Solar LED Road Lighting System

Mounting Instructions V6.2

---Field Installation ---

Signify (China) Investment Co., Ltd.

Building No. 9, Lane 888, Tianlin Road, Minhang District, Shanghai, China
Post code：200233
 Important Safety Notice(Gel battery)

The battery presents a risk of electrical shock and a high short circuit current. The
Signify mounting instructions must be strictly followed, otherwise potential application,
reliability, or safety issues may arise. Contact your local S i g n i f y service if the
instructions cannot meet special field conditions.
Only a qualified Signif y service representative who is knowledgeable in batteries and
the required precautions is permitted to service the battery. Keep unauthorized
personnel away from batteries.

Danger:
1. Do not short the battery terminals.
2. The VRLA battery can generate hydrogen gas. Hydrogen mixed with oxygen is
explosive and could be ignited by any spark/flame, static electricity, or overheated
object. Smoking is strictly prohibited during all system installation, operation, and
maintenance processes, such as welding.
3. Use proper lifting techniques to keep the battery upright and avoid any discharge of
acid when moving batteries. Wear all appropriate safety clothing and equipment.
4. Do not dispose of the batteries in a fire. The batteries may explode.

Caution:

1. The misuse of this equipment could result in human injury and/or equipment damage.
In no event will S i g n i f y be responsible or liable for either indirect or consequential
damage or injury that may have resulted from the misuse of this equipment.
2. Use tools with insulated handles to avoid inadvertent shorts.
3. Verify circuit polarities before connecting.
4. Disconnect the charging source and load before connecting or disconnecting the
battery.

Warning:
1. The solar lighting system contains VRLA batteries. Lack of preventative maintenance
could reduce the battery's lifetime or even be dangerous. Check the application
environment regularly (lighting performance, PV panel shading).
2. Failure to replace a battery before it becomes exhausted may cause the case to
crack, possibly releasing electrolytes from inside the battery and resulting in secondary
issues such as odor, smoke, and fire.
3. The battery system must be in proper maintenance according to the
"Troubleshooting & Maintenance" manual. This is essential for safety and the reliability
of the lighting system.
4. Do not dispose of lead acid batteries except through channels in accordance with
local, state and federal regulations.

Notice: The mounting instructions in this document is for standard solar lighting system
installation. If any large deviation (such as multi systems sharing pole/base/component,
component change, wiring change, installation location change, etc..) from standard
solar lighting system is needed due to special application, it is required to contact with
Signif y representative for special instructions. Otherwise, the deviation from standard
instructions may cause abnormal system operation or even dangerous situation.
 Important Safety Notice(LFP battery)

The battery presents a risk of electrical shock and a high short circuit current. The
Signify mounting instructions must be strictly followed, otherwise potential application,
reliability, or safety issues may arise. Contact your local S i g n i f y service if the
instructions cannot meet special field conditions.
Only a qualified Signif y service representative who is knowledgeable in batteries and
the required precautions is permitted to service the battery. Keep unauthorized
personnel away from batteries.

Danger:
1. Do not short the battery terminals.
2. Do not operate battery beyond published voltage, current and temperature limits;
3. Do not reverse connections(polarity) from charger to battery;
4. Do not incinerate, crush or disassemble battery;
5. Do not over charge or over discharge;

Caution:
1. The misuse of this equipment could result in human injury and/or equipment damage.
In no event will S i g n i f y be responsible or liable for either indirect or consequential
damage or injury that may have resulted from the misuse of this equipment.
2. Use tools with insulated handles to avoid inadvertent shorts.
3. Verify circuit polarities before connecting.
4. Disconnect the charging source and load before connecting or disconnecting the
battery.

Warning:
1. The solar lighting system contains LFP batteries. Lack of preventative maintenance
could reduce the battery's lifetime or even be dangerous. Check the application
environment regularly (lighting performance, PV panel shading).
2. Failure to replace a battery before it becomes exhausted may cause the case to
crack, possibly releasing electrolytes from inside the battery and resulting in secondary
issues such as odor, smoke, and fire.
3. The battery system must be in proper maintenance according to the
"Troubleshooting & Maintenance" manual. This is essential for safety and the reliability
of the lighting system.
4. Do not dispose of LFP batteries except through channels in accordance with local,
state and federal regulations.

