TraffiCalm Solar N User manual

Solar North Kit
Solar N Kit 150W 140AH
M75-SOLAR-000N
E. 5676 Seltice Way Post Falls, Idaho 83854 1-855-738-2722 [email protected]
Installation Instructions 029-04919-0000 rev D August 2019

Solar N-C-S Installation Instructions 029-04919-0000 rev D
REVISION BLOCK
REV.
DESCRIPTION
DATE
APPROVED
A
Original Release
May, 2018
JH
B
Updated Panel Info
AP
C
D
Updated Warranty
Statement
August, 2019
AP
This product was manufactured in an ISO 9001 certified facility.

Solar N-C-S Installation Instructions 029-04919-0000 rev D
Table of Contents
1Safety Information.............................................................................................................................................. 2
1.1 Intended Use ................................................................................................................................ 2
1.2 Technical Support .........................................................................................................................2
1.3 Safety Messages…......................................................................................................................... 2
1.3.1 Safety Message Format..................................................................................................... 2
1.4 Safety Considerations .................................................................................................................. 3
1.4.1 Personal Safety Equipment and Clothing ....................................................................... 3
1.4.2 Electrical Shock .............................................................................................................. 3
1.4.3 Battery Safety.................................................................................................................. 4
1.4.4 Mechanical Safety............................................................................................................ 4
2Description ......................................................................................................................................................... 5
2.1 Specifications................................................................................................................................ 5
2.2 Required Maintenance ................................................................................................................. 5
2.3 Battery Life… ...............................................................................................................................5
3Installation Requirements.................................................................................................................................. 6
3.1 Equipment Requirements.............................................................................................................. 6
3.2 Installation of Solar Panel .............................................................................................................6
3.3 Battery Box Installation… ............................................................................................................6
Warranty…............................................................................................................................................................... 9
Appendix A: Solar Kit Battery Box Drawing ..................................................................................................... 10
Appendix B: Solar Panel Structure assembly ......................................................................................................11
NOTICE: Because of TraffiCalm’s commitment to continuous improvement the content of these documents
and product specifications may change without notice. Please contact your partner or TraffiCalm Technical
service to check for updates before planning your installation.
2

Solar N-C-S Installation Instructions 029-04919-0000 rev D
2
1 Safety Information
We provide important safety information and
warnings to assist you in understanding and avoiding
potential harm to yourself, and possible damage to
equipment during the installation of TraffiCalm LED
Sign solar kit. Although we have included many
potential hazards you may encounter during the
installation of this equipment, we cannot predict all
of the possible hazards and this list should not be a
substitute for your judgment and experience.
Please read and observe all safety information
and instructions in this manual before installing
the system equipment. Also, save this installation
manual for future reference.
If you are unsure about any part of this installation or
of the potential hazards discussed, please contact
your supervisor immediately.
1.1 Intended Use
The solar kit is intended to be used to power the
TraffiCalm LED displays.
1.2 Technical Support
If you have questions about the system, its use, or
operation, please contact your local partner or call
the TraffiCalm Technical Service department at 1-
855-738-2722, in the U.S.A. Technical service
hours: Monday through Thursday, 7:00 AM to 5:00
PM and Friday from 7:00 AM to 12:00 PM Pacific
Standard Time.
1.3 Safety Messages
We include safety messages in this manual to help
you protect your safety and the safety of others. This
section contains important information to help you
recognize and understand these safety messages.
Please read all messages before
proceeding with the installation of this equipment.
1.3.1 Safety Message Format
Safety messages are designed to alert you to potential
hazards that can cause personal injury to you or
others. They can also indicate the possibility of
property damage.
Each safety message box contains the safety alert
symbol ; and one of three signal words:
DANGER, WARNING, or CAUTION; plus a safety
message.
The signal words and symbols, and their meanings,
are shown below:
DANGER
The safety message is in this box.
DANGER indicates a potentially hazardous
situation, which, if not avoided, will result in
death or serious injury and/or property damage.
WARNING
The safety message is in this box.
WARNING indicates a potentially hazardous
situation, which, if not avoided, could result in
death or serious injury and/or property damage.
CAUTION
The safety message is in this box.
CAUTION indicates a potentially hazardous
situation, which, if not avoided, may result in
minor or moderate injury and/or property
damage.
In addition to the symbols and words explained
above, each safety message identifies the hazard,
describes what you can and should do to avoid the
risk of exposure to the hazard, and tells the probable
consequences of not avoiding the hazard.
WARNING
Battery acid may cause skin irritation and eye
injury. To reduce the risk of burns or other
acid related injury resulting from handling
lead-acid batteries:
-Wear gloves, goggles, and an apron when
handling batteries,
-Handle batteries with care.

