Harbor Freight 45 Watt Solar Panel Kit Product Manual

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45 Watt Solar Panel Kit

68751 Solar Panel Kit

Read this material before using this product.

Failure to do so can result in serious injury.

SAVE THIS MANUAL.

When unpacking, make sure that the product is intact and undamaged.

If any parts are missing or broken, please call 1-800-444-3353 as soon as possible.

Visit our website at: http://www.harborfreight.com

Copyright© 2011 by Harbor Freight Tools®. All rights reserved. No portion of this manual or any artwork contained herein may be reproduced in any shape

or form without the express written consent of Harbor Freight Tools. Diagrams within this manual may not be drawn proportionally. Due to continuing

improvements, actual product may differ slightly from the product described herein. Tools required for assembly and service may not be included.

Email our tech support at: tech@harborfreight.com

Page 2 For technical questions, please call 1-800-444-3353. SKU 68751

IMPORTANT SAFETY

INFORMATION

In this manual, on the labeling, and all other

information provided with this product:

This is the safety alert symbol. It is

used to alert you to potential personal

injury hazards. Obey all safety

messages that follow this symbol

to avoid possible injury or death.

DANGER indicates a hazardous situation which, if

not avoided, will result in death or serious injury.

WARNING indicates a hazardous situation which, if

not avoided, could result in death or serious injury.

CAUTION, used with the safety alert symbol,

indicates a hazardous situation which, if not

avoided, could result in minor or moderate injury.

NOTICE is used to address practices

not related to personal injury.

CAUTION, without the safety alert symbol, is used

to address practices not related to personal injury.

WARNING Read all safety warnings and

instructions. Failure to follow the warnings and

instructions may result in electric shock, re and/

or serious injury.

Save all warnings and instructions for

future reference. The warnings, precautions,

and instructions discussed in this instruction

manual cannot cover all possible conditions and

situations that may occur. It must be understood

by the operator that common sense and caution

are factors which cannot be built into this

product, but must be supplied by the operator.

Installation Precautions

1. Exercise special caution if working on roof

or another high location. Keep proper footing

and balance at all times. Follow ladder supplier’s

precautions whenever working near or on a ladder.

2. Install all sensitive electrical components

(including wiring connections, regulator,

and battery) inside a weatherproof

enclosure to prevent electric shock.

3. Do not wire multiple panels in series. If you

need to connect two or more solar panels together,

this work must be done by a qualied electrician

unless they are connected through a regulator.

4. This solar panel kit is not designed for tie-in to a

grid. Only a licensed electrician and a licensed

building contractor can safely design and implement

a grid tie-in system. Any grid tie-in system must

meet all applicable building and electrical codes,

and must meet standards established by the area

power company. Improper grid tie-in can result in

electrocution, re, and other serious personal injury

and property damage. An incorrectly installed grid

tie-in system can cause feedback voltage, resulting

in electrocution of electrical utility workers.

5. Do not stand on or otherwise

apply pressure to panel.

6. Handle solar panel with care,

edges may be sharp.

7. Do not focus light on panel.

8. Install components with enough

space to allow proper cooling.

9. This product may occasionally produce more

current and/or voltage than its rated output.

Increase output ratings by 25% when determining

component required voltage and amperage

ratings. Refer to Section 690-8 of the National

Electrical Code for an additional multiplying factor of

125 percent (80 percent derating) which may apply.

Page 3For technical questions, please call 1-800-444-3353.SKU 68751

10. Panel must be connected using UL listed outdoor

rated wire of the correct thickness (gauge) for the

amperage rating and length (see warning number

9 also). Follow the guidelines in the chart below:

Current

in Amps

Maximum Length

5' 10' 15' 20' 25'

0-5 18

6-7 18 16

8 18 16

10

18

16

11-12 16 14

15 14 12

18

18 1620 14 12 10

22-24 12

30 16 14 10

40 12 10 8

50 14

100 12 10 6 4

150 10 84 2

200 8 6

Minimum Wire Gauge

11. Install an appropriate charge controller/regulator

to regulate output and prevent damage. Do not

attach panel to battery or power grid without proper

regulator, inverter, and/or charge controller.

