Carmanah E Series, R247-E, R829-E, R920-E User Manual

E Series

TRAFFIC BEACON USER MANUAL

84322_MANUAL_TRA_E-Series_RevA

Carmanah Technologies Corp. | 250 Bay St, Victoria, BC V9A 3K5, Canada | 1.250.380.0052 | [email protected]

| carmanahtraffic.com

E SERIES USER MANUAL

TABLE OF CONTENTS

Table of Contents

1.0

Warnings and Precautions ..........................................................................................................................4

1.1

Warranty Disclaimer ...................................................................................................................................4

1.2

Standards ...................................................................................................................................................4

1.3

Safety and Usage Precautions ...................................................................................................................4

2.0

How to Use this Manual ...............................................................................................................................7

2.1

How to Set Up the R920-E .........................................................................................................................7

2.2


2.3


2.4


3.0 Introduction .........................................................................................................................................................9

3.1

About the E Series ......................................................................................................................................9

3.2

Radio Communication ................................................................................................................................9

3.3

R920-E: Pedestrian Crosswalk with RRFB Light Bars ............................................................................ 10

3.4

R820-E: Pedestrian Crosswalk with Circular Beacons ............................................................................ 12

3.5

R829-E: School Zone Flashing Beacon .................................................................................................. 13

3.6

R247-E: 24-Hour Flashing Beacon .......................................................................................................... 15

3.7

RRFB Light Bars: Overview ..................................................................................................................... 16

3.8

Circular Beacons: Overview .................................................................................................................... 16

3.9

LED Signs: Overview ............................................................................................................................... 19

3.10

General Wiring Information ...................................................................................................................... 20

3.11

Third-Party Devices ................................................................................................................................. 21

4.0 Installation ........................................................................................................................................................ 22

4.1

Tools and Materials Required .................................................................................................................. 23

4.2

Solar Engine Installation .......................................................................................................................... 23

4.3

Integrated Solar Engine/Beacon Installation ........................................................................................... 25

4.4

RRFB Light Bars Wiring Diagram (for the R920-E) ................................................................................. 32

4.5

RRFB Light Bars Installation (for the R920-E)......................................................................................... 33

4.6

Circular Beacons Wiring Diagram (for the R820-E, R829-E, and R247-E) ............................................. 39

4.7

Circular Beacons Installation (for the R820-E, R829-E, and R247-E) .................................................... 41

4.8

Push Button Installation (for the R920-E and R820-E) ............................................................................ 44

4.9

Battery Installation ................................................................................................................................... 46

4.10

Override Box Installation.......................................................................................................................... 50

5.0 EMS Programming and Testing ..................................................................................................................... 51

5.1

EMS On-Board User Interface Operation ................................................................................................ 51

5.2

R920-E Programming .............................................................................................................................. 64



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TABLE OF CONTENTS

5.3

R820-E Programming .............................................................................................................................. 65

5.4

R829-E Programming .............................................................................................................................. 65

5.5

R247-E Programming .............................................................................................................................. 65

6.0 Commissioning ................................................................................................................................................ 66

7.0 Maintenance and Product Care ...................................................................................................................... 67

7.1

Fuse Replacement ................................................................................................................................... 67

7.2

Battery Replacement ............................................................................................................................... 68

7.3

EMS Replacement ................................................................................................................................... 68

7.4

EMS Recycling ........................................................................................................................................ 70

8.0 Troubleshooting .............................................................................................................................................. 71

8.1

BIST Error Codes .................................................................................................................................... 72

9.0 Customer Service and Warranty .................................................................................................................... 74

9.1

Additional Products .................................................................................................................................. 74

9.2

Glossary ................................................................................................................................................... 75



3

1.0 Warnings and Precautions


WARNINGS AND PRECAUTIONS

The following symbols indicate important safety warnings and precautions throughout this manual:

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 manual will familiarize you with the features, operation standards, and installation of Carmanah's E Series of flashing beacons. Failure to comply with the use, storage, maintenance, installation or placement instructions detailed in this manual 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

Batteries are shipped fully charged. Use extreme caution when handling the batteries as they can generate hazardous short-circuit currents. Remove all jewelry (bracelets, metal-strap watches, etc.) before handling the batteries.

Solar panels produce DC electricity when exposed to light and can therefore produce an electrical shock or burn. To render solar panels inoperative, remove them from sunlight or fully cover their front surface with an opaque material.

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.



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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.

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.



5

EMS



E Series

Solar Engine

Mounting Adapters

RRFB Light Bars, Circular

Beacons, LED Signs

Pedestrian

Push Button



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HOW TO USE THIS MANUAL

The E Series Universal Mount adapter (shown below) also allows mounting of the E Series on 2.0”-2.5” perforated square poles and 2.38”-2.88” diameter round poles.

2.0 How to Use this Manual

This manual contains information on all four E Series flashing beacons: the R920-E, R820-E, R829-E, and R247-

E. To figure out what sections to consult when setting up your E Series product, use the guide corresponding to your product below to find the appropriate sections to follow.

2.1 How to Set Up the R920-E

If you are setting up the R920-E, consult the following the sections in the order below:

• 3.3 R920-E Overview and Typical Configurations, Page 10-11

• 3.7 RRFB Light Bars: Overview, Page 16

• 3.9 LED Signs Overview, Page 19-20 (if installing LED Signs)

• 4.0 Installation, Page 22 (follow instructions here)

• 5.2 R920-E Programming, Page 64-65

• 6.0 Commissioning, Page 66



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HOW TO USE THIS MANUAL


• 3.4 R820-E Overview and Typical Configurations, Page 12

• 3.8 Circular Beacons: Overview, Page 16-18



• 5.3 R820-E Programming, Page 65




• 3.5 R829-E Overview and Typical Configurations, Page 13-14








• 3.5 R247-E Overview and Typical Configurations, Page 15








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3.0 INTRODUCTION

3.0 Introduction

3.1 About the E Series

The Carmanah E Series is comprised of the R920-E, R820-E, R829-E, and R247-E solar LED flashing beacons.

Each of these four products shares a common mechanical arrangement and solar engine. While each product has the same user interface on the Energy Management System (EMS) controller, different models and configurations may differ in behavior, types of fixture, fixture harnesses, wireless operation, and other aspects. Contact Carmanah if you would like to repurpose an E Series from its original model and configuration. Each system will be described in full later in this user manual.

3.2 Radio Communication

Radio communication between the same products is always present in R820-E and R920-E systems and is an option in R829-E systems. In addition to the E Series, Carmanah also manufactures larger F and G Series versions of the R920, R820, R829, and R247 products. Wireless communication works seamlessly between products regardless of whether they are E, F, or G Series. R820 and R920 systems will also activate each other when a pedestrian pushes the push button.

The radio modules use 2.4GHz DSSS (Direct Sequence Spread Spectrum) with an AES128 encrypted signal and have been tested with clear line of sight (with no nearby interference or reflected signals) to 1,000 feet (305 meters). Performance is reduced if clean line of sight is not possible.

The E Series uses a low-profile antenna that does not require any special orientation or adjustment and is immune to vandalism.



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3.0 INTRODUCTION

3.3 R920-E: Pedestrian Crosswalk with RRFB Light Bars

Overview

The R920-E solar LED Rectangular Rapid Flashing Beacon (RRFB) products are ideal for uncontrolled pedestrian-activated crosswalk applications. The R920-E configurations are combined to create a complete crosswalk set. Each R920-E is radio-controlled, and each synchronizes flashing with the other R920-Es in the group. The system will flash for a pre-set duration (field adjustable) upon activation of the push button. Spreadspectrum wireless communications activates the light bars across the street or in advance of the crossing. A typical installation consists of two pairs of light bars, with each pair mounted on poles at opposite ends of the crosswalk. Wireless communication between units means that the R920-E requires no trenching of cables across the roadway.

