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G Series
AC TO SOLAR RETROFIT GUIDE
For all AC powered G Series systems
89321_RETROFIT_GUIDE_AC_TO_SOLAR_G_SERIES_REVB
Carmanah Technologies Corp. | 250 Bay St, Victoria, BC V9A 3K5, Canada | 1.250.380.0052 | [email protected]
| carmanah.com
AC TO SOLAR RETROFIT GUIDE
Table of Contents
Carmanah Technologies Corp. | 250 Bay St, Victoria, BC V9A 3K5, Canada | 1.250.380.0052 | [email protected]
| carmanah.com
2
AC TO SOLAR RETROFIT GUIDE
1.0 Warnings and Precautions
The following symbols indicate important safety warnings and precautions throughout this guide:
WARNING indicates that serious bodily harm or death may result from failure to adhere to the precautions.
CAUTION indicates that damage to equipment may result if the instructions are not followed.
NOTE suggests optimal conditions and provides additional information.
1.1 Warranty Disclaimer
This guide will familiarize you with the features and installation of Carmanah's AC to solar retrofit kit. Failure to comply with the use, storage, maintenance, installation or placement instructions detailed in this guide could void the warranty.
1.2 Standards
Perform all installation, wiring, grounding and maintenance in conformance with local building and electrical codes. Adherence to the National Electrical Code (NEC) is mandatory to comply with any certification markings.
Non-adherence to code may void the warranty.
1.3 Safety and Usage Precautions
Use extreme caution when handling the batteries as they can generate hazardous short-circuit currents. Remove all jewelry (bracelets, metal-strap watches, etc.) before entering the cabinet.
Before lifting any heavy or bulky equipment, ensure the load is secured so moving parts do not shift, and that it can be lifted as far as needed without back strain or loss of grip. Installation may require more than one person.
Ensure the equipment is not powered during installation and wiring of the system.
Recheck all completed wiring for proper polarity prior to energizing the system.
3 Carmanah Technologies Corp. | 250 Bay St, Victoria, BC V9A 3K5, Canada | 1.250.380.0052 | [email protected]
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AC TO SOLAR RETROFIT GUIDE
Changes or modifications to Carmanah equipment not expressly approved by Carmanah could void both the user's authority to operate the equipment and the warranty.
All Carmanah traffic products use a constant-current LED output circuit. Not all traffic beacons are compatible with this output. Please contact Carmanah for additional information and guidance when adding or replacing beacons or other hardware.
This guide is specific to retrofitting the G Series cabinet from AC to solar power and is not a replacement for the complete G Series product user manual.
Visit carmanah.com
to download the complete product user manual.
Carmanah Technologies Corp. | 250 Bay St, Victoria, BC V9A 3K5, Canada | 1.250.380.0052 | [email protected]
| carmanah.com
4
AC TO SOLAR RETROFIT GUIDE
2.0 AC to Solar Retrofit Kit
Carmanah Part #
84594
N/A
N/A
N/A
N/A
N/A
N/A
Varies
Varies
Varies
Varies
Description
Solar Kit, G Series
Harness, Battery to Fuse Holder and Terminal Block, G Series
Cable Tie, 4 Inch
Battery Bumpers
Cable Tie, 4 Inch
Fuse, 15A, Littelfuse 3AB
Label, Product ID, G Series, Solar
Battery (size varies)
Solar Panel (size varies)
Solar Panel Mount (size and type vary)
Solar Panel Harness (length varies)
Quantity
2
1
6
2
1
1
2
1
1
1
1
Carmanah Technologies Corp. | 250 Bay St, Victoria, BC V9A 3K5, Canada | 1.250.380.0052 | [email protected]
| carmanah.com
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AC TO SOLAR RETROFIT GUIDE
3.0 Installation Procedure
This guide is for installing the AC to solar retrofit kit into one of the following compatible Carmanah systems:
System Release
G Series
•
SC315-G
•
R820-G
•
R247-G
•
R829-G
Current
Refer to the individual product user manual for more details at carmanah.com
. There are many different options available for the G Series cabinet so your product may look different than shown throughout this guide.
