORROSION X etc Always exercise caution when handling live battery cables and wires they can be very dangerous and pose a shock burn and explosion hazard MID SolarFlo Bedienungsanleitung 0701 e dor Maintenance Page 12 12 To replace a solar panel simply remove the J box cover unscrew the internal connections noting the WIRING CONFIGURATION sketch it Loosen the cable gland and slip the wires out Remove the 4 bolts holding the panel to the frame The factory replacement panel will be predrilled for the frame unless you bought it somewhere else to save money then you may have to drill the frame Use a block of wood behind the frame as you drill it otherwise when you punch through you ll drill into the back of the solar module possibly ruining it Rebolt it reconnect it retighten Check the solar array current meter Only bright summer sun will produce full solar array current MID SolarFlo Bedienungsanleitung 0701 e doc H
5. has 2 1 lifting eyes if a crane or other overhead lifting device is used MID_SolarFlo_Bedienungsanleitung_0701_e doc Site preparation Page 2 12 4 Site preparation Since the Solar Flo will often be installed at remote unattended sites it is essential that the installation be designed to endure the harshest weather conditions imaginable This might include earthquake hurricanes and typhoons high winds hail driving rain and ice and snow buildup as well as the occasional nearby lightning strike To accommodate various site conditions and customer preferences we offer b pre engineered site designs concrete pad steel pipe wooden pole structural rack and frost line foundation The detailed drawings and specifications provided should be adhered to closely and attention to detail on the site preparation will avoid future maintenance and service problems It will also assure the system provides the maximum reliability For example a directional antenna that shades the solar array could seriously degrade the solar panels performance causing a likely failure due to low batteries 5 Summary of installation options Concrete pad Simplest and most stable should be used whenever possible quickest installation time Steel pole Works if directional antenna is required or solar array elevation or orientation is an issue Requires concrete base on larger systems for stability 2 pipe recommended for SF 120 140 160 3
6. normal operation power down including the safety fuse For uninterrupted operation jumper between the battery and load and battery and load before disconnecting the regulator Once you are powered down loosen all 6 terminal screws slip the wires out starting with all the negatives then the positives Be careful no to touch them if you are jumpered in UPS mode Remove the two nuts holding the regulator to the backplane slide it off the studs Replace the regulator with a new one and repeat the procedure in reverse power up as specified on the door Maintenance When installed properly the Solar Flo requires little in way of maintenance other than an inspection every 6 12 months check for solar panel fouling corrosion at the batteries any signs of abuse or damage Batteries should be replaced according to your sites peak sun hour regime The reason is the hotter the climate the shorter the battery life even with sun shades and ventilation Any time a sealed battery is exposed to high temperatures its lifetime is reduced due to the accelerated aging that takes place Snug the battery terminal bolts annually during inspection wear gloves and goggles Generally the solar array does not require any maintenance unless it is subject to fouling birds or dust nearby agriculture construction ete If the solar panels require cleaning wipe them with a soft damp cloth or hose them down at night Do not hose them
7. white connector from the transmitter to the battery pack Step 4 Install the MAG meter 5 A fuse and the Cybersensor 3 A fuse Step 5 Install the solar fuse 7 5 A to 20 A depending on array size You may check system voltages at each fuse block with a digital volt meter If the sun is shining and the system is working properly you should see the battery voltage slowly rise as the solar array charges them They will normally top off at approximately 28 2 volts plus or minus according to the temperature The system is now powered up and operational To POWER DOWN repeat the sequence in reverse order that is 1 Disconnect the solar 2 Disconnect Cybersensor and MAG meter 3 Disconnect Cybersensor battery pack 4 Disconnect battery fuse 5 Disconnect safety fuse in battery compartment MID_SolarFlo_Bedienungsanleitung_0701_e doc Operation Page 8 12 10 Operation Once the Solar Flo is bolted down and powered up there is little to do except make sure the solar panels don t accumulate dust or bird poop In most climates rainfall will keep the panels clean Light dust is not a problem but heavy dust should be cleaned off preferably at night when the panels won t suffer thermal shock when the water hits them The batteries should be checked once or twice a year for signs of corrosion see maintenance Other than that there is little to do as the solar system is designed to run unattended for y
