Dumpmaster - Retrofit solar panel kit

Modified on 09/12/2024 4:05 pm NZDT

How to retrofit a solar panel kit to a Simpro Dumpmaster bin lifter.

Part required

  1. 1x Dumpmaster Solar Power Kit (🧩0090040077)
    • 1x Solar Controller, 30A
    • 1x Solar Panel, 36V/80W polycrystalline
    • 1x Solar Panel Mounting H-Bracket (usually pre-mounted onto solar panel)
    • 1x Solar Panel Mounting T-Bracket
    • 1x 12mm cable inlet gland
    • 1x 2-core flex cable, red/black, 6m long
    • 1x Male PV Waterproof Connector, 4mm
    • 1x Female PV Waterproof Connector, 4mm
    • 2x crimp connectors
    • 1x M12x80 hex bolt, with flat washer and nyloc nut
    • 2x M8x65 hex bolts, with flat washers and nyloc nuts
    • 4x M5x10 Pozidriv screws, with flat washers and nyloc nuts

Tools required

  • Phillips and Flathead screwdrivers
  • Ladder or other height-access equipment
  • Permanent marker (Vivid, Sharpie or similar)
  • Electric hand drill and bits
    • 5.0mm drill bit
    • 8.5mm drill bit
    • 10.5mm drill bit
    • 12.0mm tap bit
  • Wrench and socket set or spanners
    • 1x 8.0mm spanner
    • 2x 13.0mm spanners
  • Needle-nose pliers or crimper
  • Zip-ties

Procedure

  1. Turn the isolator switch OFF, remove the powerpack cover using a Phillips screwdriver, and disconnect the battery cables.
  2. Access the top of the mast using a ladder or other height-access equipment.
  3. Mark and drill the mounting holes and cable inlet hole.
    1. Place the T-bracket onto the top cross-member, halfway between the masts, on the side closest to the door.
    2. Mark the locations of the two mounting holes with a permanent marker.
    3. Mark the location of the cable inlet hole, approximately 50mm past the edge of the T-bracket, on the side furthest from the hydraulic ram (the ram is usually located beside the powerpack and control panel).
    4. Drill out the two mounting holes (through both sides of the cross-member) using an 8.5mm drill bit.
    5. Drill out the cable inlet hole (through the upper side of the cross-member only) using a 10.5mm drill bit, then thread the hole using a 12.0mm tap bit.Mark and drill the mounting holes and cable inlet hole
  4. Mount the T-bracket with two M8x65 hex bolts, flat washers and nyloc nuts.
  5. Install the 12mm cable inlet gland.Mount the T-bracket and insert the cable inlet gland
  6. Remove both mast covers using an 8.0mm spanner, and remove the chain-guide access cover using a Flathead screwdriver.Remove both mast covers and the chain-guide access cover
  7. Run the 2-core flex cable through the cable inlet gland and down the mast. Neatly secure the cable with zip-ties.
    Run the solar power cable through the cable inlet hole and down the mast
  8. Run the 2-core flex cable cable into the hole in the base frame, and through the base RHS cross-member.Run the power cable through the hole at the base of the mast and through the bottom frame cross-member
  9. Run the 2-core flex cable cable up into the powerpack enclosure. Neatly secure the cable with zip-ties.
    Run the power cable up into the powerpack enclosure
  10. Mount the solar controller inside the powerpack enclosure.
    1. Place the controller against the inner panel in the available space below the batteries.
    2. Mark the locations of the four mounting holes with a permanent marker.
    3. Drill out the mounting holes using a 5.0mm drill bit.
    4. Mount the controller with four M5x10 Pozidriv screws, flat washers and nyloc nuts.
  11. Connect the the 2-core flex cable to the solar controller inputs with crimp connectors, making sure the polarity is correct. The controller inputs are labelled SOLAR.

    Be sure to connect the red wire to the positive terminal, and the black wire to the negative terminal.

    Mount the solar controller and connect the two-core power cable
  12. Connect the solar controller output wires to the positive and negative battery terminals (just behind the isolator switch), ensuring correct polarity. The output wires are labelled BATT.Connect the solar controller output wires to the positive and negative battery terminals
  13. Reconnect the battery cables on top of the solar controller wires, again ensuring correct polarity. Tighten the terminal nuts.Reconnect the battery cables on top of the solar controller wires

    The solar controller should now power-on and display the battery voltage.

  14. Mount the solar panel.
    1. Lift the panel into place and align the H-bracket and T-bracket mounting holes.
    2. Insert a M12x80 bolt through the mounting holes, and secure with a flat washer and nyloc nut.
    3. Adjust the panel to a horizontal position, then tighten the nyloc nut.Mount the solar panel onto the T-bracket
  15. Connect the solar panel output wires to the 2-core flex cable using the supplied PV Waterproof Connectors, ensuring correct polarity. Neatly secure the cable with zip-ties.
    Connect the solar panel output wires to the two-core power cable
  16. Replace the removed covers and tighten all fixings.Neatly secure the cabling with zipties, replace all removed covers, and tighten all fixings
  17. The solar panel is now connected and ready to use. Place the machine in a sunny location and adjust the angle of the panel to get maximum direct sunlight as per §3.4.8 of the User Manual.

The panel output varies with available light, but will put out over 6 Amps in full light, allowing the 20Ah battery to be recharged in 3-4 hours. The controller will automatically turn off once full charge is reached. The mains charger is still connected and can be used at the same time or as back-up in case of insufficient sunlight.