Solar N-C-S Installation Instructions 029-04919-0000 rev D
3
1.4 Safety Considerations
Please consider the following safety issues before
servicing TraffiCalm Driver Feedback Signs and
power systems.
Although we have compiled this list of common
safety considerations, it should not be considered as
complete. It is not intended to take the place of your
good judgment, training, and experience. Choose the
right equipment for the job. If you are unsure of
which safety equipment is recommended or
appropriate for the job, ask your supervisor or
foreman.
1.4.1 Personal Safety Equipment and
Clothing
Personal safety equipment and clothing including
high visibility vests, hard hats, gloves, electrical
shock or electrocution protection clothing and
equipment, safety shoes, safety glasses, face shields,
goggles, and hearing protection devices are just some
of the items available to you.
1.4.2 Electrical Shock
As a trained installer of electrical equipment you are
aware of the dangers associated with servicing
electrical devices. Always be sure that the power to
the equipment, and all associated equipment, is
turned off before beginning any procedure. Use the
equipment, techniques, and procedures that you
learned during your training or apprenticeship or
other electrical industry recognized safety
procedures.
lifting techniques and have adequate help.
WARNING
To reduce the risk of burns or other acid-related
injury resulting from exploding batteries:
-Always use the recommended
charging systems with this product.
CAUTION
To avoid the possibility of injury due to falling or
unstable equipment:
-Be certain the sign is mounted to an
appropriately rated pole or equivalent
mounting surface.
-Use appropriately rated mounting
hardware.
WARNING
To reduce the risk associated with
contamination of water supplies resulting
from improper disposal of batteries containing
lead and acid:
-Please dispose of batteries in
accordance with all local government laws
and regulations.
CAUTION
An accidental short circuit may
instantly heat conductive jewelry, tools, and
surrounding objects to skin-searing
temperatures. To reduce this risk when
working around batteries:
-Keep tools, jewelry, and other
conductive objects away from the battery
terminals.
WARNING
To reduce the risk of impact hazards resulting
from falls, accident with a passing vehicle,
and/or from unstable equipment:
-Use appropriate work zone traffic
control methods, equipment, and
procedures.
CAUTION
Strain or back injury may result from
lifting equipment improperly. To reduce the
risk of strain or back injury, use proper

