Carmanah R820 User manual

OWNER’S MANUAL
Solar-Powered LED Pedestrian Crosswalk
Flashing Beacon - Model R820
© July 13, 2006, Carmanah Technologies Inc.
www.carmanah.com
Technical Support: customerservi[email protected]
Toll Free in North America: 1-877-722-8877
International: [phone] | Fax: [phone]
R820 - 36983

Owner’s Manual | Model R820
Carmanah Technologies Inc. Copyright © 2006
Document number: MAN_ROAD R820 Owner's Manual 36983_vB
Last revised: November 7, 2006
3
Table of Contents
1.0 INTRODUCTION...................................................................................................4
2.0 COMPONENT IDENTIFICATION..........................................................................5
3.0 CONFIGURATION & INSTALLATION INSTRUCTIONS.......................................6
3.1 C HOOSING AND P REPARING A S UITABLE L OCATION FOR I NSTALLATION ..............6
3.1.1 Optimal Solar Location.................................................................................6
3.1.2 Minimum Distance between Systems...........................................................6
3.1.3 Preparing the Pole Mount ............................................................................6
3.2 C ONFIGURING THE S OLAR E NGINE P RIOR TO I NSTALLATION ...............................7
3.2.1 Preparing the Bird Deterrents and Antenna for Installation...........................7
3.2.2 Temporarily Connecting System Pieces to Configure System......................8
3.2.3 Primary/Secondary Channel Selection.........................................................8
3.3 C ONFIGURING THE F LASH D URATION AND T IMER D ELAY .....................................9
3.3.1 Factory Flash and Timer Delay Settings.....................................................10
3.3.2 Battery Connection, Customized Flash Duration and Timer Delay.............10
3.4 P REPARING R820 C OMPONENTS FOR F IELD I NSTALLATION ..............................12
3.4.1 Using a New Pole, Wiring the R820 Button................................................13
3.5 I NSTALLING THE R820 ON A P OLE OR M AST A RM .............................................13
3.5.1 Selecting the Poles....................................................................................13
3.5.2 Using an Existing Pole, Wiring the R820 Buttons.......................................13
3.5.3 Mount the Solar Engine..............................................................................14
3.5.4 Install the Signal Heads .............................................................................15
4.0 SYSTEM MAINTENANCE...................................................................................16
5.0 SERVICE AND PRODUCT INFORMATION........................................................17
5.1 S ERVICE .........................................................................................................17
5.2 A DDITIONAL P RODUCTS ..................................................................................17
6.0 APPENDIX A: PRODUCT SPECIFICATIONS ...................................................18

Owner’s Manual | Model R820
Carmanah Technologies Inc. Copyright © 2006
Document number: MAN_ROAD R820 Owner's Manual 36983_vB
Last revised: November 7, 2006
4
1.0 Introduction
The Model R820 solar-powered flashing beacon increases the visibility of pedestrians using
uncontrolled crosswalks. A typical installation consists of two pairs of flashing beacons, each
mounted on poles at opposite ends of the crosswalk. Pedestrians activate the R820 solar
roadway lights by pressing a button installed on either pole. The two units communicate with each
other using radio signals. On each pair of lights, one light is flashing towards traffic approaching
the crosswalk from each direction. Coming from either direction, drivers will see two flashing
lights, one on each end of the crosswalk. When activated, drivers will see a “bouncing-ball effect”,
with lights flashing on alternate ends of the crosswalk. The R820 system can accommodate
additional beacons, either in the median, overhead, or in advance of the crosswalk.
Since the R820 operates entirely by solar power, connecting to grid power is unnecessary. In
addition, wireless communication between units means that the R820 requires no trenching of
cables across the roadway. The R820 solar-powered roadway light is designed to operate reliably
under all environmental conditions with no scheduled maintenance for up to 5 years.
WARNING: The R820 is a warning beacon and is intended to be used as a supplemental
emphasis to warning signs located at uncontrolled marked crosswalks, as specified in the
2003 Manual of Uniform Traffic Control Devices, Chapter 4K . It is not a traffic control
device. It is the responsibility of the pedestrian to ensure traffic has stopped before entering
the crosswalk; this is clearly noted on the information plate mounted with the activation
pushbutton. The R820 is only a supplement for an uncontrolled marked crossing.
WARNING: Exercise caution when handling the battery packs. They are capable of
generating enormous short-circuit currents. Remove all jewelry (bracelets, metal-strap
watches, rings) before attempting to handle or remove the battery packs.