G Series AC Cabinet Example
Carmanah Technologies Corp. | 250 Bay St, Victoria, BC V9A 3K5, Canada | 1.250.380.0052 | [email protected]
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AC TO SOLAR RETROFIT GUIDE
3.1 Removing AC Components
1. Access the inside of the power cabinet and switch the circuit breaker to the off position. Isolate the AC power at the source so it is no longer feeding the cabinet.
2. Remove the DC power and solar (spare DC power fuse) fuses from the DC input power terminal.
3. Remove the DC power wires (red and black) on the right side of the cabinet.
4. Remove the AC input wires from the terminal blocks (line, neutral, and ground). Cap them off to with wire nuts.
Carmanah Technologies Corp. | 250 Bay St, Victoria, BC V9A 3K5, Canada | 1.250.380.0052 | [email protected]
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AC TO SOLAR RETROFIT GUIDE
5. Remove the four screws securing the AC backplane and remove from the cabinet.
6. Ground wire from the buss bar: a. If you have the optional Polara XAV push button controller installed on the left side of the cabinet, disconnect the ground wire from the buss bar and secure it to one of the nearest grounding screws. It is recommended to terminate with a ring terminal. b. If you do not have the optional Polara XAV push button, remove the ground wire from the system.
There will be a ground wire that remains from the cabinet door to the inner cabinet.
3.2 Installing Battery Bumpers and Harnessing
1. Prep the surface of the inner cabinet with isopropyl alcohol and mount the 6x battery bumpers in the locations outlined below:
Carmanah Technologies Corp. | 250 Bay St, Victoria, BC V9A 3K5, Canada | 1.250.380.0052 | [email protected]
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AC TO SOLAR RETROFIT GUIDE
2. Install the battery harness to the DC Input Power terminal (red = positive, black = negative). The ring terminal ends will be secured to the battery at the end of this document.
3.3 Installing Solar Panel, Mount, and Harness
1. Refer to Section 3.3 in the G Series manual (pages 20-26) for solar panel and mount installation. The G
Series manual can be found on the Carmanah website - https://carmanah.com/support/productdownloads/ . a. Top of pole mounts (45W and 80W panels only) will contain a plastic pole cap. Systems located in Miami-Dade County will require a metal cap. Please contact Carmanah for more information.
2. Connect the solar harness to the Solar portion of the DC Input Power terminal (red = positive, black = negative).
3.4 Installing Battery and Final Connections
1. Install the solar product label above the previous label(s) on the user interface plate. Ensure the surface is cleaned with isopropyl alcohol and is dried before applying the label. a. In 2020 Q3 Carmanah changed to a separate label for the serial number/product ID. Ensure this label isn’t covered or replaced as the original serial number is vital to reference for configuration purposes. You can cross out the AC system ratings that are on the existing label.
2. Install the battery into cabinet with terminals towards you.
3. Install ring terminal on red battery wire to positive (+) battery terminal. Install ring terminal on black battery wire to negative ( −) battery terminal.
4. Insert the battery and solar fuses.
5. Ensure the EMS (Energy Management System) powers up. a. If the EMS does not power up, verify the battery fuse is not blown and the solar polarity is not backwards.
Carmanah Technologies Corp. | 250 Bay St, Victoria, BC V9A 3K5, Canada | 1.250.380.0052 | [email protected]
| carmanah.com
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AC TO SOLAR RETROFIT GUIDE
6. Test system and ensure it is operating as prior to the retrofit. a. Ensure the solar voltage (solr) is between 15-20V. b. Run the BIST (built-in self-test) and verify there are no errors, in particular the charging error
(4000). c. Let the system charge for a few minutes and confirm battery voltage rises under the battery (batt) status. For 24/7 beacon systems you may need to temporarily change the input (inpt) to NO
(normally open) so the system isn’t under a constant power draw
Carmanah Technologies Corp. | 250 Bay St, Victoria, BC V9A 3K5, Canada | 1.250.380.0052 | [email protected]
| carmanah.com
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AC TO SOLAR RETROFIT GUIDE
© 2021 Carmanah Technologies Corporation
Technical Support:
Email: [email protected]
Toll Free: 1.877.722.8877 (US & Canada)
Worldwide: 1.250.380.0052
Fax:
Web:
1.250.380.0062 carmanah.com
Carmanah Technologies Corp. | 250 Bay St, Victoria, BC V9A 3K5, Canada | 1.250.380.0052 | [email protected]
| carmanah.com
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