12. Install and use according to applicable

National Electrical Code (NEC) standards.

13. This panel is not rated for use as re-resistant

roong. If installing on a roof, install only over a re

resistant roof covering rated for the application.

14. Verify that installation surface has no hidden

utility lines before drilling or driving screws.

15. Install only according to these instructions.

Improper installation can create hazards.

16. Wear ANSI-approved safety goggles and heavy-

duty work gloves during installation. Do not

wear jewelry or metal watches when working

near solar panels, wiring or batteries.

17. Handle panel with care. Glass may break or a

sharp edge may be exposed during movement.

18. Keep installation area clean and well lit.

19. Install out of reach of children.

20. Keep bystanders out of the area during installation.

21. Do not install when tired or when under

the inuence of drugs or medication.

22. Use in 12 VDC systems only.

Battery Precautions

1. Wear splash-resistant ANSI-approved

safety goggles and electrically insulated

gloves while working near batteries.

2. Use an appropriate charge controller

whenever connected to battery.

3. Charge, store, and maintain batteries

according to supplier’s instructions.

Service Precautions

1. Before service, maintenance, or cleaning:

a. Dry solar panels and outdoor

wiring thoroughly while wearing

electrically insulated gloves.

b. Cover all solar panels with an opaque

cover, such as a blanket.

c. Disconnect all solar panels.

d. Disconnect all batteries.

2. Do not service during rain, fog, or

any other wet/humid weather.

3. Do not stand on or otherwise

apply pressure to panel.

4. Do not allow children to play with or near

this item or electrical components.

5. Inspect at least monthly; do not use if damaged,

parts are loose, water is found inside the

housing, electrical insulation is cracked or

damaged, or connections are loose.

6. Maintain product labels and nameplates.

These carry important safety information.

If unreadable or missing, contact Harbor

Freight Tools for a replacement.

7. WARNING: Handling the cord on this product will

expose you to lead, a chemical known to the State

of California to cause cancer, and birth defects or

other reproductive harm. Wash hands after handling.

(California Health & Safety Code § 25249.5, et seq.)

SAVE THESE

INSTRUCTIONS.

Page 4 For technical questions, please call 1-800-444-3353. SKU 68751

Specications

Rated Output 14.5 V~ / 15 W (per solar panel)

Open Circuit Voltage 23.5 OCV

Adapter Outlets 3,6 and 12 VDC

Note: Output will decrease as the panel gets hotter

than room temperature (~70° F). Angle, solar intensity,

cloud cover and other factors will effect output.

Installation

IMPORTANT! Read the ENTIRE IMPORTANT

SAFETY INFORMATION section at the beginning of

this manual including all text under subheadings

therein before set up or use of this product:

Note: For additional information regarding the

parts listed in the following pages, refer to the

Assembly Diagram near the end of this manual.

Location

1. Locate the Solar Panels (14) where they will

receive full, unobstructed sunlight, especially during

midday. Nearby trees or tall plants will drop debris,

requiring the panels to be cleaned more frequently.

2. The setup location for the Solar Panel Kit must

be inaccessible to children to prevent electric

shock. Build a childproof enclosure if needed.

3. Install the charge controller/regulator and batteries

in a weatherproof enclosure with proper ventilation.

Mounting

1. Select a mounting location for the Solar Panel

Kit. The Solar Panels should face the Sun, and

not be blocked by shadows. The location should

allow the Panels to be protected from accidental

damage. The location should be at, stable and

able to support the weight of the Solar Panel Kit’s

accessories. Before assembly, be sure that all

accessory cables reach their connection points

without placing any stress on the wiring.

2. Angle face of Solar Panel Frame toward true

south1 according to chart that follows:

Latitude Solar Panel Angle

0-4° 10°

5-20° Latitude + 5°

21-45° Latitude + 10°

46-64° Latitude + 15°

65° or more 80°

1 Angle towards true north if installed

in southern hemisphere.

Solar Panel Frame Assembly

1. First, attach all the components of the

frame together. See Figure 1, below.

NOTE: Do not fasten connections with hardware yet.

