Solar street lighting systems require strong protection from environmental conditions like rain (monsoons), wind, cold, and hot temperatures as well as from vandalism and theft. However, finding the proper enclosure to provide that protection in locations with those challenging conditions presented many obstacles to many solar street lighting projects across India. At IDIS India, we manufacture custom solar street light enclosures specifically designed for the challenging outdoor/indoor environments of India. The I-closure product line from IDIS India includes IP65 and IP67 rated enclosures made from polycarbonate materials, providing excellent protection for the crucial components of the solar street lights (LED drivers, photocell sensors, and battery management systems). Since 2017, we have partnered with system integrators and EPCs throughout Gujarat and elsewhere in India to address the challenges of protecting their solar street lighting systems through our line of I-closures. That means that we have over 300 different size configurations available, so whatever the size of your solar street lights is, there is an I-closure solution that will meet your unique application needs.
Street Pole Mounting Integration Solutions
Installing a solar street light on a pole can be challenging. Long-term reliability of your street lights will be impacted by wind loads, vibrational forces, and thermal expansion. The hardware we use in our vertical pole-mount brackets is SS304 stainless steel and will not corrode or loosen over time.
Our pole-mount bracket assembly accommodates a range of pole diameters from approximately 76mm-200mm; this does vary based on the specific required mounting configuration. One thing that most manufacturers have overlooked is the proper routing of wiring inside the enclosure. Our enclosures are designed to include pre-determined cable entry points to match the existing streetlight pole configurations, eliminating the need for costly and time-consuming field modifications that may compromise the IP rating of the fixture.
In addition to our pole-mount assemblies, we also provide wall-mount assemblies for attaching an inverter where pole mounting isn’t feasible. In addition to the mounting options, our wall-mount assemblies typically include additional vibration dampening characteristics.
Nighttime Thermal Cycling Management
One of the key features that street lights must endure is thermal cycling; they undergo this every single day. LED drivers produce heat during operation, but when turned off they can cool down rapidly. The constant expansion and contraction of the seals around the enclosure can create problems with condensation. Therefore, how do you mitigate moisture using fine IP ratings? I-closure enclosures utilize ventilation strategies to provide thermal management with protection. Polycarbonate maintains its flexibility from approximately -40C to +85C based upon the specific material grade selected. Louvers can be added to promote additional cooling for applications in need. The venting still allows for IP65 protection but provides a controlled flow of air.
Condensation Prevention Features
Internal condensation can severely damage electronics more rapidly than if moisture reaches the electronic device from the outside. Our equipment boxes have been designed to help reduce/eliminate the possibility of internal condensation forming within them: Internal surfaces sloped to promote water runoff; Materials chosen to minimize thermal-related expansion/contraction; Optional desiccant holder location; Suitable for fitting of breather valves to control pressure differences.
Solar Panel Wiring Feedthrough Design
To manage DC wiring from solar panels to street lighting enclosures, proper planning is necessary. The failure to properly manage the cable can lead to water ingress, degradation of cabling due to UV exposure, and unnecessary maintenance. Pre-drilled mounting points for cable glands are included in our solar powered, street light enclosures. There are usually two size options for the cable gland, M20 and M25; in addition to the standard sizes we also offer PG threaded cable glands for use outside of North America. The cable routing is not limited just to the entry points. The internal design must allow space for DC combiner boxes, fuses, surge protection devices (SPD’s), and battery connections—all while preventing interference between devices or overheating. All enclosures designed by IDIS India are designed to provide separate compartments within each enclosure for each separate function. Therefore, DC input wiring will not be routed near AC output connections thus reducing electromagnetic interference and making the installation safer.
String Combiner Integration
String combiners are used to combine the inputs from multiple solar panels (i.e., multiple solar street lighting units) into a single cable/feeder that connects to the inverter. Enclosures for these types of string combiners must accommodate the various sizes of string combiners as well as provide access for maintenance.
Common configurations are as follows: – 4-string combiners in approximately 300 x 200 x 150mm enclosures – 8-string combiners in approximately 400 x 300 x 200mm enclosures – ACDB/DCDB combination enclosures in approximately 500 x 400 x 250mm enclosures
Note: These dimensions are approximate. Please contact IDIS India for an exact specification of the enclosures based on the specific equipment used for your string combiners.
Public Access Vandal Protection
All people can access the street lights however, this means that there are people that will purposely create damages to them. Also, you need to have enclosures that can withstand accidental impacts and purposefully created damage whilst maintaining the ability to function properly. Polycarbonate is much better in impact resistance than metal will ever be, as it will not dent, rust and there is no way to create holes to gain unauthorized access to the enclosure. Most applications have a standard quarter-turn latch as a lock; however, if you are in a high security area, you will also need to consider using different types of locks. Most of our enclosures can accommodate a variety of types of locking systems depending upon your needs. Additionally, if you want to detect unauthorized access to the street light component during routine maintenance of the street light, you can add tamper-indicating seals to the inside of the enclosure.