Details on the RRFB light bars can be found below in section 3.7, Page 16.

As an alternative to light bars, R920-Es can be configured with pedestrian signage equipped with edge-lit signs.

Details on LED Signs can be found below in section 3.9, Page 19.

Typical Configurations

R920-E with Single Light Bar and

Push Button (uni-directional)

R920-E with Dual Light Bar and

Push Button (bi-directional)

R920-E Advance Warning with single Light Bar and No Push

Button (uni-directional)



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3.0 INTRODUCTION



11


3.0 INTRODUCTION

3.4 R820-E: Pedestrian Crosswalk with Circular Beacons

Overview

The R820-E configurations are combined to create a complete crosswalk set. Each R820-E is radio-controlled, and each synchronizes flashing with the other R820-Es in the group. The system will flash for a pre-set duration

(field adjustable) upon activation of the push button. Wireless communication activates the beacons across the street or in advance of the crossing. A typical installation consists of two pairs of flashing beacons, with each pair mounted on poles at opposite ends of the crosswalk. Wireless communication between units means that the

R820-E requires no trenching of cables across the roadway.

Details on the circular beacons can be found below in section 3.8, Page 16-18.

As an alternative to circular beacons, R820-Es can be configured with pedestrian signage equipped with edge-lit signs.





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3.5 R829-E: School Zone Flashing Beacon


3.0 INTRODUCTION

Overview

The R829-E School Zone Flashing Beacon operates on a programmable calendar used to set the days and times when the beacon(s) will flash. There are three ways that an R829-E can follow a calendar schedule:

1) The R829-E is equipped with the optional calendar module and has its calendar programmed by a USB connection. The R829-E operates either alone or as the Master controller in a group of wireless-enabled

R829-Es.

2) The R829-E is wireless-enabled and responds to the ON/OFF commands of a Master R829-E system that is equipped with the optional calendar module and programmed schedule.

3) A non-wireless R829-E has ON/OFF control provided via a switch attached to the hardwired inputs. This switching function could be provided by an override box (see section 4.10, Page 50), an externallymounted time switch, or both.

The optional internal Carmanah calendar requires attachment of a USB communications module to the EMS. The calendar is programmed via the USB connection and stored in the EMS. The calendar can store a schedule up to

512 days. The calendar is easily programmed using an intuitive Microsoft Windows-based graphical user interface. Once the program is established for one system, the settings are easily uploaded to other R829-E units.

Other R829-E units may also be optionally controlled wirelessly by a master R829-E that is programmed with the schedule. Uploading the programmed settings occurs on site quickly from a laptop PC.






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3.0 INTRODUCTION

Internal Calendar (Optional)

The R829-E can be optionally equipped with an internal calendar that can be programmed via USB to automatically activate and deactivate school zone flashers on a user-defined schedule. A USB cable is part of the calendar programming kit and is provided and is coiled up inside the E Series solar engine prior to shipment.

Eight different day types can be defined (including OFF all day). Each day type can be configured for up to eight

(8) ON periods of arbitrary length.

Refer to the support document “R829 School Zone Calendar Configuration Instructions” for additional information and complete programming instructions.

Minimum Windows 7 operating system is required (32-bit or 64-bit). The software can be obtained by contacting

Carmanah Traffic Sales.

Ensure you obtain the latest copy of the calendar software (Version 1.2 at August 28, 2018). Older versions of the calendar software will not operate correctly with the newest version of traffic firmware.



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3.6 R247-E: 24-Hour Flashing Beacon


3.0 INTRODUCTION

Overview

The R247-E Flashing Beacon flashes continuously 24 hours per day 7 days per week and is used for a wide range of warning applications such as stop lights, low bridges, etc.





R247-E with Integrated Signal Head



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3.7 RRFB Light Bars: Overview


3.0 INTRODUCTION

The E Series provides standard wiring to support up to two (2) RRFB light bar fixtures. The FHWA Interim

Approval 21 March 20 th , 2018 defines the flash pattern of the RRFB and specifies the J595 standard for photometrics. Each light bar consists of a left and right module, with each module having eight (8) LEDs connected in series. In addition, each end of a light bar has a single “confirmation” LED that pedestrians can see from across the street and know with confidence that the light bars are flashing in response to their pressing of the pedestrian pushbutton. Opaque adhesive covers are available to optionally cover the confirmation LED if desired.

See section 4.5 for how to install and aim light bars, Page 33-38.

Dual Confirmation Light

– No Opaque Cover

Single Confirmation Light

– Using Opaque Cover

3.8 Circular Beacons: Overview

The E Series provides standard wiring to support four (4) circular beacons. The beacons are industry-standard equipment and comply with MUTCD and ITE flash patterns, color, beam shape, and intensity. Signal heads for integrated mounting of the E Series solar engine are specially reinforced for structural strength. Beacon wiring is provided with a convenient terminal strip inside the signal head for easy wire connection.

Do not mix different sizes or colors of LED circular beacons on the same EMS.

Three (3) fixtures in an E Series must be either wired in parallel or use a “Unison” flash pattern to avoid current imbalance and ensure all fixtures receive the same amount of current while flashing and therefore produce the same brightness.



16

Single Beacon 4.5” Post


3.0 INTRODUCTION

Dual Beacon Horizontal



17

Dual Beacon Vertical


3.0 INTRODUCTION

E Series Solar Engine on

Integrated Signal Head



18


3.0 INTRODUCTION

3.9 LED Signs: Overview

In addition to RRFB light bars and circular beacons, the E Series can also support LED signs. LED signs are available in a variety of formats including stop and pedestrian crosswalk signage. LED signs are electrically connected and driven directly by the EMS like other traffic fixtures. LED signs have the same degree of intensity and flash pattern control as other fixtures.

For the E Series, do not mix different sizes or LED counts of LED Signs or mix LED signs with other types of fixtures. Mixing fixture types is possible with Carmanah’s dual-EMS cabinet-based

G Series.

If powering three (3) LED signs in an E Series, they must be either wired in parallel or use a

“Unison” flash pattern to avoid current imbalance and ensure all signs receive the same amount of current while flashing and therefore produce the same brightness.

LED Sign Installation

1. Use banding to mount the sign on the pole.

2. Open the junction box on the back of the LED sign. Set the screws safely aside.

3. Loosen the cable gland and feed the LED cable into the junction box far enough that the cable gland can properly seal.

4. Tighten the cable gland.

5. Use two twist-on wire connectors or wagos to attach the LED harness to the yellow and white LED wires inside the connection box. Observe the following polarities:

Positive: Red from E Series to Yellow in LED Sign

Negative: Black from E Series to White in LED Sign

6. Close the connection box.



19


3.0 INTRODUCTION

3.10 General Wiring Information

This section describes wiring details for the E Series harnesses and the connectors they terminate upon to allow customers to modify, replace, or adapt standard wiring as needed.

Maximum Wire Gauge for Termination on EMS

16AWG

Battery to EMS Harness

2-CONDUCTOR (RED/BLACK), 18 AWG, 300V MIN

Circular Beacon Fixture Harness

UNSHIELDED, 2-CONDUCTOR, 18 AWG, BLACK/RED, 300V MIN

Solar Panel to EMS Harness


Polara Bulldog Pushbutton to EMS Harness


Light Bar to EMS Harness

UNSHIELDED, 4-CONDUCTOR, 18 AWG, BLACK/RED/WHITE/GREEN, 300V MIN.