Figure 1

Mounting

Holes

Mounting

Holes

IMPORTANT: During assembly, make sure that

the solar panel mounting holes along the Top

Tubes (2) and Bottom Tubes (8) face OUT from

the frame assembly. See Figure 1, above.

2. Attach Corner Connectors (1) to Side Tubes (6).

Then use the Fixed Screws (9) and Nuts (10) to

fasten the Corner Connectors to the Top Tube.

See Figure 2, below.

Figure 2

Fixed Screw (9)

Nut (10)

Corner

Connector (1)

Side Tube (6)

Top Tube (2)

3. Use Fixed Screws and Nuts to fasten the Top Tubes

to the Leg Connectors (3) and then the Support Legs

(7) to Leg Connectors. See Figure 3, following.

Page 5For technical questions, please call 1-800-444-3353.SKU 68751

Figure 3

Fixed Screw (9)

Top Tube (2)

Leg Connector (3)

Support Legs (7)

NOTE: There are two possible settings for the Leg

Connectors to allow for different angles facing the sun.

Before securing Leg Supports in place, be sure to adjust

Leg Connectors so that both Connectors are set at the

same angles. This will help keep the frame balanced.

4. Verify all connections are tightened and that

the frame is secure. WARNING! Do not install

the Solar Panels until the frame is properly

assembled and balanced on surface.

5. Determine where you want to position the

frame assembly, making sure it is facing south

(for maximum sun exposure) with no obstructions

in front of it. The Charge Controller (16) must be in

a dry, well ventilated location nearby. If necessary,

build a small structure that guarantees the unit will

stay dry during rain or snow, and, provide enough

ventilation to allow the unit to vent and cool properly.

6. Set the Solar Panels onto the frame assembly,

aligning the Panels’ mounting holes with the mounting

holes on the Top and Bottom Tubes. Use the Panel

Screws (12) and Nuts to secure the Solar Panels

to the frame assembly. See Figure 4, below.

Figure 4

Panel Screw (12)

7. Connect end of lead wires coming from Solar Panels

(14) to the Splitter Cable (15). See Figure 5, below.

Figure 5

Splitter

Cable (15)

8. Connect the ends of the Battery Clamps to the

battery terminals on the back of the Charge

Controller. Then attach the Battery Clamps to

the battery’s terminals. WARNING! Be sure to

connect all matching polarities. Black (-) is negative

and red (+) is positive. See Figure 6, below.

Charge

Controller (16)

Battery Terminals

Fuse

Figure 6

9. Connect Splitter Cable to Extension Cable (20) and

then to the Charge Controller. See Figure 7, below.

Figure 7

Extension

Cable

(20)

Splitter

Cable (15)

Page 6 For technical questions, please call 1-800-444-3353. SKU 68751

Wiring

Note: Only a licensed electrician and a licensed building

contractor can safely design and implement a grid

tie-in system. Any grid tie-in system must meet all

applicable building and electrical codes, and must meet

standards established by the area power company.

1. Run wires from panels, through weatherproof

grommets and into enclosure where charge

controller/regulator is located. Use wires

of the proper size and rating and use twist

connectors (not included) to connect wires.

2. Connect to Charge Controller according

to Controller’s instructions.

3. Secure all connections using terminals, or solder

all wire splices to ensure good connections.

4. Weatherproof all connections and route the wire in

a way that it will not be torn loose from the panel.

Operation

Note: Performance of the Solar Panels will vary

dependent on site location, angle of the panels in

relation to the arc of the sun, and available sunlight.

Recharging a Battery

1. To recharge a 12 volt battery (not included),

while paying attention to the proper polarity

(black (-) is negative and red (+) is positive),

connect the two ring terminals on the Battery

Clamp to the Battery Terminals on the back of

the Charge Controller. See Figure 8, below.

2. Connect the black clamp to the black or negative

(-) terminal on the battery (not included). Finally,

connect the red clamp to the red or positive (+)

terminal on the battery. Avoid accidental contact of

the red and black battery clamps to each other.

3. Turn on the Charge Controller. See the On/Off switch

in Figure 8, below. Initially charge for three days.