Notice: The mounting instructions in this document is for standard solar lighting system
installation. If any large deviation (such as multi systems sharing pole/base/component,
component change, wiring change, installation location change, etc..) from standard
solar lighting system is needed due to special application, it is required to contact with
Signif y representative for special instructions. Otherwise, the deviation from standard
instructions may cause abnormal system operation or even dangerous situation.
1. Battery Box Installation

A1 Installation Preparation
Testing Tool List
Compass and Protractor
The follow tools are necessary. Electrical screw driver
Multimeter
DC clamp meters
Triangular spanner(opens hatch door)
Other tools:
a.Waterproof tape
b.Screw driver
c.Spanner
Note: The tools listed do not include items
needed for pole installation and other d.Diagonal Pliers
construction work. e.Nose Pliers

A2 Installation Preparation

A: 12V Gel Battery Subsystem

Battery cable (-) DC clamp meters

Battery cable (+)

1. The tightness and integrity of

Ventilation tube the battery should be checked
before installation.
2. Carefully check the battery
Thermal sensor cable voltage before installation to
ensure it is more than 12.5V. If
less than 12.5V, field charging is
necessary. (For 24V battery
subsystems, make sure that the
voltage is more than 25V).

B: 24V Gel Battery Subsystem

Battery cable (+) for series connection
Warning:
Battery cable (+) Short circuit must be avoided at
all times during the operation.

Battery cable (-) for series connection

Thermal sensor cable

Ventilation tube

Battery cable (-)

A2 Installation Preparation

C: 12.8V LiFePO4 Battery Subsystem

Battery cable (+)

Battery cable (-)

D: 25.6V LiFePO4 Battery Subsystem

Battery cable (+)

Battery cable (-)

A3 Placing the Battery into Chamber
A: 12V Gel Battery Subsystem & 12.8V/25.6V LiFePO4 Battery

Lay the battery into the chamber carefully.

Battery

Warning:
Do NOT pull the cable or
ventilation tube during installation
and delivery.(For Gel battery).

Do NOT broken the NTC and

connectors during the
installation.

Chamber

B: 24V Gel Battery Subsystem

Warning:
Do NOT pull the cable or
ventilation tube during installation
Battery and delivery.(For Gel battery).

Do NOT broken the NTC and

connectors during the
installation.

Chamber
A4 Laying Battery Subsystem Cables
A: 12V Gel Battery Subsystem
& 12.8V/25.6V LiFePO4 Battery

Lay battery cables, thermal sensor cable,

and ventilation tube penetrating t h e
e mbe dde d duct, pulling them into the
pole from the bottom.

For 12.8V/25.6V LiFePO4 Battery, there

are not ventilation tube and thermal
sensor cable.

B: 24V Gel Battery Subsystem

1. Lay the battery cables, thermal sensor

cable, and ventilation tube penetrating the
embedded duct, pulling them into the pole
from the bottom.
2. Series connect the batteries with one
red cable and one black cable.

Warning:
Series connect the batteries
with MC4 Male(RED cable)
and MC4 Female (Black cable).
B1 PV Panel Subsystem Installation

Single PV Panel

Dual PV Panels

Four PV Panels
B2 PV Panel Connection
Single PV Panel Dual PV panels in Series Mode

1. Connect one panel’s positive terminal to the other

panel’s negative terminal.

Connect panel cables and extension cables.

2. Connect panel cables and extension cables.

Dual PV Panels in Parallel Mode Four PV Panels (Series - Parallel Mode)

1. Group PV A/B in series mode, Group PV C/D in
series mode.

B
A

D
C

1. Connect positive terminals and negative terminals 2. Connect the two PV groups to the 2-to-1
to the 2-to-1 connectors. connectors.
2. Connect the 2-to-1 connectors to extension cable. 3. Connect the 2-to-1 connectors to extension cable.
B3 Pull the Cable through the Panel Bracket (Dual PV panels as example)
Philips connector size:

Pull the cable through

the hole on the panel Warning:
bracket 1. The hole size must be more than
Ø40 mm.
2. Cutting the cable connector will
breach the warranty and may cause
water ingress, cable short circuit, or
even safety issues. (If the cable length is
not long enough, an extension cable is
available for order)
3. Do NOT seal the hole after cable
installation.

Note：The way the cable goes into the bracket may be different due to the actual design.

