Carmanah E Series, R920-E, R820-E, R247-E, R829-E User Manual

84322_MANUAL_TRA_E-Series_RevA

E Series

TRAFFIC BEACON USER MANUAL

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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 How to Set Up the R820-E .........................................................................................................................8

2.3 How to Set Up the R829-E .........................................................................................................................8

2.4 How to Set Up the R247-E .........................................................................................................................8

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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E SERIES USER MANUAL

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

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E SERIES USER MANUAL

WARNINGS AND PRECAUTIONS

1.0 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

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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.

E SERIES USER MANUAL

WARNINGS AND PRECAUTIONS

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.

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E SERIES USER MANUAL

WARNINGS AND PRECAUTIONS

EMS

E Series

Mounting Adapters

RRFB Light Bars, Circular

Pedestrian

Solar Engine

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Beacons, LED Signs

Push Button

E SERIES USER MANUAL

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 R247­E. 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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E SERIES USER MANUAL

HOW TO USE THIS MANUAL

2.2 How to Set Up the R820-E

If you are setting up the R820-E, consult the following the sections in the order below:

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

• 3.8 Circular Beacons: Overview, Page 16-18

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

• 4.0 Installation, Page 22 (follow instructions here)

• 5.3 R820-E Programming, Page 65

• 6.0 Commissioning, Page 66

2.3 How to Set Up the R829-E

If you are setting up the R829-E, consult the following the sections in the order below:

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

• 3.8 Circular Beacons: Overview, Page 16-18

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

• 4.0 Installation, Page 22 (follow instructions here)

• 5.4 R829-E Programming, Page 65

• 6.0 Commissioning, Page 66

2.4 How to Set Up the R247-E

If you are setting up the R247-E, consult the following the sections in the order below:

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

• 3.8 Circular Beacons: Overview, Page 17-18

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

• 4.0 Installation, Page 22 (follow instructions here)

• 5.4 R247-E Programming, Page 65

• 6.0 Commissioning, Page 66

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E SERIES USER MANUAL

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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E SERIES USER MANUAL

3.0 INTRODUCTION

R920-E with Single Light Bar and

R920-E with Dual Light Bar and

R920-E Advance Warning with

Button (uni-directional)

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

Push Button (uni-directional)

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Push Button (bi-directional)

single Light Bar and No Push

E SERIES USER MANUAL

3.0 INTRODUCTION

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E SERIES USER MANUAL

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.

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

Typical Configurations

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E SERIES USER MANUAL

3.0 INTRODUCTION

3.5 R829-E: School Zone Flashing Beacon

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
mounted 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.

), an externally-

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

As an alternative to circular beacons, R829-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.

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E SERIES USER MANUAL

3.0 INTRODUCTION

Typical Configurations

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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E SERIES USER MANUAL

3.0 INTRODUCTION

3.6 R247-E: 24-Hour Flashing Beacon

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.

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

As an alternative to circular beacons, R247-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

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R247-E with Integrated Signal Head

E SERIES USER MANUAL

3.0 INTRODUCTION

Dual Confirmation Light

Single Confirmation Light

3.7 RRFB Light Bars: Overview

The E Series provides standard wiring to support up to two (2) RRFB light bar fixtures. The FHWA Interim
Approval 21 March 20
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.

– Using Opaque Cover

th

, 2018 defines the flash pattern of the RRFB and specifies the J595 standard for

– No 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.

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E SERIES USER MANUAL

3.0 INTRODUCTION

Single Beacon 4.5” Post

Dual Beacon Horizontal

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E SERIES USER MANUAL

3.0 INTRODUCTION

Dual Beacon Vertical

E Series Solar Engine on

Integrated Signal Head

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E SERIES USER MANUAL

3.0 INTRODUCTION

For the E Series, do not mix different sizes or LED counts of LED Signs or mix LED signs with

G Series.

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.

other types of fixtures. Mixing fixture types is possible with Carmanah’s dual-EMS cabinet-based

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.

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E SERIES USER MANUAL

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

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

Polara Bulldog Pushbutton to EMS Harness

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

Light Bar to EMS Harness

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

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E SERIES USER MANUAL

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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E SERIES USER MANUAL

4.0 INSTALLATION

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

examination and solar simulations for your site.

4.0 Installation

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

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.

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E SERIES USER MANUAL

4.0 INSTALLATION

a. Imperial socket set

direction

h. Drill and drill bits

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:

b. Crescent wrench
c. Tap and die set
d. Imperial Allen Wrench Set
e. Fish tape
f. Level
g. Compass or Pre-Determined equatorial

4.2 Solar Engine Installation

1. Attach the post adapter to the solar engine.

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

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

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