Solar N-C-S Installation Instructions 029-04919-0000 rev D
4
1.4.3
Battery Safety
Batteries may produce an explosive gas under some
conditions. This gas may easily be ignited by a spark
or flame as you work near the battery. To reduce the
risk of explosion, disconnect the battery, work in a
well ventilated area, avoid the use of devices that
create sparks or use open flames, and use appropriate
personal safety equipment and clothing.
1.4.4 Mechanical Safety
CAUTION
Strain or back injury may result from
lifting equipment improperly. To reduce the
risk of strain or back injury, use proper
lifting.
WARNING
To reduce the risk of electric shock related injury
resulting from contacting hazardous AC voltage:
-The charging activity on this
equipment must be performed by qualified
personnel who is someone with previous
training or who has received factory
training on these or similar types of
equipment so that they thoroughly
understand the techniques, tools, and
methods required to properly service this
equipment.
WARNING
To reduce the risk associated with
contamination of water supplies resulting
from improper disposal of batteries containing
lead and acid:
-Please dispose of batteries in
accordance with all local government laws
and regulations.
CAUTION
An accidental short circuit may
instantly heat conductive jewelry, tools, and
surrounding objects to skin-searing
temperatures. To reduce this risk when
working around batteries:
-Keep tools, jewelry, and other
conductive objects away from the battery
terminals.
-Do not connect the battery stub
ring lugs to the harness until they are
securely attached to a battery first.
WARNING
Battery acid may cause skin irritation and eye
injury. To reduce the risk of burns or other
acid related injury resulting from handling
lead-acid batteries:
-Wear gloves, goggles, and an apron when
handling batteries,
-Handle batteries with care.
WARNING
To reduce the risk of impact hazards resulting
from falls, accident with a passing vehicle,
and/or from unstable equipment:
-Use appropriate work zone traffic
control methods, equipment, and
procedures.
WARNING
To reduce the risk of burns or other acid-related
injury resulting from exploding batteries:
-Always use the recommended
charging systems with this product.

Solar N-C-S Installation Instructions 029-04919-0000 rev D
5
2Description
The solar kit provides power for a TraffiCalm LED
display system using the energy of the sun. Display
operating endurance obtained will vary with
installation location and conditions, battery
condition, weather conditions, and display settings.
Depending on the part number supplied (see cover
page) this kit may include one 130 watt solar panel,
or one 85W solar panel or one 55W solar panel, a
battery box, mounting brackets, and appropriate
conduit to connect the system. The battery box
contains four batteries and the charge control device.
The following tables contain the specifications for
the solar panels and the batteries.
2.1 Specifications
Solar Panel:
Polycrystalline 140W, 12V, (Pmax 18.5V, 8.11A).
Battery (4-each):
Sealed 12V, 35AH, AGM, 23-lbs, 7.68” x 5.12” x
6.10” with “button” connectors. Non-Spillable
DOT approved.
Solar Charger:
Morning Star Sunsaver 20L.
20A rated input (solar panel).
Regulation Voltage 14.1V.
Regulation method is PWM.
Maximum Solar Voltage 25V.
Wiring Harness battery connection is fused at 10A
fast acting with an ATO 32V fuse.
Enclosure:
NEMA 3R rating.
Mounting bracket for banding or bolting provided.
Enclosure is insulated with R3.3 foil faced rigid foam
insulation on all inside surfaces. Batteries sit on
polycarbonate shelves.
Weight – 120lbs. (with batteries)
2.2 Required Maintenance
Although this system is designed to require little
maintenance, the system will perform most
efficiently if a small amount of maintenance is
performed.
Inspect and clean the solar panel periodically. Check
for local vegetation shading the panel and prune back
as needed.
When replacing battery be sure to use a sealed
battery of the correct voltage and capacity ratings.
2.3 Battery Life
These are suggestions for obtaining the greatest
battery lifetime.
oNever let the battery sit in a discharged state
for more than a few days.
oDuring extended cloudy days monitor the
battery level and either recharge as necessary
or reduce the power consumed by the display
by limiting its operation.
oTry to configure the display in such a way as
to ensure that no more than 50% of the
battery charge is removed at any time.
oPerform a maintenance charge on the battery
3 to 4 times each year.
CAUTION
To avoid the possibility of injury due to falling or
unstable equipment:
-Be certain the sign is mounted to an
appropriately rated pole or equivalent
mounting surface.
-Use appropriately rated mounting
hardware.