20


3.0 INTRODUCTION

3.11 Third-Party Devices

A third-party device (3PD) is non-Carmanah equipment that interacts with the E Series in one or more ways:

• The E Series provides a status signal to 3PD (e.g. Digital Output signals when E Series fixtures are flashing, allowing 3PD equipment such as overhead lighting to activate)

• The 3PD provides control signal to E Series (e.g. time switch, passive pedestrian detection, water level detectors)

• The E Series only provides power to 3PD (e.g. radio/communications)

Contact Carmanah Traffic Sales to discuss adding a third-party device to your E Series.



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4.0 INSTALLATION

4.0 Installation

Make sure the installation location has an unobstructed view of the sun’s path.

Obstructions such as trees or buildings could significantly reduce the amount of sunlight on the solar panel. Shade analysis is highly recommended to understand how shadows will change according to the time of year. Contact Carmanah for a detailed examination and solar simulations for your site.

The E Series flashing beacons can be installed in under an hour (assuming the pole is already in place in the field to mount the unit on). No trenching, external cabling, traffic disruption, or site remediation is required.

Installing an E Series beacon consists of the following steps:

1. Connect the mounting adapter to the solar engine.

2. Mount the solar engine on the post, feeding the cables down the post.

If mounting RRFB light bars:

3. Mount the LED light bar universal bracket(s) to the post. See section 4.5.

4. Mount the LED light bar(s) to the universal bracket(s), pulling the cables through the light bar and connect the wires to the LEDs.

If mounting Circular Beacons:

3. Mark the positions of the flashing beacons onto the pole. Drill the holes for the cable exit/entry points for the flashing beacons.

4. Mount the signal head to the pole after wire has been passed through the mounting bracket.

If mounting LED Signs:

3. Mark the positions of the LED sign onto the pole. Drill the holes for the cable exit/entry points for the LED sign.

4. Mount the LED sign to the pole after wire has been passed through the mounting structure and out the hole.

If mounting Pedestrian Push Buttons:

5. Mount the pedestrian push button to the post, pulling the cable through the push button mount and connect the wires to the push button.

To finish installation:

6. Place the batteries into the solar engine and connecting them to the battery harness.

7. Ensure both fuses are intact and connected.

8. Configure the EMS as required using the onboard user interface.



22


4.0 INSTALLATION

9. Close the solar engine and ensure the solar panel is facing the equator (pointing south if you are in the northern hemisphere).

4.1 Tools and Materials Required

The following tools and materials may be required to mount your Carmanah flashing beacon depending on the E

Series model and configuration: a. Imperial socket set b. Crescent wrench c. Tap and die set d. Imperial Allen Wrench Set e. Fish tape f. Level g. Compass or Pre-Determined equatorial direction

4.2 Solar Engine Installation

h. Drill and drill bits i. Fine-tip felt marker j. Multi-bit Screwdriver k. Pelco Roger Wrench (Optional) l. Ladder or lift device m. Lithium grease

1. Attach the post adapter to the solar engine.

2. Lower the solar engine onto the post, feeding the cables down the post.



23


4.0 INSTALLATION

3. For a side mount, attach the solar engine to the retaining nut.

4. For a 2” or 2.5” perforated square post, secure the adapter to the post using appropriate fasteners.



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4.3 Integrated Solar Engine/Beacon Installation


4.0 INSTALLATION

When installing a version of the E Series that has its solar engine integrated directly into the top of a signal head

(e.g. R247-E), the pole adapters must be mounted to the pole first (so the lock washer can be tightened). The solar engine can then be fastened.

1. Attach the post adapter to the post using the appropriate fasteners.

Cast Mount

Fits 2” square post, 2.5” square post, 2 3/8” round pole and 2 7/8” round pole



25


4.0 INSTALLATION

Reinforced Signal Heads

The E Series is available in a mounting option where the solar engine is attached directly to the top of a reinforced signal head. This option is available for both 8” and 12” signal heads.

Your E Series system may have been ordered with a mix of standard and reinforced signal heads.

When mounting the E Series solar engine directly to a signal head, you must ensure that the signal head is the reinforced version. The following two diagrams show how a reinforced signal head can be identified by its stiffening plate(s).

Stiffening Plates

8” Reinforced Signal Head

12” Reinforced Signal Head



26


4.0 INSTALLATION

Integrating the E Series Solar Engine to a Reinforced Signal Head

To attach the E Series solar engine to the top of a reinforced signal head, assemble as shown below.

Serrated Lock Ring

Octagonal Lock Nut and Set

Screw (install set screw into tapped hole in lock nut)

Attachment of Solar Engine to Reinforced Signal Head



27


4.0 INSTALLATION

Load Spreader Plate for 12” Reinforced Signal Heads

12” reinforced signal heads ship with a trapezoidal “load spreader” plate included. The thick aluminum load spreader plate provides additional reinforcing to the stiffener plate to maximize wind resistance. Installation of the load spreader plate is optional for the E Series depending on the local wind speeds. The load spreader is mandatory for the larger F Series systems. To install the load spreader plate, simply place it in the bottom of the

12” signal head prior to installing the hex nipple.

Hex Nipple

Load Spreader

Assembled Hex Nipple and Load Spreader at base of Reinforced 12” Signal Head



28


4.0 INSTALLATION

2. Mount the solar engine and signal head assembly to the post mount pointing the signal head in the direction required.



29

3. Tighten the nipple to secure the system in place.


4.0 INSTALLATION



30

4. Ensure the solar panel is facing south and then tighten the nut.


4.0 INSTALLATION



31

4.4 RRFB Light Bars Wiring Diagram (for the R920-E)


4.0 INSTALLATION



32

4.5 RRFB Light Bars Installation (for the R920-E)

1. Feed the light bar cable(s) through the post, creating a drip loop.


4.0 INSTALLATION

2. Mount the light bar universal bracket(s), feeding the light bar cable through the center of the bracket.

Bolts and banding not supplied.



33


4.0 INSTALLATION

3. Mount the light bar(s) onto the universal bracket(s), feeding the light bar cable through the housing.

4. Bolt the light bar to the universal bracket as shown below.



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4.0 INSTALLATION

5. Align the light bar toward the traffic as required. The angle can be adjusted +/- 3 degrees. Tighten mounting nuts to lock in place.

6. Secure the light bar cable using supplied cable ties as shown.



35


4.0 INSTALLATION

7. Push the light bar wires into the light bar connectors, following the color scheme as noted on the LEDs.

Mount the light bar so that the black and white wires are on the left side. This ensures that the RRFB flash pattern, which must start on the left, is compliant with the FHWA requirements.

8. Slide on light bar cover and secure with the four provided screws.

Light bars with the backside painted black include 4 pin in Torx anti vandal screws. The anti-vandal screws prevents vandals from twisting the light bar grossly out of alignment. Two fasten to the top of the light bar, and two fasten to the bottom of the light bar. A T-15 Torx security bit is required to loosen the screws to gain access to the inside of the light bar.



36


4.0 INSTALLATION

Locations of Anti-Vandal Screws

9. If the pedestrian confirmation light is not required in one direction, use the supplied opaque label to cover the indicator light.



37


4.0 INSTALLATION



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4.0 INSTALLATION

4.6 Circular Beacons Wiring Diagram (for the R820-E, R829-E, and R247-E)

Harness, EMS to Circular Beacon

Up to 4X

Optional Circular Beacons Circular Beacon



39


4.0 INSTALLATION



40


4.0 INSTALLATION

4.7 Circular Beacons Installation (for the R820-E, R829-E, and R247-E)

The E Series provides standard wiring to support up to four (4) circular beacons.

If using a single integrated engine and beacon, proceed to the next section.