Owner’s Manual | Model R820
Carmanah Technologies Inc. Copyright © 2006
Document number: MAN_ROAD R820 Owner's Manual 36983_vB
Last revised: November 7, 2006
5
2.0 Component Identification
1. LED Signal Module
2. Polycarbonate Signal Head
3. Solar Engine
4. Antenna Assembly
5. Bird Deterrent
6. Pole (not included)
7. Push-Button Mounting Plate
8. Push-Button
9. Push-Button sign
10. Sign (not included)
11. Top Brackets (optional)
12. Bottom Brackets (optional)
2 .
3
4
11 11
6
2
2
1
1
2
3
4
10
8
7
6
9
5
12 12

Owner’s Manual | Model R820
Carmanah Technologies Inc. Copyright © 2006
Document number: MAN_ROAD R820 Owner's Manual 36983_vB
Last revised: November 7, 2006
6
3.0 Configuration & Installation Instructions
Installing the R820 is a quick and relatively smooth procedure that can normally be carried out by
existing road maintenance crews. The installation instructions in this manual are divided into
three parts: choosing a location, unit configuration and pre-wiring in the shop, and field
installation. Please read this manual to determine what tasks should be completed in the shop
prior to the field installation portion of the job.
Required Tools:
•Socket Set
•Crescent Wrench
•Tap and Die Set
•#2 Phillips Screwdriver
•5/32” Allen Key
•Fish Tape
•12-15 ft Ladder
•Level
•Compass
3.1 Choosing and Preparing a Suitable Location for Installation
Likely a suitable location will already have been selected
at the time of order. However, please ensure that each
of the criteria outlined in this section have been met
before proceeding with the installation.
3.1.1 Optimal Solar Location
As the Carmanah Model R820 is a solar-powered
device, it is critical to position the unit in relation to the
optimum angle of the sun in order to achieve maximum
solar power generation.
To do this, the Solar Engine must ideally be installed in a
non-shady location where it can be angled towards the
equator for maximum solar exposure during daylight
hours. See section 3.5.3 for more details.
3.1.2 Minimum Distance between
Systems
Figure 1 shows the minimum distance that must be
maintained between independent systems using the
same radio channel. If independent systems are required to be located
less than 300 meters from each other the radios in each independent
system MUST be set to different channels.
Please refer to section 3.2.3 for information on setting the radio channel.
3.1.3 Preparing the Pole Mount
The R820 lights are mounted on a pole that will be most likely be affixed to a base with the
necessary mounting hardware. If concrete foundations will be used, concrete bases will need to
be poured before the installation of the system. See Figure 2.
Figure 2: Concrete Base
Figure 1: Minimum Spacing Between Two
Systems Using the Same Radio Channel

Owner’s Manual | Model R820
Carmanah Technologies Inc. Copyright © 2006
Document number: MAN_ROAD R820 Owner's Manual 36983_vB
Last revised: November 7, 2006
7
3.2 Configuring the Solar Engine Prior to Installation
R820 solar roadway beacons should be configured before being installed at the selected location.
This is especially important when installing multiple R820 units as the job can be divided between
shop and field time.
3.2.1 Preparing the Bird Deterrents and Antenna for Installation
There are two items attached to the Solar Engine: bird deterrents
and an antenna. Both items are shipped with the R820 solar
roadway light. The small deterrents discourage birds from using
the R820 as a perch.
The antenna broadcasts or receives the radio signal to ensure
each of the R820 beacons act as a system. The antenna is
shipped inside the Solar Engine component when it comes from
the factory. As shown in Figure 3, the antenna is wrapped in foam
and placed on the left side of the enclosure.
To set up the external pieces attached to the Solar Engine,
complete the following steps:
1. Identify the three bird deterrents and set aside.
2. Remove the cover with the solar panels from the top of
the Solar Engine.
3. Attach each of the three bird deterrents, included with
the R820, to the top of the solar panel via the pre-drilled
holes. Ensure the solar panels remain as clean as
possible.
4. Detach the co-axial cable from where it is connected
inside the Solar Engine, and remove and unwrap the
attached antenna.
5. Remove the mounting screw for
the antenna bracket, located on
the side of the Solar Engine.
6. Insert the co-axial cable through
the hole in the side of the Solar
Engine, and carefully thread the
co-axial cable onto the gold
colored fitting on the electronics
enclosure from where it was just
removed it.
7. Pull the cable through the hole
and position the antenna bracket
over the mounting screw hole on
the side of the Solar Engine.
8. Use the mounting screw to attach
the antenna bracket to the Solar Engine.
Figure 2: Bird Deterrents
Figure 3 (top): R820 as shipped from the factory.
Figure 4 (bottom): Antenna Assembly
Antenna wrapped in
foam
Co-axial
cable
Antenna