8. Battery replacement Page 10 12 Step 6 Starting at the top slide the batteries out carefully as they are heavy 60 80 Ibs and can easily sprain limbs and break bones if not handled properly Set the old batteries aside and make a quick inspection of the battery compartment Clean out any dirt cobwebs or debris that will hamper air circulation Replace any damaged or crushed foam Step 7 Replace the batteries and foam starting at the bottom carefully moving the polarity and position of the battery terminals Connecting the batteries wrong can result in equipment damage and even fire so pay attention When in doubt consult the schematic on the door Step 8 Once the new batteries are installed replace the battery hold down bracket first Make a visual check that the battery cables are red at the positive terminals and black at the negative terminals R side of batteries The left side jumpers positive to negative are white Do not overtighten the battery cable bolts in the battery terminal since the terminals are soft lead they will often take a set after a short period of time It is a good idea to retighten them after a few hours and check them periodically but don t overtighten Step 9 Replace the safety fuse then the DIN rail battery fuse then the load fuse and the solar fuse last MID SolarFlo Bedienungsanleitung 0701 e doc Solar voltage regulator 11 12 11 12 Solar voltage regulator For
9. Mount the antenna to the UNISTRUT as described below with the hardware provided Connect the cable to the antenna tighten gently and slide the weather boot up the cable and over the threaded connector to discourage weathering and corrosion at the connection Visually check to be sure the antenna is straight up and down in both directions from the back and side Recheck all fasteners and connections for tightness Power up During the power up you will be connecting the batteries solar panels MAG meter and Cybersensor link The sequence in which you power up is critical if you connect the wrong components out of sequence damage to the electronics can result Note Use the envelope marked fuses for power up not the spare fuses on the door Always connect the battery first and when powering down disconnect it last Failure to do so can result in the electronics seeing open circuit solar panel voltage as high as 45 volts The battery has 2 fuses the main fuse on the DIN rail and the safety fuse at the farthest positive battery terminal MID SolarFlo Bedienungsanleitung 0701 e doc Power up 1 2 TES 1 4 1 5 Page 7 12 Step 1 Connect the safety fuse first 15 A by plugging it into the waterproof socket taking care not to bend the blades Replace the waterproof cap Step 2 Insert the battery fuse 10 A on the DIN rail taking care to insert it in the proper slot Step 3 Plug in the
10. TOR the panels should be tilted at least 10 to avoid dirt accumulation Most systems in the Continental U S will use a 45 tilt optimum for winter Your solar array tilt angle will be preset at the factory for unitized systems Measuring the tilt angle is only an issue with pipe and pole mounted systems MID SolarFlo Bedienungsanleitung 0701 e doc Installation 6 2 6 3 Page 5 12 Pipe mount attached array For pipe mount systems with an attached solar array special mounting brackets must be used to clear the pipe These extended brackets are extended 3 6 to accommodate the pipe running vertically between the enclosure and solar array This configuration utilizes the solar array for shading to prolong battery life A concrete pad without anchor bolts is recommended to support the weight of 180W systems and larger providing stability and keeping the pole from leaning Pipe or pole mount detached array A pipe or pole mount system with a detached solar array is utilized where the solar array must be mounted higher and separate from the solar array Orientation theft resistant solar access and potential shading are among the reasons for a detached solar array The array should be oriented toward the equator as discussed earlier with the distance between the top and bottom brackets determining the correct angle solar deployment For pad mounted system solar deployment is very quick and simple once the system is bo
11. ears Fuse replacement Occasionally a fuse will blow usually due to the wrong size or placement and sometimes when two battery packs are connected due to a current inrush to the weaker pack Normally a blown fuse is visible the area under the number will turn black You can check the fuse by placing your volt meter probes in the screw holes above and below the fuse Set the meter on 2 or diode if the ohms are higher or infinite the fuse is blown If it doesn t beep in the diode position it s blown Before replacing it measure the current across that fuse to determine if a fault short circuit or other problem exists Put your meter on the DC 10 AMPS setting and put the probes against the screws above and below the particular fuse Check the current it should be within the specifications posted on the fuse holder If not troubleshoot the wiring and equipment to find the problem Battery replacement Periodically the batteries have to be replaced Depending on climate this will occur every 3 years or so in hot weather 5 to 7 in colder ones It is EXTREMELY IMPORTANT to replace the batteries with exactly what is specified on the door of the enclosure The wrong batteries may cause chemical burns and equipment damage may produce explosive gases and can cause a total system meltdown Note Protective goggles or face mask insulated tools and extreme caution required MID SolarFlo Bedienungsanleitung 0701 e doc Battery replace
