Solar Light Tower
This solar light tower includes six 265 watt solar panels, solar charging system, battery bank, LED light array, dust to dawn sensor, timers, battery charging system, and pneumatic mast mounted on trailer with outriggers and removable tongue. This 1.59KW solar generator system replenishes up to 363 amp hours of usable battery capacity per day, assuming 5.5 hours of peak charging sunlight. This system delivers 24 volts for lighting, cameras, sensors or other electronics equipment mounted atop a 30-foot collapsible, pneumatic mast.
Solar Panel Assembly
This unit is comprised of six 265-watt polycrystalline solar panels, generating a total maximum output of 1590 watts. The panels are mounted to a rotating axis assembly. There are two assemblies, one on each side of the solar trailer. The panels can be rotated until they face inwards, which protects the panels during transport. When deployed, the panels are rotated until they face upwards. On most models, we offer a locking pin system, preset with a winter and summer angle position for the panels.
In order to optimize the sun capture, the panels are set to +/- 15 degrees of the latitude of the trailers location on the earth. Houston, Texas, for example, is at latitude of 30 degrees, so the winter setting is 45 degrees and the summer setting would be 15 degrees. While this does not make a huge difference, every little bit helps. The position of the panels are set via locking stabilization arms with key holes, which increases stabilization of the solar array during deployment in with high wind applications.
Once the panels are set the correct solstice position, one section of panel is elevated into position via a hydraulic actuating system. This sets one set of 3 panels above the other section of three panels so they make a consistent plane angle to the sun. The entire panel deployment can be done easily by one person, since the axis system supports the weight of the panels during positioning. The entire process takes just a few minutes.
As part of the deployment, operators will set the four outriggers into position by pulling them out and pinning them into position. Four 2,000 lbs hand crank leveling jacks are used for leveling. The jacks can be leveled by hand crank or attachment provided for power drills. These outriggers can be extended 2' out from the side of the trailer for added stability. This will offset the effects of wind on the panels and the light mast.
Solar Charging System
In this 24 volt DC system, each panel is terminated with a fused combiner box with a single lever action cut-off switch. With the switch set to the ‘on’ position, the combiner box passes power to the 80-amp capacity Outback Extreme charge controller.
This solar light tower uses the Outback Extreme maximum power point tracking (MPPT) series charge controller system since it standard temperature threshold is more than 160 degrees Fahrenheit, due to its integrated heat sink and fan assembly. Oddly enough, most charge controllers are not rated past 104° Fahrenheit despite the fact the will always be close to direct sunlight. In the summer time in Texas, our fabrication shop is normally warmer than that, so this solar light tower uses a charge controller that would support the southern heat. This charge controller maximizes the solar power gained from the PV array, and prevents over and under charging of the battery bank. We improve on that capability by shading the charge controller and adding additional air flow from the exhaust of a 1400 CFM component cooling system.
The charge controller charges a 750-amp capacity battery bank. This 24 volt battery system in comprised of 12-volt 8D deep cycle acid glass mat (AGM) batteries tied together in series. Of course, with most battery technology, the battery bank cannot be drained below 50% without destroying the batteries. With that in mind, this effectively reduces the total capacity of this system to 375 amps at 24 volts.
The panels produce approximately 11 amps per hour per panel to charge this system. On a bright sunny day, the six panels would generate and deliver up to 363 amps back to the batteries in 5.5 hours. This conservative number of 5.5 hours is pretty standard conservative number for the solar industry. Many parts of the world have more and some have less. While this solar trailer can be optimized for the angle of the sun, the panel assemblies do not follow the path of the sun, so we use this conservative number to ensure successful operation. In areas with longer days, additional battery banks can be purchased to increase the capacity of the system. The solar trailer has capacity for 2 additional battery banks or 1 additional battery bank and supplemental generator for areas with shorter days or sporadic sunlight.