1. Thread the flashing beacon harness through the beacon arms. Then, mount the top flashing beacon arm to the pole using stainless banding or bolts (not supplied). Use the gasket on the top mounting arm to ensure water doesn’t leak past the connection and enter the signal head from the top.

Nut and gasket are inside signal head

2. Connect the flashing beacon harness to the terminal block inside beacon housing. Complete the flashing beacon assembly and attach the bottom arm mount to the pole using stainless steel banding or bolts (not supplied).



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4.0 INSTALLATION

Wiring for Yellow Beacon



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4.0 INSTALLATION

Positive on leftmost terminal (position #1) and Negative on rightmost terminal (position #6)



43


4.0 INSTALLATION

4.8 Push Button Installation (for the R920-E and R820-E)

If the E Series is wired for a pushbutton but none is needed (such as an advance RRFB), insulate the ends and secure the wires.

ADA regulations specify that the button should be 42” from the ground.

The push button can be connected in either polarity.

1. For round poles, cut holes to size and tap as required. Deburr the hole that the push button wiring will pass through.

2. Feed the push button cable through the pole, creating a drip loop.

3. Mount the push button to the post, connecting the wires to the push button.



44


4.0 INSTALLATION

4. Attach the button mounting adapter to the pole, connect the button cable to the button, and attach the button to the mounting adapter.



45


4.0 INSTALLATION

4.9 Battery Installation

Once the solar engine is secured and the beacons and other devices are in place, the batteries can now be installed.

ELECTRICAL SHOCK HAZARD.

DO NOT LET THE BATTERY TERMINALS COME INTO CONTACT WITH ANY EXPOSED

METAL.

Batteries are shipped fully charged. Use extreme caution when handling the batteries as they can generate hazardous short-circuit currents. Remove all jewelry (bracelets, metal-strap watches, etc.) before attempting to handle the batteries.

Batteries must be installed with the terminals facing outward as shown below.

1. Open the solar engine and install the batteries, connecting each battery using the correct polarity.



46


4.0 INSTALLATION



47

2. Secure batteries with battery strap; note proper routing.


4.0 INSTALLATION

3. The system will start once the batteries are connected. If it is part of a radio-connected group, all members of the group will now be able to communicate with each other. See the “5.0 EMS Programming and Testing” section (Page 51-65) to adjust default settings and to perform system testing and commissioning.



48


4.0 INSTALLATION

4. Close the latch and solar panel to complete installation.

5. Ensure the solar panel is facing the equator (pointing south if you are in the northern hemisphere).



49


4.0 INSTALLATION

4.10 Override Box Installation

The R829-E and R247-E are available with a lockable pole-mounted manual override box that i s mounted lower down on the mounting structure to allow easy access by individuals on the ground. The override box is used for forcing the R829-E to flash regardless of the calendar schedule and for forcing the R247-E to temporarily cease flashing. For R829-E systems, this box will also contain the USB connection for programming the internal calendar. The USB cable is used to communicate calendar data between the R829-E and a windows PC.

The override box can be mounted on 2” square perforated and round poles. Assembly required.



50

5.0 EMS Programming and Testing


5.0 EMS PROGRAMMING AND TESTING

The E Series’ Energy Management System (EMS) has several programming functions and settings. These are accessed through the On-Board User Interface (OBUI). Specific products will use a subset of the complete OBUI settings, which will be covered in this manual’s sections specific to each product.

5.1 EMS On-Board User Interface Operation

The EMS OBUI has three buttons to navigate and change settings and activate functions as required. The Up arrow, Down arrow, and SET button are used to scroll through menus, access and change settings, and accept new settings.

Use the Up and Down arrow buttons to scroll through the menu.

Press and hold the SET button to edit a setting.

The display will blink when the setting is ready to edit.

Use the Up and Down arrow buttons to adjust the setting when in edit mode.

Press and hold the SET button to accept the new setting. The display will flash 3 times to indicate the setting has been accepted.

Using the Up or Down buttons on the OBUI, the following menu items will appear:



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LED Fault



The LED Fault message does not normally appear in the OBUI menu, and only appears when the EMS has detected that at least one fixture is shorted, or all fixtures are not properly connected (open circuit). When the problem has been corrected and flashing is triggered, the LED Fault menu item will again disappear.

Broadcast to other systems? No User-adjustable? No

Battery Status

Battery Status reports general battery state as well as actual battery voltage. When the Battery Status reads

“Char” (Charge), the voltage is lower than normally desirable, but the system will continue to operate normally.

When the Battery Status reads “Lo”, the system is in Low Voltage Disconnect (LVD). LVD is a safety mechanism that the EMS invokes to preserve remaining battery charge and prevent a complete exhaustion of the battery.

When in LVD, the fixtures will not flash and the digital output signal (if used) is also turned off.

User-adjustable? No Broadcast to other systems? No



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Solar Status



The Solar Status indicates whether the system has determined it is night or day based on the photosensor located in the top of the body near the antenna. The second value that is displayed is the output voltage of the solar panel and is useful for troubleshooting. Solar panel voltage in sunlight will typically be between 15 and 20 volts.


Flash Pattern

The EMS can be programmed for 8 different flash patterns.

• RFB1 Standard FHWA RRFB WW+S (Wig Wag and Simultaneous) flash pattern

• RFB2 WSDOT custom pattern for circular rapid flashing beacons

• 0.1U Unison flash 0.1 second pulse 60 flashes per minute

• 0.25U Unison flash 0.25 second pulse 60 flashes per minute

• 0.5U MUTCD-compliant unison flash 0.5 second pulse 60 flashes per minute

• 0.5A MUTCD-compliant alternating flash 0.5 second pulse 60 flashes per minute. Carmanah default.

• 0.1UF Unison quick flash. Burst of three 0.1 second pulse flashes. 60 bursts per minute.

• 0.1AF Alternating quick flash. Burst of three 0.1 second pulse flashes. 60 bursts per minute.

The flash pattern is pre-set at the factory based on your requirements and installation location, which are typically discussed at the time of ordering. Should the installation location or situation change, you can adjust this setting.

Please contact Carmanah Customer Service prior to making any adjustments.



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If a single fixture is being used, the flash pattern must be a “unison” pattern, otherwise if it is set for alternating the EMS will look for a second fixture and generate an LED fault when it doesn’t find one. The EMS uses a single LED driver that toggles two “banks” on and off. Bank 1 controls fixtures 1 and 3, while Bank 2 controls fixtures 2 and 4. For alternating flashing, fixtures are attached to different Banks. An RRFB light bar uses both banks to achieve its mix of alternating and simultaneous flashing.

3 circular beacons will need to be either set for “Unison” flashing or connected to the same bank to provide consistent intensity. Alternating flashing with equal brightness of all 3 fixtures is not available. This is explained in detail in the “Intensity” section.

User-adjustable? Yes

Input Type

Broadcast to other systems? No

The Input Type setting determines a key difference between the EMS acting as a pedestrian crosswalk system, a

24/7 flasher, or a school zone flasher. Set Input Type according to the following options:

“Push Button”. Used for pedestrian crosswalks (R920, R820). A push button is wired to the push button inputs of the EMS, and when the button is pushed and a momentary short-circuit across the inputs is created, the fixtures will flash for the duration set in the “Duration” setting.

Carmanah default.

“Normally Open”. Used for School Zone Flashers (R829) or any application where the flashers must activate on demand. The usual state of the push button input terminals is to be open and not have a short-circuit across them. While the terminals are open, fixtures do not flash. If a short-circuit is applied across the terminals - provided by a time switch, override switch, or some other device - the fixtures will begin to flash and will continue to flash as long as the short-circuit is applied.