12. g the Solar Flo on a concrete pad it is preferable to lift the entire unit using the 2 1 lifting eyes at the top of the enclosure A lifting eye with two short lengths of chain with a devise on each end is the preferred method of lifting to avoid damage to the enclosure or solar array DO NOT LIFT THE UNIT BY THE SOLAR ARRAY IF A FORKLIFT IS USED SLIDE THE FORKS TOGETHER AND APPROACH FROM THE DOOR SIDE NOT THE SOLAR SIDE POSITION THE FORKS UNDER THE ENCLOSURE BETWEEN THE TWO STEEL PEDESTALS LIFT CAREFULLY TAKING CARE TO NOT GO TOO FAR UNDER WITH THE FORKS OR THEY WILL DAMAGE THE SOLAR ARRAY DO NOT INSTALL THE SYSTEM WITH THE SOLAR PANELS DEPLOYED AS IT WILL HAVE A GREATER TENDENCY TO TIP VERIFY THE ANCHOR BOLT ORIENTATION WITH A COMPASS BEFORE INSTALLING THE Solar Flo THE BOLT PATTERN SHOULD MEASURE 18 50 WX 11 25 FRONT TO BACK THE FRONT TO BACK BOLTS SHOULD POINT NORTH SOUTH MID_SolarFlo_Bedienungsanleitung_0701_e doc Installation Page 4 12 Solar panel side th south 1 2 13 anchor bolt O T A PLCS 11 25 I 1850 Door side north ONCE THE GALVANIZED STEEL PEDESTAL FEET HAVE BEEN LOWERED OVER THE 1 22 ANCHOR BOLTS USE A STAINLESS STEEL FLAT WASHER LOCK WASHER AND HEX NUT PROVIDED TO SECURE THE SYSTEM DO NOT OVERTIGHTEN FOR PIPE AND POLE MOUNT INSTALLATIONS ALWAYS INSURE THAT THE SOLAR ARRAY FACES SOUTH IN THE SOUTHERN HEMISPHERE THE PANELS FACE NORTH NEAR THE EQUA
13. lted down The two bolts holding the solar array legs to the module frame are loosened and removed and the shipping ty wraps are cut One person holds the bottom of the solar array lifting up until the hole in the leg aligns with the lower hole in the module frame Replace the bolts and it s deployed To install a detached array the upper crosspiece is clamped to the pole with the stainless steel U bolts provided It is oriented E West so the solar array will face either true south Northern hemisphere or true north Southern hemisphere Next the vertical rails are bolted to the top crossmember allowing them to dangle The lower crosspiece is then clamped at the measured distance for the particular site according to latitude This specific information is included with each system and the support angles form a 90 angle with the pipe when deployed properly MID SolarFlo Bedienungsanleitung 0701 e dor Installation 6 4 6 12 Antenna mounting The antenna mounting referred to herein is for the Cybersensor antenna only although other antennas can be accommodated in a similar fashion The mounting bracket fort he Cybersensor antenna is the short piece of UNISTRUT already bolted to the top of the enclosure The antenna cable has already been run and secured under the stainless steel hold down clips Adjust the antenna length to 37 as specified and tighten the hose clamp as directed in the antenna mounting instructions
14. ment Page 9 12 The only batteries acceptable for use in the Solar Flo are those GEL or AGM batteries manufactured by COMCORDE or EAST PENN Battery sizes vary from 80 Ah to 130 Ah always consult the door for the proper replacement 10 1 Step 1 Power down the system If continuous uninterrupted service is required you may purchase a 24 volt back up battery with the correct cables and diode to provide uninterrupted power during a battery change out see replacement parts batteries Step 2 Remove battery fuse last at DIN rail then remove the safety fuse at the positive terminal Step 3 Remove the white interbattery jumpers to Step 4 Remove the positive and negative battery connections and fold the wires back slightly to avoid accidental arcing across the terminals Use extreme caution even dead batteries can still pack tremendous energy enough to cause serious burns or an explosion before you can react DO NOT CUT THE CABLE TIES HOLDING THE battery cables to the battery hold down bar they will serve as a convenient reminder of how they go back Step 5 Loosen the 1 4 bolt holding the Unistrut to the stainless steel clip tilt the hold down bracket to clear the clip and bulkhead and carefully raise it out of the holder at the bottom of the enclosure Move the Unistrut battery hold down and cables out of the way so you have clear access to the batteries MID SolarFlo Bedienungsanleitung 0701 e doc
15. otline Tel 49 7025 9208 0 or 30 Fax 49 7025 9208 15 Badger Meter Europa GmbH Subsidiary of Badger Meter Inc N rtinger Strasse 76 72639 Neuffen Germany E mail badger badgermeter de www badgermeter de
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