Solar N-C-S Installation Instructions 029-04919-0000 rev D
6
3Installation Requirements
This section describes the components, tools, and
information you must have available before
installing TraffiCalm 140Ah Solar Kit.
3.1 Equipment Requirements
In addition to the Driver Feedback Sign to be
installed, you will need the following suggested
items if you intend to follow these directions:
oPole and Footing material
oStainless steel banding and banding clips and
application tool or adjustable steel banding
for installing Battery Box & Sign
oAssorted hand tools.
oSocket set and drive handle.
oU-Bolts for installing solar panel
3.2 Installation of Solar Panel
NOTE
It is the installer’s responsibility to
ensure that this installation
complies with local and national
codes.
Use a pole of proper size with an appropriate footing
for the soil and load conditions. Consult with a
professional Civil engineer for proper pole selection
and footing design for the local area. Assemble
the solar panel mounting bracket using directions
supplied with the mounting bracket components.
Install the mounting bracket onto the pole with user
supplied (U-Bolts).
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 cast by the sign pole, which occurs at “Solar
Noon”. To estimate what time solar noon will occur
in your area go to the NOAA web site with your
longitude and latitude.
http://www.srrb.noaa.gov/highlights/sunrise/sunrise.h
tml
Set the bracket angle using your current latitude +15
degrees as measured from horizontal (flat) to the final
position. Example: If the latitude is 45-degrees, set
the panel angle 60-degrees away from flat. You may
be able to get a small amount of additional power by
calculating the set angle using: Latitude *0.9 +29.
This results in a steeper angle than the other method,
optimizing collection around the noon hours during
the winter months, which is when the most solar
energy is available.
Install the solar panel onto the mounting bracket.
3.3 Battery Box Installation
Note: you may wish to cover the solar panel during
daylight installation to prevent accidental short
circuit of energized panel during installation.
Attach the “I” bracket to the battery box using
the included hardware.
a. Attach the “I” bracket to the center holes of
the battery box using two 3/8-16 x 1-1/4 inch
bolts, two 3/8-inch flat washers, and two
lock washers. (These bolts are hidden when
the battery box is mounted on the pole.)
b. Install 3/8-16 x 1-inch bolts in the remaining
four holes of the bracket with a flat washer
and a lock washer on each bolt.
Attach the battery box to the pole with user-
supplied 3/4-inch banding and a buckle in two
places (as close to each cross arm of the bracket
as possible).
Connect battery power to the Electronic Control
System (ECS) see Figure 3-1 (15” DFB ECS

Solar N-C-S Installation Instructions 029-04919-0000 rev D
7
Shown with optional beacon cable set, see your
display installation manual for other display size
connections).
Figure 3-1. 15” Display ECS Access Panel
a. 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, but if installed at the bottom,
extra wire (#14 Red and Black, not supplied)
will have to be spliced in to make up the
extra length used.
b. At the bottom of the ECS, remove the access
panel and route the power cord and green
ground wire through the conduit receptor
located on the access panel. Plug in the
power connector to the power connector
receptacle located inside the ECM. Connect
the ground wire to the green wire located
inside the ECS.
c. Secure the conduit to the conduit receptor.
d. Install the access panel cover.
Route solar panel wires to the battery box. See
Figure 3-2.
a. Remove the battery box cover.
b. In the battery box, remove the two right side
screws and loosen the two left side screws on
the solar charger.
c. Pull the charger away from the mounts and
allow it to hang out of the way.
d. Remove the insulation panel that was under
the charger and store it in a safe place. (This
gives access to the conduit fittings from
inside of the enclosure.)
e. Install the wires and cable from the sign and
solar panel (solar panel left, sign right)
through the provided conduit fittings, and
then tighten the conduit connectors onto the
pre-installed fittings.
f. Replace the insulation panel removed earlier,
and re-install the solar charger.
Figure 3-2. Remove Solar Charger from
Battery Box
Connect ECS wires to solar charger in battery
box. See Figure 3-3.
a. Connect the ground wire from the display to
the solar charger mounting screw.
b. Connect the ECS power cable lead with the
white stripe to the solar charger terminal
marked “LOAD +”, which is terminal 6.
c. Connect the other ECS power cable lead to
the terminal marked “LOAD –“, which is
terminal 5.
Figure 3-3. Wiring Solar Charger
in Battery Box
Install the batteries in the battery box. Install the
battery Ring Lug stubs onto the batteries first.
Then connect the batteries to their respective
connectors (one set provided per shelf) in the
harness matching orange to orange and black to
black. The operating voltage is 12VDC. At this
point the display has power.
Connect the wires to the solar panel.
a. At the solar panel, make sure the opaque
cloth is still covering the panel.