Owner’s Manual | Model R820
Carmanah Technologies Inc. Copyright © 2006
Document number: MAN_ROAD R820 Owner's Manual 36983_vB
Last revised: November 7, 2006
8
3.2.2 Temporarily Connecting System Pieces to Configure System
To configure the flash duration and timer delay, the R820’s button, signal heads and batteries
must be temporarily connected.
1. Carefully unwrap the three wires
running from the mounting tee
located on the bottom of the Solar
Engine.
2. Remove the button assembly from
the button mounting plate.
3. Attach the button wire from the
Solar Engine to the button
contacts.
4. The button wire has two ring
terminal connectors.
5. Connect the remaining two wires
to the two signal heads.
Note: The signal head
connections use Molex
quick connectors.
3.2.3 Primary/Secondary Channel Selection
The channel chosen for each system must be the same in each unit of that system. Five channel
switches give the possibility of 32 unique channels as shown in Figure 9, below. Each R820
system is shipped set to a factory default of one Primary and one or more Secondary, all at
Channel 0.
Note: If the settings require changing at a later date, the batteries must be unplugged and then
reconnected after the system is reconfigured for the new settings to take effect, as the system
Figure 5: Button Connector Wires
Figure 6: Button
Mounting Plate
Figure 7: Button Contacts
Figure 8: Signal Heads

Owner’s Manual | Model R820
Carmanah Technologies Inc. Copyright © 2006
Document number: MAN_ROAD R820 Owner's Manual 36983_vB
Last revised: November 7, 2006
9
reads the settings only upon power-up. It is recommended that configuration occur when the
batteries are unplugged to minimize any potential safety hazard.
Note: For a system (two or more units) there must be only one primary – the remaining units in
the system must be configured as secondary.
To set the channels for each system:
1. Remove the logic card housing cover located between the two
batteries (See Figure 10).
2. The DIP switches are located on the logic card and has eight
individual switches (See Figure 11).
•Switch 1 is used to configure the unit as a
Primary or a Secondary. “ON” position is
PRIMARY. “OFF” position is SECONDARY.
•Switches 2 and 3 are not used.
•Switches 4 through 8 are used to set the
channel.
3.3 Configuring the Flash Duration and Timer Delay
The customer can select the length of time the lights should flash after each button press and an
optional delay time between uses. This is done in the first five (5) minutes following power-up of
Figure 9: Channel Selection
Figure 11: DIP switch
settings indicating a
Primary unit on channel 0
Figure 10: Logic
Card Housing

Owner’s Manual | Model R820
Carmanah Technologies Inc. Copyright © 2006
Document number: MAN_ROAD R820 Owner's Manual 36983_vB
Last revised: November 7, 2006
10
the system. If the customer does not attempt to enter the configuration mode upon power-up, but
simply presses the button, the previously stored settings will be utilized.
Each of the R820 units in a crosswalk installation must be configured individually, with the same
settings. After product configuration is completed, the settings are stored in non-volatile memory.
If the batteries are re-connected, and no change in configuration is desired, the product will
continue to operate with its previous settings. The R820 system has two user-configurable
parameters:
Flash Duration - The amount of time the light will flash after each button press by a pedestrian.
The flash duration is set in 5-second increments, up to one minute. This command sequence sets
the length of time the system will flash after one button press, and should consider the length of
time it will take a pedestrian to cross the street.
Timer Delay - The amount of time the light will delay between uses before accepting a new
button press. The delay is set in 5-second increments, up to one minute. If the delay is set to 0, a
button press while the light is flashing causes the light to restart its timer at the time of the button
press (the light will flash for "flash duration" seconds after the new button press).
3.3.1 Factory Flash and Timer Delay Settings
The default factory configuration is a 20 second flash duration with a zero second delay between
activations. What this means is, if a second pedestrian should press the button while the light is
flashing, the light will flash for 20 seconds starting from the moment the button is pressed.
To customize the flash duration and timer delay, follow the
instructions provided in the next section.
3.3.2 Battery Connection, Customized Flash
Duration and Timer Delay
The R820 ships with two battery packs that are disconnected
for shipping. Configuration of flash duration and timer delay is
performed during the five minutes immediately following
battery connection. Battery connection is as outlined below:
1. Find the two connection wires from each battery pack:
the longer terminating with a male connector, and the
shorter terminating with a female connector.
2. With the bases of the batteries facing the person doing
the installing, attach the long harness (male) of the left
side battery to the short harness (female) of the right
side battery.
3. Attach the long harness (male) from the right hand battery to the “Battery” connection on
the PCB harness end of the battery nearest to the end of the PCB connectors. The short
harness (female) from the left hand battery will remain unused.
4. The flash duration and timer delay for the system are now ready to configure as per the
table below:
Figure 12:
Left side battery pack
showing short (female) and long
(male) leads