“Normally Closed”. Used for 24X7 flashers (R247). The flashers will flash continuously, day and night, unless a short-circuit is applied to the push button input terminals. In “Normally Closed” mode with the fixtures flashing, although there is no physical short-circuit across the push button terminals, the EMS will behave as though there is. The override box can be used to switch the beacons ON or OFF.

If the system is equipped with a radio, in either of these three modes the system will broadcast changes at the push button input terminal. If Input is configured as “BTTN”, other systems wirelessly connected to it will respond as though they were configured as a pedestrian crossing that had received and activation signal. Similarly, a system with input configured as “NO”



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(Normally Open) that has its contacts shorted will cause other wirelessly-connected systems to turn on and stay on as long as they haven’t received a follow-up OFF signal from “NO” input.


Flashing Duration

Broadcast to other systems?

No (changing the setting will not broadcast the change)

Flashing Duration is used for pedestrian crosswalks and sets the amount of time the fixtures will flash before extinguishing. The available settings are:

• 5 to 60 seconds in 1 second steps

• 60 to 1200 seconds in 60 second steps

• 3600 seconds

The Carmanah default duration is 20 seconds. Longer duration flash periods are useful for applications such as warning traffic of heavy equipment on logging and mining haul roads, etc.

Broadcast to other systems? Yes User-adjustable? Yes

Intensity (LED Driver Current)

The value shown in the user interface is the total current being provided to the fixtures, and divides among them depending on how many fixtures are connected and whether they are flashing in unison or alternating.

For RRFB light bars and circular using the RRFB flash pattern, the value shown is the total current when both left and right modules of a light bar or both circular beacons are on simultaneously (The “S” simultaneous portion of the WW+S RRFB flash pattern). When only one module or beacon is illuminated, the EMS automatically reduces the current to half the value shown on the UI because it knows, with the “RRFB” flash pattern, that the current will be flowing through one module/fixture.

The following table provides some examples of how a user might configure system intensities:



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Fixtures Flash Pattern EMS Intensity Setting Resulting Fixture Current

Two Circular Beacons Alternating

Two Circular Beacons Unison

One Light Bar RRFB 1

300mA

400mA

260mA

300mA

200mA

During the “Simultaneous” phase,

260mA is provided to the light bar and is split equally between the left and right modules, resulting in 130mA per module.

During the wig-wag phase, the EMS

Two Light Bars RRFB 1 520mA automatically reduces the current to one half (130mA) which flows through one side of the light bar or the other side.

During the “Simultaneous” phase,

520mA is provided to both light bars and is split equally between the left and right modules in each light bar, resulting in

130mA per module.

During the wig-wag phase, the EMS automatically reduces the current to one half (260mA) which flows through either both left sides of the two light bars or both right sides of the light bars. The current splits equally between the light bars, so each module receives 130mA.

The intensity is pre-set at the factory based on your requirements and installation location, which are typically discussed at the time of ordering. Should the installation location or situation change, you can adjust this setting.

Please contact Carmanah Customer Service prior to making any adjustments.

Intensity adjustments are 20mA per step.

The maximum output current of the LED driver is 1400mA.

As mentioned in the Flash Pattern section, 3 fixtures will need to be either set for “Unison” flashing or connected to the same bank to provide consistent intensity. Alternating flashing with equal brightness of all 3 fixtures is not available. If 2 fixtures are connected to bank 1 and the third fixture is connected to bank 2, the fixtures on bank 1 would be half as bright as the fixture on bank 2 because the LED driver current would be split between them.

The output current will never be lower than 20mA. If the EMS is applying AAA, night Dimming, or ALC that would theoretically set the output current below 20mA, it will enforce a minimum of

20mA regardless.

When programming intensity for RRFBs or ITE-compliant circular beacons , minimum current settings must be applied. Contact Carmanah for guidance.

User-adjustable? Yes Broadcast to other systems? No



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Night Dimming

Night Dimming sets the night intensity as a fraction of daytime intensity expressed as a percentage. It is set in

10% steps. For no night dimming, this is set to 100%. Carmanah default is 30% for all fixtures except red beacons which are not dimmed at night per FHWA.

If using night dimming and your system must meet intensity compliance such as ITE or RRFB’s

J595, ensure that a worst-case night dimming does not dim the fixtures below the required current needed to achieve compliance.

Broadcast to other systems? Yes User-adjustable? Yes

Ambient Auto-Adjust

Ambient Auto Adjust (AAA) is a feature unique to Carmanah traffic products. AAA automatically adjusts fixture intensity within a range of 50% to 100% of the intensity setting on the display depending on ambient brightness.

This improves visibility in bright sunlight, or conversely, reduce brightness in overcast days to prevent glare. AAA is set either on or off. The AAA value that is reported on the UI is from 1 to 10. A reading of “1” means ambient light levels are 1,000 lux and the intensity is being dimmed to 50%. A reading of “10” means ambient light levels is at least 27,000 lux and 100% daytime intensity is being applied.

The AAA value is displayed in real time, so it is a good feature to use for troubleshooting the photosensor operation. A flashlight can be used to shine bright light into the photosensor and invoke a “10” value.

If using AAA and your system must meet intensity compliance such as ITE or RRFB’s J595, ensure that a worst-case AAA of 50% does not dim the fixtures below the required current needed to achieve compliance.

Carmanah default is “on”.

User-adjustable? Yes Broadcast to other systems? Yes



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Automatic Light Control (ALC)

Automatic Light Control (ALC) is a Carmanah patented energy management system. ALC is an optional setting that allows the EMS to reduce the fixture brightness in response to unexpected deficiencies in sunlight energy that result in unusually large decreases in battery charge. ALC activates if battery charge gets as low as 70%, which should never be encountered in normal circumstances if the system was properly sized and solar simulated for its location.

When ALC is set to “on”, the UI will report the amount of ALC being applied as a percentage. For example, a reading of 70 would mean that ALC is reducing the fixture brightness to 70% of its normal setting. If battery voltage continues to decrease, the ALC value will also decrease until LVD (Low Voltage Disconnect) is eventually reached.

Carmanah default is “on.”




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LED Temperature

LED Temperature is set according to the color of the LED in the fixture. The EMS uses this information to apply fine adjustments to the fixture current to account for changes in LED efficacy with changing ambient temperature which ensures consistent brightness regardless of temperature.

NOTE: Although the R920-G uses yellow light bars, LED Temperature is set to OFF.

Carmanah default is set to the fixture type at time of manufacture.

Broadcast to other systems? No User-adjustable? Yes

Internal Calendar

If an E Series is configured as an R829-E and has the optional calendar module installed, it will be provided with a

USB cable that allows users to program an internal calendar for scheduling when the fixtures should flash during school hours. When Calendar is set to “on”, the fixtures will flash according to the schedule programmed in the calendar. The calendar accounts for Daylight Savings Time (DST) and leap years and has a maximum schedule length of 512 days. The software to communicate with the R829 calendar system is available from Carmanah.

Where a group of radio-equipped R829-Es are used, setting CALENDAR to “On” will make an R829-E a “Master” system in a group of wireless-equipped R829s. The other R829 “Slave” systems should have their calendars turned off, and they will flash only whenever the Master system broadcasts on or off signals as it turns on and off itself.

Even if the Calendar setting is “off”, a calendar can still be programmed into the EMS using the

USB cable. The R829-E will simply not follow the programmed schedule until the calendar setting is turned on.

The E Series calendar function requires users to update their PC software to the latest version before it can be used.