Figure 8 On/OFF Switch

USB

Output

Digital Voltage

Meter

12V

Female

Output

Female

Inverter

Output

Overload

Discharge

Indicator

Digital

Voltage

Meter

Switch

4. Never leave the battery (not included) unattended

while charging. When battery is fully charged, the

reading on voltage display will show “13” or above.

NOTE: The voltage display will have to be turned on

in order to monitor the battery voltage. (Press the

Voltage Meter Switch to turn off the Voltage Meter

when not monitoring the battery voltage since it

consumes energy.) Twelve (12) Volt batteries should

charge to 13 Volts for a full charge. To stop charging

the battery, turn Power Switch to OFF and disconnect

the solar panels from the Charge Controller.

NOTE: The Charge Controller provides “overcharge”

protection. If the battery voltage is higher than 14.5

V, the regulator will shut off charge from solar panel.

5. The Charge Controller provides the

following protection while charging:

a. Over-discharge Protection: When the

electricity level of the battery goes too low

(below 11 volts) from product usage, the Charge

Controller will automatically shut off the power

output to prevent damage to the battery. If

this occurs, stop using the battery and charge

it until the Voltage display shows 13 volts.

b. Overcharge Protection: If the electricity level

on the battery goes too high (above 14.5 volts)

the Charge Controller will automatically shut off

power input to prevent damage to the battery.

c. Overload Protection: If the output current

exceeds 4 amps the fuse (see Figure 6) will

blow to prevent damage to the controller in

the Charge Controller. If this occurs, have a

qualied service technician replace the fuse.

Note: The On/Off switch of the Charge Controller

must be in the “On” position to activate the three

protection functions mentioned above.

Using 12 Volt Lights

and Accessories

Note: The Charge Controller must be

in “ON” position at all times.

6. If the 12V Lights (18) aren’t already

attached to the sockets on the end of

each light wire, gently snap them in.

7. Plug the other end of the 12V Light’s wire into

either of the 12 Volt DC outlets on the Charge

Controller as shown in Figure 9, below.

Page 7For technical questions, please call 1-800-444-3353.SKU 68751

12V DC

Outlets

3V DC

Outlet

6V DC

Outlet

Figure 9

8. To turn on and off the lights, press the switch on

the outside of each light socket. NOTE: You may

plug in the each light into to either 12V DC outlet.

Note: This system can also be used to power

other small 3V and 6V DC small appliances.

9. Plug the appropriate plug on the Multi

Adapter into the appliance. The adapter

has 3, 6 and 12 Volt DC plugs.

10. Insert the plug on the other end of the wire

attached to the Multi Purpose Adapter into the

appropriate DC Outlet on the Charge Controller.

11. Activate your appliance. CAUTION! Only

on appliance can be used at a time with

this adapter and the adapter must be

plugged into the same voltage output.

12. When nished, unplug the Multi Adapter wire

plug from the Charge Controller and then

unplug the Multi Adapter from the appliance.

13. To charge cell phone or other small electronic item,

plug the item’s power cored into the USB Port on

the front of the Charger Controller. See Figure 9.

14. Use the Inverter Output and the 12V Female Output

ports to connect the male adapters for 12V accessory

items that need to be charged. See Figure 9, above.

Servicing

Procedures not specically explained in this

manual must be performed only by a

qualied technician.

TO PREVENT SERIOUS INJURY FROM ELECTRIC

SHOCK: Before service, maintenance or cleaning:

a. Dry solar panels and outdoor

wiring thoroughly while wearing

electrically insulated gloves.

b. Cover solar panels with an opaque cover.

c. Disconnect all solar panels and batteries.

TO PREVENT SERIOUS INJURY FROM

ELECTRIC SHOCK OR CUTS:

Do not use damaged solar panel.

If wiring insulation is damaged or

weathered, glass is cracked, or housing

is opened, have the problem corrected

before further use.

Note: It is normal to see up to 20% degradation in

amorphous silicon solar panel performance within the

rst 6 months before the amorphous coating stabilizes.

Cleaning

Clean and inspect the Solar Kit system MONTHLY,

or more frequently to maintain peak efciency.

