1. Selection of construction site

Inspect the construction site and surrounding environment to ensure the feasibility of project implementation.

There shall be no shelter around the installation site to ensure the normal daylighting of solar panels. If it is difficult to ensure that there is no shelter all day, try to ensure that there is no shelter between 9:00 a.m. and 15:00 p.m.

The installation site must have smooth drainage. If there are low-lying ponding points such as rivers or puddles within 10m from the installation site, the lowest point of the foundation must be higher than the highest water level within 50 years.

Public facilities such as cables and optical cables shall not be laid underground at the installation site.
According to the construction design, determine the lamp pole position and lamp distance. If there is any change on site, negotiate with the owner to determine the solution in time.

2. Lamp pole foundation embedded

Dig a pit at the lamp pole positioning to make the lamp pole foundation: the company provides the foundation embedding drawings of street lamps of corresponding specifications.
After excavation, the ground wire shall be used to detect whether there are obstacles and underground pipelines underground. If there are obstacles, it shall be moved away, and barbaric construction shall be avoided.

The foundation pit is paved with 8 cm thick cushion.

The concrete for foundation pouring shall be processed and manufactured in a centralized manner, mixed evenly with a mixer, and transported to the construction site by vehicles.

When pouring the concrete independent foundation on the cushion, it shall be vibrated while pouring; Before pouring, the embedded parts of anchor bolts shall be embedded, and the anchor bolts shall be grouted twice.

Pay attention to the bolt protection measures on the lamp pole foundation to prevent damage to the bolts.

For the lower embedded threading pipe (protective pipe), a special person shall be assigned to align the foundation outlet hole with the battery outlet hole in time. The upper part shall be located in the middle of the embedded part and 5cm higher than the concrete embedded part (to avoid water).

The bending of the embedded threading pipe shall be avoided as far as possible. Its inner diameter shall not be less than 1.5 times the outer diameter of the steel wire hose. If the protective pipe is bent, it shall not be less than 2 times, Try to avoid dead bends. The lower port should be inclined slightly downward. The pipe orifice must be blocked with something to avoid sediment and other sundries pouring into the pipe to block the threading pipe during construction.

After pouring, level the embedded parts and level the concrete foundation surface.

Before installing the lamp pole foundation, the perpendicularity shall be found from two directions.

The perpendicularity shall be monitored during installation, and the perpendicularity deviation shall not be greater than 5mm to ensure the perpendicularity of the lamp pole.

The prepared foundation must be cured for 2-5 days (it shall be controlled by the construction personnel according to the ambient temperature during construction). During the maintenance process, the upper surface of the foundation shall be tested irregularly to ensure its level. If it does not meet the requirements, it shall be repaired in time.

3. Install battery and buried battery box

There shall be no ponding at the buried place of the battery.

Before burying the storage battery box, the working pit shall be excavated, and the size is generally 1m * 1m * 1m or more (the length and width vary according to the specification of the storage battery box, and the depth varies according to the region, so it shall be below the local frozen layer).

After excavation, the ground wire shall be used to detect whether there are obstacles and underground pipelines underground. If there are, it shall be moved away smoothly, and barbaric construction shall be avoided.

If the battery voltage is higher than 12.6 V (12 V system), it is qualified. Then place the battery horizontally in the battery box and fix it firmly to ensure that the battery terminal is bright and free of pollution.

If necessary, polish the terminal with a steel wire brush or sandpaper, firmly connect the battery output wire (positive and negative poles are separated), and coat two wires with a steel wire hose, then it is sleeved on the threading nozzle of the battery box (the overlapping length is about 25mm) and fastened in the middle with a double steel wire hoop. Do a good job in waterproof, anti-corrosion, short circuit prevention, and thermal insulation, and finally cover the upper cover of the battery box for waterproof treatment.