Screenshot of Carmanah Calendar software:



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Radio Enable


Radio Enable is used to turn the radio module on or off. This feature can be used for troubleshooting. The EMS will automatically disable the radio if Low Voltage Disconnect activates. A system without a radio will still show the “RF” entry, but it will not have any effect on behavior.

Carmanah default is “off.”



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Radio Channel




For radio-equipped systems, the Radio Channel setting is used to configure the channel that is used for communication with other similar systems in the same group. E Series groups near each other will have their channels set to different values to ensure there is no accidental cross-activation between them. Changing the channel is a useful troubleshooting step if some systems are experiencing intermittent issues. The 2.4GHz band that the E Series radio module uses is public spectrum, and there may be a strong interference signal nearby.

Systems without radios will still show a channel assignment, but it will not have any effect on behavior.

Channel changes are not broadcast to adjacent systems.

Carmanah default is channel “5.”


Radio Detection Status

Radio Detection Status indicates whether the EMS has detected a radio module. Detection is more than sensing the physical presence of the radio. The EMS interacts with the radio and tests several things before declaring the radio “detected”.

User-adjustable? No Broadcast to other systems? No



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Digital Output

The Digital Output feature of the EMS provides a steady 12-volt output signal whenever the system fixtures are flashing. This is a useful feature for signaling the flashing state to other equipment such as overhead lighting.

When set to “ALL”, Digital Output will provide a steady 12-volt output signal whenever the fixtures are flashing day or night. When set to “Nite”, the 12-volt output signal will appear only when the fixtures are flashing at night (as determined by the photosensor). The 12-volt signal is intended to control external relays up to 30mA current draw.

Contact Carmanah Sales for support on how to use the Digital Output feature. The Digital Output feature is wired out during the E Series’ fabrication and is not intended to be wired by end users after purchase.

Carmanah default is “ALL.”


Push Button Input Status

Input Status reports different states depending on the type of product the E Series is configured for.

Pedestrian Crosswalk: Input Status will normally read Open. During the time that the push button is held down,

Input Status will report Closed. If the pushbutton is held down or shorted for at least 20 seconds, Input Status will show “Shrt” (for short-circuit).

School Zone Flasher: Input Status will read Open whenever the internal calendar or the attached time switch is not activating the fixtures. When the fixtures are flashing due to activation of either of these two sources, Input

Status will read Closed.

24-Hour Flasher: Input Status will normally read Closed. Although there is no physical wire across the input terminals, the EMS internally considers the terminals to be connected in order to invoke constant flashing. If a short is applied to the input, 24-hour flashing will cease, and the Input Status will change to Open.



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User-adjustable? No

Activation Count




Activation Count keeps track of the average number of daily pedestrian push button activations over a 90-day window. The data is stored in volatile RAM memory and is erased if power is removed and system reboots, at which time Activation Count averaging will restart. If it has been fewer than 90 days since the last bootup, the

EMS averages over the number of days since bootup. For this feature, the EMS considers a “day” as 24 hours passing, rather than using day/night transitions detected by the photosensor.


LED Fixture Test

The LED Fixture Test function causes the fixture(s) to flash independently of an activation input from a physical push button, time switch, internal calendar or external control. The test will activate the fixture flashing for 5 seconds. “Test” is a good way of confirming a problem is not caused by the fixtures.

Installers can do this from the EMS without having to climb down to the push button or override box to test.




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Built-In Self-Test (BIST)



The Built-In Self-Test (BIST) runs a self-test on the system. After the BIST has been started by selecting “Yes”, the display will flash “Test” for the duration of the test and will then display hexadecimal information that can be interpreted (using the table below) to represent one or more issues. The BIST can be used for troubleshooting remotely with Carmanah Customer Service.

The BIST is primarily designed as a tool for manufacturing and is intended to be run in a manufacturing environment. When the BIST is run out in the field, it may report an error with ambient brightness sensor because it is expecting brightness levels that would be encountered inside the manufacturing assembly. Shining a flashlight on the ambient brightness sensor during the BIST test should result in no error being generated.

Results are used for troubleshooting the system.

Refer to BIST Error Codes in section 8.1 for hexadecimal interpretation table, Page 72-73.


Firmware Version

The Firmware Version menu item provides the current version of firmware in the EMS.

Firmware cannot be updated via the USB communications cable.

User-adjustable? No

5.2 R920-E Programming


To uniquely configure the E Series EMS as an R920-E, do the following:

 Set the flash pattern to RFB1 or RFB2

 Set input type to bttn

 Set flash duration



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 Set the temperature to OFF

 Set Calendar to off

 Set RF (Radio) to on

 Set Radio Channel (Channel 5 is default)





 Set the flash pattern to your desired setting

 Set input type to bttn

 Set flash duration

 Set the temperature to either red or yellow to match the circular beacon color


 Set RF (Radio) to on

 Set Radio Channel (Channel 5 is default)



 Set the flash pattern

 Set input type to NO (Normally Open)


 Set Calendar to ON if using the internal calendar or if the R829-E is the Master in a group of wirelesslyconnected R829s.

 Set RF (Radio) to ON if the system is in a group of wirelessly-connected R829-Es. Otherwise, set RF to

OFF



 Set the flash pattern

 Set input type to NC (Normally Closed)



 Set RF (Radio) to OFF



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6.0 COMMISSIONING

6.0 Commissioning

After installing and programming the E Series beacon, the following commissioning verification checklist helps ensure that everything is working as it should be and that your flashing beacon is ready to serve the public for many years of reliable and sustained operation.

 All settings are correct, particularly the LED driver current (“Intensity” in EMS user interface), flash pattern and flash duration (if applicable)

 No LED fault message on the EMS.

 For single or triple fixture systems, ensure the flash pattern is set for unison

 Fixtures flash properly:

 R920-E or R820-E: Press pushbutton or use “TEST” at the EMS user interface at EMS.

 R829-E: Use “TEST” at EMS user interface or activate override switch

 R247-E: Use “TEST” at EMS user interface

 Light fixtures are tightened and pointed in the correct direction toward oncoming traffic lanes.

 Retrieved calendar from R829-E is confirmed to be accurate.

 Solar panel pointed south (or wherever custom instructions required).

 Override box (if equipped) correctly activates or deactivates the flashing (depending on E Series model configuration).

 The solar panel is properly latched, and the solar engine body is secured tightly and unable to spin.

 No debris covering the photosensor window on top of the solar engine.

 Vents are clear, and screens are intact.

 Sealing gaskets on door are intact.

 Solar panel is producing voltage in sunlight (use EMS “Solar” menu item).

 System has clear sky access and no removal of obstructions is required.

 Note the possibility for nearby foliage to eventually shade the solar panel. If so, set a reminder to inspect later.

 Battery voltage is healthy (use either a voltmeter or EMS “Battery” menu item).

 Verify both fuses are intact so that the system doesn't just run off a single battery (use voltmeter to confirm fuse continuity or disconnect each fuse individually and confirm the other fuse still allows EMS to operate).

 Yellow fuse holders are tightly sealed to prevent water ingress.

 RRFB light bar flashing starts with left module first.

 Remote systems are turning on and off correctly via wireless control.

 Verify the indicator LEDs on the ends of light bars can be seen by pedestrians across the street.



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7.0 Maintenance and Product Care


7.0 MAINTENANCE AND PRODUCT CARE

The E Series solar engine is designed to operate reliably for years with virtually no need for maintenance.

Carmanah recommends routine inspections of the solar panels to ensure that they are unobstructed by anything that may prevent effective solar charging, including:

• Dirt and dust

• Snow

• Leaves

• Debris

• Shade that may have developed after installation due to adjacent plant growth.