Battery Bank System
The battery bank consists of six 12-volt acid glass mat (AGM) batteries that are mounted to a removable tray. These AGM batteries are sealed and require no maintenance. The batteries are spaced apart, strapped to the battery tray and covered with a protective shield. The shield provides security and also shaded protection from the sun. The construction of the battery tray system enables the batteries to ventilate while shading and securing them. Much like a forklift battery bank, the entire battery tray system can be replaced in one operation. The trailer includes room for an additional battery bank system or a supplemental generator, both of which can be purchased separately and installed in the field.
Alternate Charging System
The battery bank is equipped with a line voltage AC rapid battery charging system that allows operators to plug the trailer into 120V or 240V AC to charge the battery bank without removing the batteries. This charging system consists of a multi-stage charging algorithm with safe start, short circuit protection, and overcharge protection. 100' of 12/3 SOOW cable terminated in a 5-20P straight blade or L5-20P twist lock cord cap for 120V systems or 6-20P straight blade or L6-20 twist lock cord cap for 240V systems allows operators to plug this unit into line voltage and charge the battery bank during long periods of cloudy days or when not in use. The lights can be operated while the batteries are charging.
Component Control Center
In order to ensure that the 50% threshold on the batteries is controlled, this solar trailer includes a system of min/max voltage sensors and relays that monitor the voltage produced by the batteries and will automatically shut off power distribution when the battery capacity falls below 50%. This protects the batteries from failure. We also include ground fault protection and an Outback Mate 3 monitoring system to track and log all activities related to the charger controller and battery health, including solar panel array amperage input and battery charger meter. This monitoring system has a visual display within the control box to show current status of the entire system. In the event there is an issue with the solar trailer, the SD card can be removed from the Mate 3 and sent to VOLT Industries for analysis.
All the electrical components, including the combiner panel, charge controller, over/under battery monitoring and ground fault isolation are encapsulated in a NEMA 3R job box that is bolted to the trailer. The electrical components, including switches, breakers, and cables are are compatible with solar arrays. Since most of these components are not rated for high heat, our component cooling system circulates air within the job box at 1400 CFM when the ambient temperature exceeds 90° Fahrenheit. The component control center also includes a terminal block so that customers can mount additional electronic gear without interfering with the charging systems. The job box that contains the component control system includes locks for security purposes.
The trailer itself houses a built in wire raceway that brings power from the component control center and batteries to the light mast. At the base of the light mast there is an access panel for making connections from the power source to the cabling within the pneumatic mast.
Pneumatic Light Mast
The aluminum pneumatic mast reaches 30' in height above the deck of the trailer via the use of a low voltage air compressor located within the job box. The compressor is equipped with a pressure switch that maintains the pressure within the mast. Once the mast is deployed from the component control center, its operation is automated. The air compressor will turn on briefly when the pressure in the mast falls below the fully inflated threshold. In normal operation, the air compressor may turn on once every few days for about 5 minutes to top off the mast. When it is time to take the mast down for transport, the operator simply release the pressure switch and the mast will slowly release pressure and lower to its full collapsed height of 8.25' above deck.
At the top of the mast, we include a mounting bracket that is 44" wide and 2" by 2" by 1/4" thick, which provides a strong and stable platform for standard payloads up to 150 lbs. of electronics, including lights, camera or sensors. These mounting brackets can be built to customer specifications to include the holes necessary to mount their gear. Included with this unit is high output LED light fixtures. The mast can be rotated a full 360°. By loosening the T-Handle, operators can rotate the mast with easy in either direction. The mast can be positioned in one of four different keyhole lock-ways to ensure the mast does not move during higher winds, and locked back in place by re-tightening the T-handle. This ensures the mast does not move once position is set. Alternatively, the mast can be locked into place by tightening the T-handle down in between the keyholes, however, higher wind speeds may offset the mast head slightly after position without guy wires. The mast itself spins freely with easy once the T-handle has been loosened, and can typically be rotated with a single hand.