After the working pit is excavated, the battery box shall be buried, and the levelness of the battery box shall be found. The inner diameter of the embedded threading pipe (protective pipe) shall not be less than 1.5 times the outer diameter of the steel wire hose. When the protective pipe is bent, it shall not be less than 2 times to avoid dead bending.

The protective pipe shall be free of perforation, crack, and uneven defects, and the inner wall shall be smooth without burr and sundries.

The steel wire hose passes through the ground from bottom to top. After installation, the earthwork shall be backfilled, the original road surface shall be restored, and the construction site shall be cleaned.

First, level the solar panel support (the panel support may be bent during transportation) so that the solar panel can be placed on it smoothly.

The solar panel shall be firmly fixed on the support with bolts, nuts, and gaskets. When the solar panel is placed vertically, the junction box shall be located above. When the solar panel is placed horizontally, the junction box shall be close to the direction close to the lamp pole assembly.

4. Connect the solar panel cable

Connections where the system voltage is 12 volts or 24 volts.

Connect the red wire to the positive pole of the solar panel and the black wire to the negative pole of the solar panel, and then tighten the waterproof sealing nut under the junction box to fasten the wire in the junction box.

After the two wires are connected, be sure to measure whether there is the voltage at the output end. The terminal head of the red wire is positive; The terminal head of the black wire is negative. In sunny weather, the open-circuit voltage of solar panels shall be greater than 17-18 V (12 V system) or 34-36 V (24 V system). When the light is weak, the voltage is lower.

Series and parallel connection of solar panels: if solar panels need to be connected in series or in parallel, there must be anti-reverse connection diodes in the junction box of solar panels. If the system voltage of the street lamp is 24 V and the voltage of the solar panel is 17-18 V, the solar panels shall be connected in series by connecting the positive pole (or negative pole) of the first solar panel and the negative pole (or positive pole) of the second solar panel.

If the voltage of the solar panel is 34-36 V, the solar panels shall be connected in parallel, the method of parallel connection is that the positive and negative poles of the first solar panel are correspondingly connected with the positive and negative poles of the second solar panel.

Connect the solar panel cable.

After all of the wiring is completed, cover the cover of the junction box and fasten it with screws.
After checking, you can do the next step of solar panel work.

5. Installation of lamp posts, lamps, and cables

Before the installation of the lamp pole, visually check that the welds of the lamp pole are symmetrical and free of false welding. The plastic spraying shall be free of the bulge, pinhole, crack, or missing spraying. The straightness error of the pole body shall be less than 3%.

During the installation of the lamp pole, the surface coating shall be prevented from being strangled or cut as much as possible. It is strictly prohibited to use a steel wire rope to straighten or throw it from the vehicle.

The lamp pole shall be installed upright, and the vertical deviation shall not be greater than half of the lamp tip diameter. The lamp pole shall be set on a line parallel to the longitudinal axis of the road, and the transverse displacement shall not be greater than half of the pole root diameter.

Before installing the light source, check whether it is normal, so as to avoid unnecessary trouble caused by installing the light source that may be damaged during transportation.

The lamps shall be installed correctly and perpendicular to the longitudinal axis of the road, with an error of no more than 3 degrees. After installation, there shall be no skew by visual inspection.
During the installation of the lamp pole, the bolts of each part shall be provided with a flat pad and the spring pad shall be firm. After fastening, the exposed nut of the bolt shall not be less than two pitches.

All bolts of the lamp cap and lamp body must be fastened, and reinforcement measures shall be taken for the parts that may rotate under wind pressure.

Use the pre-threaded wire to thread the wire. When threading, it is forbidden to pull hard to avoid scratching or even breaking the sheath wire. Sufficient margin must be reserved for the sheath wire connecting the solar panel and the light source; The power cord connecting the controller shall be bent downward to prevent water from flowing into the terminal along the wire.

6. Adjust the direction and angle of the solar panel

Adjust the angle of the solar panel according to the design requirements.

Use the compass to adjust the front of the solar panel to face the due south direction (equatorial direction).

Fasten the fixing bolts after adjustment.