The frequency of the inspections depends on location and local weather patterns. A yearly visual inspection of the

E Series solar engine is typically sufficient. The E Series is designed to be maintenance free, but maximum system performance is achieved when the LED lenses and solar panels are clean. When inspecting the interior, ensure that the vent screens are undamaged and that the vents are clear and allow airflow.

7.1 Fuse Replacement

It is important to ensure both fuses are working. With two fuses in the system, it is possible for one fuse to be blown while the system continues to operate normally using the remaining battery. In this event, the available battery capacity, and therefore system autonomy, will be half of what it should be, and the single working battery will be working harder and cycling deeper than it should be, which will shorten its service life. To replace the fuse:

1. Make sure you’re not wearing any metal jewelry or holding any tools or other conductive objects.

2. Disconnect the batteries.

3. Check all wiring for any faults that may have caused the fuse to blow.

Fuse holders

4. Pull the fuse holder apart and check the fuse.

5. Replace a blown fuse with an identical fuse: 3AG (1/4" x 1-1/4") fuse



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7.2 Battery Replacement

When the E Series system’s batteries require replacement, it is recommended that the same model and manufacturer of the original E Series battery be used. You should replace both batteries at the same time.

As part of the E Series’ battery interactions, the general health of the battery is tracked in a form of “odometer.” If battery status is reported as “Bad”, it is this function that has determined the battery health is too poor to be reliable and batteries should be replaced. Battery health is evaluated by considering such things as the total number of charge and discharge cycles, and the amount of time spent in a low state of charge. When placing new, fully-charged batteries in the E Series, observe the following procedure to reset the health odometer:

1. Begin with the new batteries disconnected

2. Press and hold down the “Set” button

3. While continuing to hold down the “Set” button, connect one of the new batteries

4. While continuing to hold down “Set” button, wait for the word "Zero" to appear and then disappear from the display

5. After you've seen "Zero", you can release the “Set” button

The battery health meter inside the E Series is now reset (i.e. it knows that new, healthy batteries have been installed). The battery status should read “Good” if the new batteries are 12.6V or higher, or “Char” (Charge) if it is under between 11.7 and 12.6 volts.

Battery replacement procedure should not be carried out in windy conditions. In all cases, the area at the base of the post must be roped off to prevent people from being injured or killed by falling batteries.

7.3 EMS Replacement

Caution - The solar panel may still be producing energy if it is exposed to light. Cover the solar panel or ensure it is not exposed to sunlight to prevent risk of injury.

Sensitive electronics can be damaged by electrostatic discharge. Observe proper ESD precautions when installing the new EMS.

1. Open the solar panel.

2. Disconnect the battery fuses.

3. Remove the 4 screws securing the metal housing containing the EMS PCB (Energy Management System

Printed Circuit Board). Carefully remove the radio antenna if present.

4. Turn the metal housing over to reveal the circuit board and review the wire positions on the existing EMS.

Photograph the existing wire terminations if convenient.

5. Remove the wires from all terminal block connectors by pressing the wire release button with a small screwdriver or other suitable small tool to pull the wires out of the connectors.

6. Secure the solar panel wires with insulation tape. The solar panel wires may still have voltage on them that could damage the electronics if they contact the circuit board.

7. Remove the 4 screws securing the old EMS to the metal housing and set the old EMS aside.

8. Remove the new EMS from its antistatic bag and secure it to the metal housing with the 4 screws previously removed.



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9. Beginning with the solar panel wires, check that the wire strands are straight and that all the strands will go into the terminal. This will avoid short circuits created by stray wires that didn’t penetrate the connector. Twist the wire strands as necessary to keep the strands together.

10. Reconnect the solar panel power wires in the correct polarity as they were originally found.

11. Reconnect the remaining wires as they were originally found. Carefully pull on all wires to ensure they are secure.

12. If a radio module is present, carefully thread the antenna connector to the module. Do not damage the circuit board with tools.

13. Replace any cable ties that were removed to ensure wires have proper strain relief.

14. Secure the EMS enclosure into the cabinet with the supplied screws.

15. Reconnect battery fuses.

16.

The system should now be operating and the front display on the EMS should light up.

17. The replacement EMS should already be pre-programed from the factory for your location and installation requirements. You may review the settings if necessary. See the information decal on the back of the solar panel and the user manual for additional information.

NOTE: Depending on your system, some connections may not be installed.



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7.4 EMS Recycling

Production of the EMS required the extraction and use of natural resources. The EMS may contain substances that could be harmful to the environment or human health if improperly handled at the product’s end of life. To avoid release of such substances into the environment and to reduce the use of natural resources, we encourage you to recycle the EMS in an appropriate way that will ensure most of the materials are reused or recycled appropriately. Check your local municipality for electronics recyclers.



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8.0 TROUBLESHOOTING

8.0 Troubleshooting

Symptom

The EMS does not activate or display any information.

LEDs won't flash when push button on the same post is pressed.

LEDs on same post flash, but other systems in the wireless group w on't flash .

One LED fixture fl ashes, but other fixtures on the same post does not fl ash.

Possible Cause and What to Check

This is typically caused by low or no voltage from the batteries.

Check both battery fuses. See the “Maintenance and Product Care” section of this manual for fuse information.

Using a voltmeter, measure the battery voltage. Battery voltage should be a minimum of 12 volts, with 12.6 volts being nominal normal voltage. If the voltage is very low, charge or replace the batteries and monitor the system for proper operation. Ensure that the solar panel is clean, clear of debris, and is not shaded by buildings or vegetation. If the solar panel is covered or shaded, this will prevent proper battery charging. Once the batteries have proper voltage, check the EMS by running the BIST test and lookup the error codes in the “BIST Error Codes” section of this manual.

This can be caused by either button failure, a wiring issue, low battery voltage, or the unlikely event of an EMS failure.

Check that the button is functioning, and it is providing the typical feedback. If the button has an LED or audio feedback, ensure that these are working. Check the wiring to the button for continuity and make sure the wires are not pinched anywhere along their length.

Check the wiring to the LED fixtures for continuity and make sure the wires are not pinched anywhere along their length.

Check that the wiring pattern (polarity) is correct on the LED fixtures.

Check the battery voltage, either through the OBUI or with a voltmeter

(see item above).

Test the system using the “Test” function. If the LEDs flash using the

OBUI functions, then the problem is in the button or wiring to the button.

If one system is activated, but the other systems in the group are not turning on, this points to a radio issue.

Ensure that all the units are set to the same radio channel using the

OBUI. See the EMS Programming and Testing section of this manual.

Ensure that the units are not too far apart. The maximum distance for proper radio communication is 1,000 unobstructed feet (305m), but realworld effects and signal path can limit range to less than half that value.

There can be no barriers or obstructions between systems, such as buildings or billboards.

This is likely caused by improper wiring of the fixtures. Ensure that the wire colors and polarities match the instructions in this manual. Check that the electrical connections are secure.



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The LEDs are dim when flashing .

The LEDs appear too bright when fl ashing

Fixtures flash when no button is pressed

LED Open Fault is showing on

User Interface


8.0 TROUBLESHOOTING

The battery voltage may be too low for proper operation and the system has activated Automatic Light Control (ALC). Check the OBUI for ALC status and battery voltage.

Ensure that the solar panel is clean, clear of debris, and is not shaded by buildings or vegetation. If the solar panel is covered or shaded, this will prevent proper battery charging and drive the system into ALC.

Check for debris covering the ambient light sensor on top of the solar engine and confirm the photosensor is correctly detecting day and night.

A flashlight can be shone into the photosensor to simulate day, and the photosensor can be covered to simulate night.

Confirm the intensity is set correctly to a value that has been confirmed to be sustainable using a solar simulation.