B4 Mark the Angle between True South and Arm

Ensure the arm is

Road perpendicular to the road side

1. Measure the angle (a) between

true south and arm
(facing south for the northern
hemisphere and facing north for
True south the southern hemisphere)

2. Draw a mark by using pen on the pole where facing

the true south (a).（Please notice the angle direction）
B5 Draw a Mark on the PV Panel Bracket

On the PV panel bracket, draw a mark

on the side facing the panel

B6 PV Panel and Luminaire Fixation Preparation

Put a pad (such as a wooden box)

underneath the pole for easy
installation and protection.
B7 Test Voltage of PV Panels and Lay the Cable
1. Measure the voltage of the PV Panels and
ensure the value is within 10V-45V. If the
value is less than 10V or above 45V, the PV
panel has a problem and it cannot be
installed (make sure that the PV panel is
under sunlight and is not covered by
anything ).

2. Pull the cable through the pole

(Dual PV panels as example)

B8 Mount the PV Panel Bracket

Mount the PV panel

bracket into the pole.

(Dual PV panels as example)

 B9 Adjust the PV Panel Angle
Adjust the PV panel bracket and
align the marks on the PV panel
bracket and pole.

PV panel support mark

Pole mark

Rotate the PV
panel bracket

(Dual PV panels as example)

B10 Affix the PV Panel Bracket

Tighten the bolts and make sure that

the PV panel bracket has been Affixed.

(Dual PV panels as example)

3. Luminaire System Installation

C1 Mount Luminaire (Dual PV panels as example)

It is recommended to check the luminaire,

connector, and wire appearance before
installation.

Pull the luminaire cable through the pole.

Warning:
1. Make sure that the cable connector
can pass through the narrowest part of
the pole (more than Φ40mm).
Philips Connector size: 2. Cutting the cable connector results
in a breach of the warranty and may
16.5
53.6 cause water ingression, cable short
circuit, or even safety problems.
16.5

C2 Luminaire Fixation

Mount the luminaire and adjust the

installation angle to m a k e sure it Is
unbiased. Tighten screws.
(The fixing torque request is different
depend on the diff erent luminaire,
please follow the luminaire MI.)
4. Pole and Controller System Installation (Dual PV panels as example)

D1 Erect the Pole Solution 2：By crane

Warning: Be careful
that the luminaire
and PV panel don't
hit the crane arm.

Lift by crane

Solution 1：By man-power

Press the bottom

of t h e pol e f o r
positioning.

Pull

For reference only

Affix the pole

Push by man-power

Press the bottom

of t h e pol e f o r
positioning.

Note:
Whoever insta lls the syste m
takes full responsibility for safety.

For reference only For reference only

D2 System Connection---
OCU 600W MPPT COMBO CC
1.Connect the luminaire to the Combo CC first.
2.Connect the Battery to the Combo CC, Please note
the positive and negative.
OCU MPPT 3.Connect the PV panel to the Combo CC, Please note
Combo CC Connect to RMU
（Option） the positive and negative.
4.Connect thermal sensor from battery to Combo
CC;(only for Gel battery)
Luminaire 5.Connect the RMU to the Combo CC。（Optional）

PV
Panel
Vent tube
(only for Gel battery)

+ -
Battery
Warning: The thermal sensor must be connected well,
otherwise the battery will be damaged, potentially
causing a dangerous situation.
System Connection---
OCU 200Wp & 400Wp MPPT Combo CC

Connect to RMU
（Option）
200Wp & 400Wp 1.Connect the luminaire to the Combo CC first.
MPPT Combo CC 2.Connect the Battery to the Combo CC, Please note
the positive and negative.
3.Connect the PV panel to the Combo CC, Please note
the positive and negative.
4.Connect thermal sensor from battery to Combo
CC;(only for Gel battery)
Luminaire 5.Connect to the Hybrid Controller。（Optional, only
for 200W/400W).
PV Panel 6.Connect the RMU to the Combo CC。（Optional）

Vent tube
Hybrid Charge
(only for Gel battery)
Controller (Option)

+ - Warning: 1. If there is no AC connection, the warranty

will be breached, the battery's lifetime reduced, and the
system's performance will be downgraded.
2. The thermal sensor must be connected well,
Battery otherwise the battery will be damaged, potentially
causing a dangerous situation.
 System Connection---
HCU Gen4 MPPT Combo Charge Controller