1. Wear electrically insulated gloves and

ANSI-approved safety goggles. Dry solar

panels and outdoor wiring thoroughly.

2. Cover solar panels with opaque cover.

3. Disconnect all solar panels and batteries.

4. Clean solar panels one at a time with mild, non-

abrasive cleanser and soft cloth and paper towels.

Do not clean with brushes or abrasive cleaners.

5. Inspect general condition of Solar Kit system

(panels, batteries, controllers, and mounting). Check

for loose hardware, wiring insulation damage or

weathering, cracked glass, open housing, cracked

or broken parts, loose or corroded contacts, and any

other condition that may affect its safe operation.

6. Maintain batteries according to supplier’s instructions.

Adjustment

To increase efciency:

1. In the Winter, increase the panels’ angle by 10°.

2. In the Summer, decrease the angle by up to 10°.

3. In Spring and Fall, keep the angle

recommended on page 4.

Page 8 For technical questions, please call 1-800-444-3353. SKU 68751

Record Product’s Serial Number Here:

Note: If product has no serial number, record month and year of purchase instead.

Note: Some parts are listed and shown for illustration purposes only,

and are not available individually as replacement parts.

Parts List

Part Description Qty.

1 Corner Connector 4

2Top Tube 2

3 Leg Connector 2

4 Tube Connector 2

5Middle Tube 1

6Side Tube 2

7 Support Leg 2

8Bottom Tube 2

9 Fixed Screws 12

10 Nut 24

Part Description Qty.

11 Back Frame 3

12 Front Frame 3

13 Panel Screws 12

14 Solar Panel 3

15 3-In-1 Splitter Cable 1

16 Charge Controller 1

17 Battery Clamp Cable 1

18 Lighter Cable 1

19 Multi Adapter 1

20 Extension Cable 1

Page 9For technical questions, please call 1-800-444-3353.SKU 68751

PLEASE READ THE FOLLOWING CAREFULLY

THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM IN

THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER OR DISTRIBUTOR MAKES ANY

REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS

TO THE PRODUCT, OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT. IN FACT, THE

MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD

BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS, AND NOT BY THE BUYER. THE BUYER ASSUMES

ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT

PARTS THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO.

Assembly Diagram

SKU# 90599

45w solar power kit

Part

No. Description Part

No. Description

1 Syphon pipe 11 Back plastic frame

2 Top connection pipe 12 Front plastic frame

3 3 holes pipe 13 Solar panel fix screws

4 3 holes pipe 14 Solar cell

5 Middle connection pipe 15 3 in 1 connection cable

6 Connection pipe ( right side ) 16 Charge regulator

7 Support leg 17 Battery clamp

8 Bottom pipe 18 12VDC light

9 Fix screws 19 Multi-purpose cable

10 Srew nut 20 Extension cable

Page 10 For technical questions, please call 1-800-444-3353. SKU 68751

90 Day Warranty

Harbor Freight Tools Co. makes every effort to assure that its products meet high quality and durability standards,

and warrants to the original purchaser that this product is free from defects in materials and workmanship for the

period of 90 days from the date of purchase. This warranty does not apply to damage due directly or indirectly,

to misuse, abuse, negligence or accidents, repairs or alterations outside our facilities, criminal activity, improper

installation, normal wear and tear, or to lack of maintenance. We shall in no event be liable for death, injuries

to persons or property, or for incidental, contingent, special or consequential damages arising from the use of

our product. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the

above limitation of exclusion may not apply to you. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER

WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS.

To take advantage of this warranty, the product or part must be returned to us with transportation charges

prepaid. Proof of purchase date and an explanation of the complaint must accompany the merchandise.

If our inspection veries the defect, we will either repair or replace the product at our election or we may

elect to refund the purchase price if we cannot readily and quickly provide you with a replacement. We will

return repaired products at our expense, but if we determine there is no defect, or that the defect resulted

from causes not within the scope of our warranty, then you must bear the cost of returning the product.

This warranty gives you specic legal rights and you may also have other rights which vary from state to state.

3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-3353