Solar N-C-S Installation Instructions 029-04919-0000 rev D
8
b. In multi-panel parallel solar arrays inspect
that blocking diodes are properly installed on
the solar panel terminal blocks (in the solar
panel wiring boxes) to prevent back feeding
on shaded panels.
c. 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.
8. Connect the solar panel wires to the solar
charger in the battery box. See Figure 3-3.
a. Make sure the opaque cloth is still covering
the panel.
b. Connect the solar panel red wire to the
positive (+) terminal of the solar charger “SOLAR +”
terminal (4).
c. Connect the solar panel black wire to the
solar charger “SOLAR –“ terminal (3).
Check the panel operation and battery charging using
a volt meter. During daylight hours, if the battery
voltage rises above night levels, then the solar panel
and charger are working.
Monitor the charge process through a full charge. If
the charge voltage is excessive, then the charger may
have failed and will damage the batteries unless
action is taken to disconnect the solar panel until
repairs are made.
The charger is temperature compensated. It is
normal for the charge voltage to be higher when the
weather is cold, and lower when the weather is hot.
The normal full charge voltage varies -28mV per
degree C of deviation from 25°C.
Note: The solar panel only provides power
when illuminated by the sun. If the panel was
covered during installation, remove the cover
before performing this test.
For best results, start with a new fully charged
battery. Never mix old and new batteries. Be sure
to ground the solar panel rack and battery box
properly according to code.

Solar N-C-S Installation Instructions 029-04919-0000 rev D
9
TraffiCalm Systems, a division of MOR Manufacturing, provides the following warranty for its traffic
calming solutions whether sold directly by TraffiCalm or by an authorized TraffiCalm distribution
partner.
Warranty
•TraffiCalm Systems warrants the product, excluding batteries, will be free of defect in
materials and workmanship for a period of two (2) years beginning on the day the end
user receives the product. Warranty is only valid if the product is ineffective for its
intended purpose due to defects in materials or workmanship.
•Warranty is only valid if the product is installed, operated and maintained in accordance
with the manufacturer’s instructions and recommendations (available upon request).
•TraffiCalm’s sole responsibility and the purchaser’s and user’s exclusive remedy shall be
that TraffiCalm will furnish replacements for defective parts.
•Replacement parts will carry the unexpired warranty of the parts they replace. Non warranty
repairs are guaranteed for a period of 90 days.
•Claims made under this warranty will be honored only if TraffiCalm is notified of a failure
within the warranty period, reasonable information requested by TraffiCalm is provided,
and TraffiCalm is permitted to verify the cause of the failure.
•TraffiCalm assumes no liability for any incidental or consequential damages, in any way
related to the product regardless of the legal theory on which the claim is based.
This warranty does not cover damage resulting from:
o Accidents, vandalism, impact with a foreign object or acts of God.
o Product modifications made by someone not authorized by TraffiCalm
o Failure of Customer to follow TraffiCalm’s published operating instructions,
o Failure to follow TraffiCalm’s published site selection and installation instructions,
o Removal or relocation of the unit,
o Electrical work external to the unit, virus/hacker activity, and externalcomputer
errors.
THIS WARRANTY IS MADE IN LIEU OF ALL OTHER WARRANTIES AND CONDITIONS,
EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES
AND CONDITIONS OF MERCHANTABILITY.
E. 5676 Seltice Way Post Falls, Idaho 83854 1-855-738-2722 [email protected]

Solar N-C-S Installation Instructions 029-04919-0000 rev D
10
Appendix A: Solar Kit Battery Box Drawing
BOTTOMVIEW

Solar N-C-S Installation Instructions 029-04919-0000 rev D