The trailer itself is built on a 3500lb rated axle and is approximately 16' long and 6' wide. The trailer is equipped with a removable tongue for storage, transport and security purposes. The tongue features an adjustable hitch, allowing operators to raise or lower the height of the hitch for towing purposes. Hitch options include 2" ball coupler and 3" pintle hitch. Safety chains come standard. For an additional charge, we offer removable wheels in addition to the removable tongue for extra security. The four built in outriggers can be slid out from the frame and pinned into place. A standard crank style support leg can be used to secure each outrigger to the ground. The outrigger feet are over-sized and equipped with through holes for additional ground anchoring mechanisms. D-rings allow the trailer frame to be anchored down for long term deployment and high wind applications. The trailer has an industrial grade finish for rust and corrosion resistance.
The trailer is equipped with an electric brake setup and electronic safety breakway device. All safety lighting on the trailer meet or exceed DOT and FMVSS regulations. This unit is equipped with stop, tail, turn signals, and license plate lights. Wiring is provided by an industrial grade trailer 7-pin flat trailer plug (other options available upon request). Reflective tape along the sides of the trailer provides increased night time visibility. This trailer is approved for highway use, and will clear standard height interstate bridges.
The lighting system on this unit is comprised of four 120 watt high output LED flood lights producing 10,800 lumens each attached to the end of the telescoping light boom. These floodlights produce a wide flood light pattern capable of illuminating a minimum of 3 acres with a combined total of 43,200 lumens of light. The light assembly consists of twelve LEDs paired with specular reflectors to produce a wide light distribution overpowering that of a 1000 watt quartz flood lights. This light is constructed of six angled boards that helps provide a wider spread. Instead of the light only shining forward, the center board is concentrated to go straight out while the boards on the side are 45° offset. These LED flood lights are designed to withstand demanding conditions and is waterproof, vapor proof, and built to resist the damaging effects of an outdoor environment.
Each floodlight is securely fastened to the light boom and each lamp includes a support bracket to help maintain lamp stability within its housing. The lamps are connected to the power source via a water tight male pin connector that attaches to a receptacle located on the end of the telescoping boom. The mast head assembly can be removed from the pneumatic mast for storage and transportation purposes. A mounting bracket located on the bed of the trailer provides safe and secure storage of the LED lights and mast head during transportation.
Unlike gas burning and arc type lamps that have glass bulbs, LEDs have no filaments or fragile housings to break during operation. Instead of heating a small filament or using a combination of gases to produce light, light emitting diodes (LEDs) use semi-conductive materials that illuminate when electric current applied and emitting light. With LED lights, there is no warm up time or cool down time before re-striking and provide instant illumination when powered on, adding to the reliability of LED technology. By nature, LED light sources run significantly cooler than traditional lamps, reducing the chance of accidental burns and increased temperatures due to heat emissions. This solid state design of light emitting diodes provides a more reliable, stable, durable, and energy efficient light source over traditional lighting.
The LED light heads are wired independently of each other. Each light head is wired into the NEMA 3R control box. Operators control the light heads via an on/off switches, allowing 0%, 25%, 50%, 75%, and 100% intensity levels. Additional operation includes the ability to set the lights to power on automatically via a built in dusk-to-dawn sensor or built in timer system, both equipped on this solar security tower. The dusk-to-dawn sensor automatically powers the lights on when ambient light levels drop below a specific level, which can be adjusted by the operator. The automatic timer allows operators to set a specific time for the lights to power on and power off. This allows the light fixtures to be enabled automatically, manually, or in timed intervals and the intensity can be adjusted from 100% down to 25% lumen output to increase runtime.
This solar powered light tower generator is shipped via common freight. Each unit is equipped with side mounted skid pockets for loading with fork lifts, and 4-corner mounted eyelets allow for crane picking and air transportation methods. The 4-corner eyelets also allow operators to secure this trailer in transportation, ensuring the unit does not move during transit.
VOLT Industries is a manufacturer of light tower systems and can customize systems to meet custom requirements. Contact us at 1-866-805-4328 or [email protected] to learn more.
|Specifications / Additional Information
|Country of Manufacture||United States|
FREE FREIGHT INCLUDED WITH THIS ORDER