The TraffiCalm Solar Power Kit is designed to provide power for TraffiCalm LED display systems using solar energy. The kit's operating endurance varies based on installation location, weather conditions, battery condition, and display settings.
Kit Components:
Depending on the part number, the kit includes:
- One 60W, 100W, or 150W solar panel.
- A battery box.
- Mounting brackets.
- Appropriate conduit for system connection.
- Four batteries and a charge control device within the battery box.
Technical Specifications:
Solar Panel Options:
- Polycrystalline 60W, 12V: Pmax 17.8V, 3.37A.
- Polycrystalline 100W, 12V: Pmax 17.3V, 4.63A.
Battery:
- Type: Sealed 12V, 35AH, AGM.
- Weight: 23 lbs.
- Dimensions: 7.68” x 5.12" x 6.10".
- Connectors: "Button" type.
- Safety: Non-Spillable, DOT approved.
Solar Charger:
- Model: Morning Star Sunsaver 20L.
- Rated Input (solar panel): 20A.
- Regulation Voltage: 14.1V.
- Regulation Method: PWM.
- Maximum Solar Voltage: 25V.
Wiring Harness:
- Battery Connection Fuse: 10A fast-acting, ATO 32V fuse.
Enclosure:
- Rating: NEMA 3R.
- Mounting: Bracket for banding or bolting provided.
- Insulation: R3.3 foil-faced rigid foam insulation on all inside surfaces.
- Battery Storage: Polycarbonate shelves.
Installation Requirements:
- Pole and Footing Material: User-supplied, appropriate for soil and load conditions. Consultation with a professional Civil engineer for proper pole selection and footing design is recommended.
- Mounting Hardware: Stainless steel banding, banding clips, application tool, or adjustable steel banding for battery box and sign. U-Bolts for solar panel installation.
- Tools: Assorted hand tools, socket set, and drive handle.
Installation Procedure:
- Mounting Bracket Assembly: Assemble the solar panel mounting bracket using the provided directions.
- Mounting Bracket Installation: Install the mounting bracket onto the pole using user-supplied U-Bolts.
- Solar Panel Orientation:
- In northern latitudes, aim the bracket at true South (not magnetic south). True South is the direction facing the sun parallel to the shortest shadow of the day, occurring at "Solar Noon." NOAA's website can help estimate Solar Noon based on longitude and latitude.
- Set the bracket angle using your current latitude +15 degrees from horizontal. For example, a 45-degree latitude requires a 60-degree panel angle from flat. An alternative calculation (Latitude *0.9 +29) provides a steeper angle, optimizing collection during winter months.
- Solar Panel Installation: Install the solar panel onto the mounting bracket.
- Battery Box Installation:
- Attach the "I" bracket to the battery box using the included hardware (two 3/8-16 x 1-1/4 inch bolts, two 3/8-inch flat washers, and two lock washers for center holes; 3/8-16 x 1-inch bolts with flat and lock washers for remaining four holes).
- Attach the battery box to the pole using user-supplied 3/4-inch banding and a buckle in two places, as close to each cross arm of the bracket as possible.
- Note: It is recommended to cover the solar panel during daylight installation to prevent accidental short circuits.
- Connecting Battery Power to ECS:
- Route the supplied 5-foot conduit with DC power wire and ground cable from the battery box to the bottom of the ECS. It can be installed at either the top or bottom of the battery box. If installed at the bottom, extra #14 Red and Black wire (not supplied) may need to be spliced.
- Remove the access panel at the bottom of the ECS, route the power cord and green ground wire through the conduit receptor, plug the power connector into the receptacle inside the ECM, and connect the ground wire to the green wire inside the ECS.
- Secure the conduit to the conduit receptor and install the access panel cover.
- Routing Solar Panel Wires to Battery Box:
- Remove the battery box cover.
- In the battery box, remove the two right-side screws and loosen the two left-side screws on the solar charger.
- Pull the charger away from its mounts and remove the insulation panel underneath, storing it safely.
- Install the wires and cable from the sign and solar panel through the provided conduit fittings, then tighten the conduit connectors.
- Replace the insulation panel and re-install the solar charger.
- Connecting ECS Wires to Solar Charger:
- Connect the ground wire from the display to the solar charger mounting screw.
- Connect the ECS power cable lead with the white stripe to the solar charger terminal marked "LOAD +" (terminal 6).
- Connect the other ECS power cable lead to the terminal marked "LOAD –" (terminal 5).
- Installing Batteries:
- Install the batteries in the battery box.
- Install the battery Ring Lug stubs onto the batteries first.
- Connect the batteries to their respective connectors (one set per shelf) in the harness, matching orange to orange and black to black. The operating voltage is 12VDC.