Check the Ambient light Auto-Adjust (AAA) setting on the OBUI. Turn off the AAA to see if this corrects the dim LEDs.

Settings on the EMS can affect the apparent brightness of the LEDs. The intensity setting on the user interface can be turned down to a more suitable brightness level. Verify all fixtures are working. If a fixture stops working, the current that would normally flow through it is redirected into the remaining fixtures, which increases their brightness.

This is likely caused by another nearby system on the same radio channel activating the system.

Ensure that all units in a group are set to the correct radio channel using the OBUI while also ensuring that nearby systems at a different location are using a different channel.

This is likely caused by using a single fixture with an alternating flash pattern. The EMS is looking for the other fixture in the alternate pattern and declares an “LED Open” fault when it doesn’t find one. Set flash pattern to unison.

8.1 BIST Error Codes

The BIST (Built-In Self-Test) is a useful feature of the EMS for troubleshooting. After the BIST has finished, a code will be displayed on the user interface, which will correspond with one or more results.

The BIST is used in manufacturing for testing a fully assembled system. In manufacturing, the ambient brightness sensor is tested by applying varying light levels and measuring response.

Hence, when BIST is run on a system deployed in the field, the BIST will not detect a variation in ambient light and will generate a 0080 error. This does not indicate an issue with the ambient brightness sensor, but rather the conditions under which the test was run are different from those the EMS expects.

The hexadecimal number that will be displayed after the BIST test is created by adding together the individual error codes. For example, if there were a charger problem (4000) and a problem with the fixture LED (8000), the hexadecimal sum would be C000. 4 + 8 =12, which is “C” in hexadecimal.



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8.0 TROUBLESHOOTING

The BIST codes can be used to assist Carmanah technical support in solving product configuration or performance issues. Please contact Carmanah technical support if the issue you encounter is not easily solved be reviewing the information provided in this document.

Code

0002

0008

0010

0020

0080

4000

8000

Error

Temperature check.

Checks that temperature is between 15° C and 35° C. With installation sites frequently having temperatures outside of this range, code 0002 will often be generated while there is no real issue with temperature.

Battery check.

Checks that battery voltage is between 11.7 V and 17.268 V (max charge voltage at

-40° C). Nominal is 12.6 volts when unloaded and not charging.

Checks that V supply on EMS control board is between 3.2 V and 3.4 V. Nominal is 3.3 volts.

Keypad check.

Checks all push buttons on user interface (up, down and enter).

Ambient Brightness Sensor (ABS) check.

Checks that the current lux measured by the ABS is above the minimum (90lux).

Charger check.

Runs charger at two set points. Checks that the charge current stays within allowed range (10 mA to 4.5 A). Checks that the solar voltage is stable (less than 50 mV change between set points).

LED fixture check.

Enables one bank at a time. Checks that the LED voltage is between 6 V and

28 V. Checks that the current is close to the set intensity. If a single fixture is used, and an alternating flash pattern is programmed, the system will generate an error because it expecting to see current flowing through two fixtures in alternation.



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9.0 CUSTOMER SERVICE AND WARRANTY

9.0 Customer Service and Warranty

The E Series is covered by a limited warranty for the product excluding batteries, and a separate limited warranty for the batteries.

Visit www.carmanahtraffic.com for additional information or contact the customer service department.

Before contacting Carmanah’s customer service department, please have the serial number of your system available, a brief description of the problem, as well as all details of the installation (location, pole type, type and quantity of fixtures, etc.) The serial number can be found on the inside of the solar panel, and on the outside of the system just below the solar panel hinge.

To contact Carmanah’s Customer Service Department:

Mail: Carmanah Technologies Corporation

250 Bay Street

Victoria, BC Canada V9A 3K5

Phone: 1.250.380.0052

1.877.722.8877 (Toll Free in U.S. and Canada)

Fax: 1.250.380.0062

Email: [email protected]

Web: carmanahtraffic.com

9.1 Additional Products

Carmanah offers a variety of solar-powered and energy-efficient LED lighting products. In addition to the E Series, the F and G Series are available as larger versions which are fully compatible with the E Series. Carmanah also provides cabinet-based and AC-powered systems for applications that may require third-party devices, longer autonomy, more activations per day, or have poor solar availability. Along with traffic products, Carmanah also manufactures solar LED outdoor lighting products. For more information, please visit our website at carmanahtraffic.com.



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EMS:

Solar Engine:

UI/OBUI:


9.0 CUSTOMER SERVICE AND WARRANTY

9.2 Glossary

Autonomy: The number of days or nights the E Series can continue to operate normally without any battery charging from the solar panels.

Energy Management System. The electronic controller inside the E Series that is responsible for managing the solar input energy, battery charging, LED drivers, and other power and operational functions

The complete, self-contained assembly of solar panel, batteries, EMS control module, wiring, fuses, and mechanical enclosure

User Interface/On-Board User Interface. The 4-digit display and 3-button interface on the

EMS that allows users to interact with the system programming.

84322_MANUAL_TRA_E-Series_RevA



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Carmanah E Series, R247-E, R829-E, R920-E User Manual

E Series

TRAFFIC BEACON USER MANUAL

Table of Contents

1.0 Warnings and Precautions

1.1 Warranty Disclaimer

1.2 Standards

1.3 Safety and Usage Precautions

2.0 How to Use this Manual

2.1 How to Set Up the R920-E

2.2 How to Set Up the R820-E

2.3 How to Set Up the R829-E

2.4 How to Set Up the R247-E

3.0 Introduction

3.1 About the E Series

3.2 Radio Communication

3.3 R920-E: Pedestrian Crosswalk with RRFB Light Bars

Overview

Typical Configurations

3.4 R820-E: Pedestrian Crosswalk with Circular Beacons

Overview

Typical Configurations

3.5 R829-E: School Zone Flashing Beacon

Overview

Typical Configurations

Internal Calendar (Optional)

3.6 R247-E: 24-Hour Flashing Beacon

Overview

Typical Configurations

3.7 RRFB Light Bars: Overview

3.8 Circular Beacons: Overview

3.9 LED Signs: Overview

LED Sign Installation

3.10 General Wiring Information

3.11 Third-Party Devices

4.0 Installation

4.1 Tools and Materials Required

4.2 Solar Engine Installation

4.3 Integrated Solar Engine/Beacon Installation

Reinforced Signal Heads

Integrating the E Series Solar Engine to a Reinforced Signal Head

Load Spreader Plate for 12” Reinforced Signal Heads

4.4 RRFB Light Bars Wiring Diagram (for the R920-E)

4.5 RRFB Light Bars Installation (for the R920-E)

4.6 Circular Beacons Wiring Diagram (for the R820-E, R829-E, and R247-E)

Harness, EMS to Circular Beacon

Up to 4X

Optional Circular Beacons Circular Beacon

4.7 Circular Beacons Installation (for the R820-E, R829-E, and R247-E)

4.8 Push Button Installation (for the R920-E and R820-E)

4.9 Battery Installation

4.10 Override Box Installation

5.0 EMS Programming and Testing

5.1 EMS On-Board User Interface Operation

LED Fault

Battery Status

Solar Status

Flash Pattern

Input Type

Flashing Duration

Intensity (LED Driver Current)

Night Dimming

Ambient Auto-Adjust

Automatic Light Control (ALC)

LED Temperature

Internal Calendar

Radio Enable

Radio Channel

Radio Detection Status

Digital Output

Push Button Input Status

Activation Count

LED Fixture Test

Built-In Self-Test (BIST)

Firmware Version

5.2 R920-E Programming

5.3 R820-E Programming

5.4 R829-E Programming

5.5 R247-E Programming

6.0 Commissioning