7. Connection of controller

The output line of the solar cell, the output line of the lamp cap, and the connecting line of the battery.

The three groups of wires shall be connected to the controller in the following order:

1. Connect the battery;

2. Connect the load (light source);
3. Connect the solar panel (operate according to the requirements of the installed controller).

If this wiring sequence is violated, the whole system will not work normally.

Connect the battery first. The first measure whether the voltage of the battery is within the specified range, and then make the positive and negative wire ends of the battery (there shall be no burr on the metal head. The length of the metal head depends on the depth of the terminal hole of the controller, not too long, so as to avoid overlapping short circuits between wires).

After the wire ends are connected, insert the positive pole into the battery “+” marked on the controller Tighten the screws and connect the negative pole to the corresponding “-” terminal hole.

Check whether there is voltage. Pay attention to be careful during wiring. Do not short circuit the positive and negative poles of the battery through the casing or tools in your hand.

After the battery is connected to the controller, the controller starts to work and the corresponding battery indicator light is on. After ten minutes, the output terminal of the load shall have voltage. Connect the load (light source) and the light source will be lit immediately.

Then connect the load (light source) and pull out the protective wire sleeve of the light source. The red wire is the positive pole and the black is the negative pole. Connect them to the load terminal of the controller (in the light source “+” and “-” terminal holes marked on the controller). Note: the positive and negative poles shall not be connected incorrectly, otherwise the load may be damaged.

After the light is on, the solar panel can be connected in another minute or two.

Finally, connect the solar panel. Pull out the protective wire sleeve of the solar panel. The red wire is the positive pole and the black wire is the negative pole. First, measure the voltage between the first line. When the light is weak, the voltage is lower. In sunny weather, the open-circuit voltage of the solar panel should be greater than 18 V (12 V system) or 36 V (24 V system).

The positive and negative poles of the solar panel are not afraid of short circuits in a short time. Connect the two wires of the solar panel to the corresponding terminals of the controller. Note that the positive and negative poles cannot be connected incorrectly.

After the controller is connected to the solar panel, if there is enough voltage (more than 10 volts) on the solar panel, the controller considers it to be in the state of dawn. In ten minutes, the street lights will be turned off.

When you turn on the lights again, you’ll have to wait until it’s dark. At this point, all wires of the controller have been connected. Carefully recheck: whether the connection between the wiring terminal of the controller and the three groups of wires is well connected, whether there are burrs, whether there are exposed metal wires, and whether the screws for fixing wires are tightened.

8. Commissioning

A detailed inspection shall be carried out before commissioning, and the controller, solar panel cable, load cable, battery cable, and fuse shall be carefully rechecked to see whether they are connected properly.

After the operation, send personnel to inspect the on time, off time, and luminous efficiency of each solar street lamp, and take corrective measures immediately in case of problems to ensure normal operation.

Make operation records and establish file management.

9. Precautions

When installing solar panels, handle them with care. It is strictly prohibited to short circuit or throw solar panels.

The connecting wire of the solar panel shall be firmly fixed at the support to prevent the terminal from loosening or even falling off due to long-term sagging or pulling of the power line.

When installing the lamp cap and light source, handle with care to ensure that the transparent cover is clean and free of scratches. It is strictly prohibited to roll and throw.

Do not touch the battery terminal when moving the battery. It is strictly prohibited to short circuit, roll or throw the battery.

Pay attention to the positive and negative poles during wiring. It is strictly prohibited to connect reversely. The wiring terminals are crimped firmly without looseness. At the same time, pay attention to the connection sequence and do not short circuit the line.

Do not touch the “+” and “-” poles of solar panels or batteries at the same time to prevent electric shock.

For street lamps with an inverter power supply, the inverter outputs a high voltage, which is life-threatening to touch.

Avoid scratching the lamp body during installation.

The bolt connections of the lamp cap, lamp arm, lamp pole assembly support, and solar panel are firmly connected without looseness.