1.Connect the PSU to the HCU First;

HCU 2.Connect the luminaire to the HCU;
PV Panel
3.Connect the Battery positive cable to HCU;
4.Connect the Battery negative cable to HCU;
5. Connect the PV panel to the HCU;
6.Connect thermal sensor from battery to HCU;(only
for Gel battery)
7. Connect the AC grid to the Hybrid charge controller.
To AC Luminaire

Vent tube
(only for Gel battery)

+ - Warning: 1. If there is no AC connection, the warranty

will be breached, the battery's lifetime reduced, and the
system's performance will be downgraded.
Battery 2. The thermal sensor must be connected well,
otherwise the battery will be damaged, potentially
causing a dangerous situation.

System Connection---
200Wp & 400Wp MPPT Combo CC + Hybrid Charge Controller

Connect to RMU 1.Connect the luminaire to the Combo CC first.

（Option） 2.Connect the Battery positive cable to “Y-harness 2 to
1” and then connect it to the Combo CC and Hybrid
charge controller,
3.Connect the Battery negative cable to “Y-harness 2 to
200Wp & 400Wp Hybrid Charge 1” and then connect it to the Combo CC and Hybrid
MPPT Combo CC To AC Grid
Controller charge controller,
4. Connect the PV panel to the Combo CC, Please note
the positive and negative.
5 .Connect thermal sensor from battery to Combo
Lumi CC;(only for Gel battery)
PV Panel
naire 6. Connect Hybrid signal cable to combo CC。
7. Connect the AC grid to the Hybrid charge controller
8.Connect the RMU to the Combo CC。（Optional）

Vent tube
(only for Gel battery)

Warning: 1. If there is no AC connection, the warranty

+ - will be breached, the battery's lifetime reduced, and the
system's performance will be downgraded.
2. The thermal sensor must be connected well,
Battery
otherwise the battery will be damaged, potentially
causing a dangerous situation.
D3 System Testing

PV panel cable
(black)

After installing during the daytime, use a clip-on

current meter to test the charge current. If
sunlight is normal, a current value above 0.5A
means the charge loop is fine. Disconnect the PV
panel and wait for 10 minutes. If the luminaire
turns on, it means that the discharge loop is fine
(you can also use hand-held terminal testing
system).

600W OCU MPPT Combo CC

LED indicators:

LED Light Indicators Status Descriptions

Steady on Solar panel voltage is higher than light control voltage
Off Solar panel voltage is lower than light control voltage
Slow flash In charging
BMS protection or full charge
PV indicator
Or BAT overvoltage
Quick flash Or PV overvoltage
Or over temperature (Ambient temperature)
Or limited current charging
Steady on Battery works properly
Battery is not connected
BAT indicator Off
Or lithium battery over discharge protection
Quick flash Battery over discharge
Steady on Load is turned on
Off Load is turned off
LOAD indicator
Slow flash Load open circuit
Quick flash Load short circuit

200W/400W OCU MPPT Combo CC

LED indicators:

Indicators Status Description

LED Blinking 1 Sec ON/off Battery Charging Normal Charging
LED Blinking 0.5 Sec ON/off (Green/orange as per design)) Battery Recovery (LFP)
2 LEDs No Indication Battery Discharging/LED Load ON
Red LED ON for 800mSec and Off for 5 Sec Battery Deep Discharge cut off
Both LED Green/Orange & Red blinking @ 1 sec rate Any fault in system
D4 Ventilation Tube Fixation
2. The open end of the ventilation
tube must be installed 500mm higher
than the charge controller;(only for
Gel battery)
1. Bend the end of the tube and affix it
with a tape to prevent water ingress. You
must affix the tube with a round avoid
deformation, damage, or block ventilation,
otherwise potential safety issues may arise.
(Only for Gel battery)

3. Use bonding tape to affix the tube with

Luminaire cable or PV cable;
(Only for Gel battery)

4. Fix the Controller in the service hatch.

5. Installation Completion

E1 Close the Service Hatch

triangle

E2 Backfilling
Warning: Buying the battery
directly into soil is not recommend

2. Restore the ground to its

original appearance
1. Close the lid of
battery pit

Anti-theft depending on customer needs