Graffiti and UV Protection
Graffiti and UV exposure damage the look and function of public installations. I-closure polycarbonate formulations use special UV stabilizing chemicals to help prevent yellowing and brittleness. Their smooth exterior keeps graffiti from sticking and makes it easy to remove with ordinary solvents. The result is a professional-looking installation for its entire life.
LED Driver Heat Dissipation Requirements
A lot of heat is produced by the LED drivers and must be dissipated for long-term dependability. If not, then thermal management will result in a reduction of LEDs’ operational lifespan with associated colour change and unplanned failures. But, how much heat? LED drivers for higher watt power street lights can produce 20 to 50 watts of waste heat depending on both the driver and load efficiencies. This waste heat has to ultimately be evacuated elsewhere. Our enclosures have thermal management features such as: heat sink mounting locations; ability to be integrated with a cooling fan; ability to accommodate thermal interface materials; an optimized strategic placement of ventilation holes; and an internal air circulation pattern for hot air displacement away from the more sensitive components while maintaining IP protection.
Thermal Modeling and Testing
Through the use of thermal analysis for critical applications, IDIS India ensures that there are sufficient heat-dissipation methods available. Our NABL accredited test facility validates thermal performance through testing under different loading conditions. Testing can include temperature mapping of enclosures at different ambient and load conditions, which allows designers to optimize the enclosure specifically for that driver configuration.
Municipal Installation Standards Compliance
For municipal street lighting projects, it is essential that they meet local codes and regulations as well as state and federal standards. Projects that do not meet these requirements will delay approval and increase the overall cost of the project. I-closure enclosures meet applicable standards for solar powered lighting systems that are set forth by the Indian Standards Institute’s IS 16103 for solar powered lighting systems. We are CE certified and RoHS compliant, which supports our ability to meet international project requirements. However, compliance to all standards is more than having basic certifications. The following items influence enclosure design and compliance: installation requirements; means of access; identification marking system; and maintenance requirements. Many municipalities will specify the required mounting height(s) for lighting; access to the light fixtures; and identification marking system. Our enclosures fulfill each of these needs, without compromising the protection or function of the enclosure.
Documentation and Certification Support
There is a lot of documentation necessary for local municipal projects such as materials certificates, test reports and compliance declarations. To facilitate the project approval process, IDIS India provides complete documentation packages. Our ISO 9001 quality management system guarantees documentation consistency and traceability from the outset of manufacturing.
Photocell Sensor Window Design
Automatic street light control systems are components that consist of photocell light sensors, which detect the presence of ambient light and require a clear line-of-sight to the sky, while at the same time, provide some degree of protection from the elements and from tampering. The photocell sensor window design can significantly affect the sensor’s performance and long-term reliability. A poor window design can result in a falsely detected on/off switch condition, early sensor failure and/or protection from a sense of enclosure being lost. The enclosures we provide for our solar-powered street lights have the option to have a photocell sensor mounted in a designated location with a window designed for this application. The window will be made from a material that provides the sensor with an unobstructed view of the light source and that maintains good optical clarity while also providing UV protection. The position of the photocell window will be determined based on the sensing requirements of the sensor and the potential for obstruction to be created by the mounting hardware or by the route in which the photocell cable is routed; therefore, providing a reliable means of automatic operation for the duration of the installation’s service life.
Sensor Integration Options
Photocell sensors vary in their mounting, wiring and connection configuration. Our enclosures can accommodate: Top-mounted photocell sensors with a clear view to the sensor on the top Side-mounted photocell sensors (to meet particular needs) Integrated sensor housing (with IP rated connection) Replaceable mounting systems for photocell sensors Custom mounting solutions for photocell sensors may be available based upon specific project needs.
Why Choose I-closure for Solar Street Lighting
Enclosure failure is a major concern for all solar street light projects. When protection systems fail, it puts an entire lighting installation in the dark, creating a public safety hazard and a maintenance emergency. IDIS India understands the critical importance of street lighting infrastructure. Our manufacturing facility in Ahmedabad produces enclosures purpose built to address the unique climate challenges of India, while also adhering to rigorous international quality standards. With a typical active customer base of 1,200+ and a workforce of over 100 employees, we have the capacity to support both small municipal projects as well as large-scale deployments. Please contact IDIS India today to discuss your specific requirements for solar street light enclosures. Our technical team would be happy to work with you to help specify the correct I-closure solution for your specific application requirements.
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