Replace Solar Regulator in SP-Series Solar Power Pack

Solar regulator replacements do not follow a regular maintenance schedule. Regulator failures are rare and may only be necessary if improper charging behavior is observed:

  • Weak or no charging response on unloaded battery with clean panel in direct sunlight.
  • Excessively high charging voltages on the battery (significantly greater than 15V).

Should a regulator require replacement, contact NexSens to source a SA3018 solar regulator and then proceed.

  1. Remove the solar pack from its mounting location and place it on a flat work surface.
    1. Typically the easiest means of removing the solar pack is to remove both socket head cap screws from the angle adjustment bracket using a 3/16″ hex driver.

The angle adjustment screws are connected to the pole mount bracket.


  1.  Loosen the four screws securing the battery housing to the panel mount using the same 3/16″ hex driver.

Loosen enclosure screws using 3/16″ hex driver.


  1. Carefully lift up on the enclosure and set the housing to the side.  Avoid placing tension on the connected solar panel cable as it is moved.

Carefully invert enclosure to access battery and solar regulator assembly.


  1. Remove the battery from the enclosure and disconnect the negative and positive cable leads.

Remove old battery.


  1. Locate the two Molex connectors linking the regulator to the solar panel and the UW-6 pigtail, respectively, and disconnect both.

Disconnect the old solar regulator Molex connectors.


  1.  Connect the new regulator such that:
    1. The yellow & black regulator cable pair connects to the solar panel lead.
    2. The red & black regulator cable pair connects to the UW-6 plug lead.
    3. The black wires from both pairs of connectors align.

Regulator assembly connection.


  1. Re-connect the leads to the  battery and carefully place it back inside the housing. Ensure none of the cabling is pinched.

Install new battery. Verify no cables are pinched between the battery and housing.


  1. Replace the small bag of desiccant in the enclosure.

Replace desiccant bag.


  1. Verify the panel bracket’s O-ring is free from debris and damage and is seated properly in its groove.

Verify panel bracket O-ring alignment before closing.


  1. Re-align the battery enclosure with the solar panel mount and tighten down the four screws evenly using a 3/16″ hex driver.

Tighten enclosure screws using 3/16″ hex driver.


  1. Check the pack voltage to verify the battery is properly connected.
  2.  Place the pack outdoors exposed to sunlight for a couple of hours and compare the starting and ending voltages to confirm the system is charging properly.