- Connecting Wires to Solar Panel:
- Ensure the opaque cloth is still covering the panel.
- In multi-panel parallel solar arrays, inspect that blocking diodes are properly installed on the solar panel terminal blocks to prevent back feeding on shaded panels.
- Connect the battery box red wire (+) to the panel + on the solar panel terminal block.
- Connect the battery box black wire to panel negative in the panel terminal block.
- Connecting Solar Panel Wires to Solar Charger:
- Ensure the opaque cloth is still covering the panel.
- Connect the solar panel red wire to the positive (+) terminal of the solar charger “SOLAR +" (terminal 4).
- Connect the solar panel black wire to the solar charger "SOLAR –“ (terminal 3).
- General: Read and observe all safety information and instructions. Contact your supervisor if unsure about any part of the installation.
- Intended Use: The solar kit is intended solely to power TraffiCalm LED displays.
- Safety Messages: DANGER, WARNING, and CAUTION messages indicate potential hazards.
- Personal Safety Equipment: Wear gloves, goggles, and an apron when handling batteries. Use high visibility vests, hard hats, electrical shock protection clothing, safety shoes, safety glasses, face shields, and hearing protection devices.
- Electrical Shock: Always turn off power to equipment before servicing.
- Battery Safety:
- Batteries may produce explosive gas; work in a well-ventilated area, avoid sparks/open flames, and use personal safety equipment.
- Battery acid can cause skin irritation and eye injury. Handle batteries with care.
- Always use recommended charging systems.
- Dispose of batteries according to local government laws.
- Keep tools, jewelry, and other conductive objects away from battery terminals to prevent short circuits and skin-searing temperatures.
- Do not connect battery stub ring lugs to the harness until securely attached to a battery first.
- Mechanical Safety:
- Use appropriate work zone traffic control methods, equipment, and procedures to reduce impact hazards from falls, passing vehicles, and unstable equipment.
- Use proper lifting techniques and adequate help to prevent strain or back injury.
- Ensure the sign is mounted to an appropriately rated pole or mounting surface with appropriately rated mounting hardware to avoid injury from falling or unstable equipment.
- AC Voltage: Charging activity on this equipment must be performed by qualified personnel with training on servicing such equipment.
Maintenance Features:
- Low Maintenance Design: The system is designed to require minimal maintenance.
- Solar Panel Inspection: Inspect and clean the solar panel periodically.
- Vegetation Management: Check for and prune back local vegetation shading the panel.
- Battery Replacement: Use sealed batteries of the correct voltage and capacity ratings.
- Battery Life Optimization:
- Never leave the battery in a discharged state for more than a few days.
- During extended cloudy periods, monitor battery level and recharge or reduce display power consumption.
- Configure the display to ensure no more than 50% of the battery charge is removed at any time.
- Perform a maintenance charge on the battery 3 to 4 times each year.
Testing and Monitoring:
- Panel Operation Check: Check panel operation and battery charging with a volt meter. During daylight, if battery voltage rises above night levels, the solar panel and charger are working.
- Charge Process Monitoring: Monitor the charge process through a full charge. If charge voltage is excessive, disconnect the solar panel until repairs are made to prevent battery damage.
- Temperature Compensation: The charger is temperature compensated, meaning charge voltage will be higher in cold weather and lower in hot weather. Normal full charge voltage varies -28mV per degree C of deviation from 25°C.
- Initial Setup: For best results, start with a new, fully charged battery. Never mix old and new batteries.
- Grounding: Ensure the solar panel rack and battery box are properly grounded according to code.
Warranty:
TraffiCalm Systems warrants the product (excluding batteries) to be free of defects in materials and workmanship for two (2) years from the end user's receipt. The warranty is valid only if the product is ineffective due to defects in materials or workmanship and is installed, operated, and maintained according to manufacturer's instructions. TraffiCalm's sole responsibility is to furnish replacements for defective parts. Replacement parts carry the unexpired warranty of the parts they replace. Non-warranty repairs are guaranteed for 90 days. Claims are honored if TraffiCalm is notified within the warranty period, provided reasonable information, and permitted to verify the cause of failure. TraffiCalm assumes no liability for incidental or consequential damages.
Warranty Exclusions:
Damage resulting from accidents, vandalism, impact with foreign objects, acts of God, unauthorized product modifications, failure to follow TraffiCalm's operating or installation instructions, removal or relocation of the unit, external electrical work, virus/hacker activity, and external computer errors are not covered. This warranty is made in lieu of all other warranties and conditions, express or implied, including but not limited to implied warranties and conditions of merchantability.
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