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

E / F Series

84323_MANUAL_TRA_E-F-Series_RevA

TRAFFIC BEACON USER MANUAL

For the R920-E/F, R820-E/F, R829-E/F, and R247-E/F flashing beacons

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E / F SERIES USER MANUAL

TABLE OF CONTENTS

Table of Contents

Table of Contents .....................................................................................................................................................2

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

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

1.2 Standards ...................................................................................................................................................4

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

1.4 System Components ..................................................................................................................................6

2.0 Introduction .........................................................................................................................................................7

2.1 About the E and F Series............................................................................................................................7

2.2 Radio Communication ................................................................................................................................8

2.3 R920-E and R920-F: Pedestrian Crosswalk with RRFB Light Bars ...........................................................8

2.4 R820-E and R820-F: Pedestrian Crosswalk with Circular Beacons ....................................................... 10

2.5 R829-E and R829-F: School Zone Flashing Beacon .............................................................................. 11

2.6 R247-E and R247-F: 24-Hour Flashing Beacon ..................................................................................... 12

2.7 RRFB Light Bars: Overview ..................................................................................................................... 13

2.8 Circular Beacons: Overview .................................................................................................................... 13

2.9 LED Enhanced Signs: Overview ............................................................................................................. 14

2.10 Third-Party Devices: Overview ................................................................................................................ 14

3.0 Solar Engine Installation ................................................................................................................................. 16

3.1 Tools and Materials Required .................................................................................................................. 16

3.2 Solar Engine Mounting to Round Post .................................................................................................... 17

3.3 Solar Engine Mounting to Square Post with Universal Cast Mount ........................................................ 18

3.4 Solar Engine Mounting to Square Post with Steel Mount ........................................................................ 19

3.5 Solar Engine Mounting to Side of Post .................................................................................................... 20

3.6 Reinforced Signal Head for Integrated Solar Engine / Signal Head ........................................................ 21

3.7 Integrated Solar Engine with Signal Head – Round Post ........................................................................ 22

3.8 Integrated Solar Engine with Signal Head – Square Steel Post ............................................................. 24

3.9 Integrated Solar Engine with Signal Head – Square Wood Post ............................................................ 26

3.10 Integrated Solar Engine with Signal Head – Side of Post ....................................................................... 28

4.0 Fixture, Push Button, & Battery Installation ................................................................................................. 30

4.1 RRFB Light Bar Installation ..................................................................................................................... 30

4.2 Circular Beacon Installation ..................................................................................................................... 35

4.3 LED Enhanced Sign Installation .............................................................................................................. 36

4.4 Push Button Installation ........................................................................................................................... 37

4.5 Battery Installation ................................................................................................................................... 39

5.0 Installation of Optional Accessories ............................................................................................................. 43

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E / F SERIES USER MANUAL

TABLE OF CONTENTS

5.1 Calendar Upload / Override Switch Kit Installation .................................................................................. 43

5.2 RTC Time Switch Installation (F Series only) .......................................................................................... 44

5.3 Information Display Company Time Switch Installation (F Series only) .................................................. 45

5.4 Applied Information or FCU Modem Kit Installation (F Series only) ........................................................ 46

5.5 3PD Time Switch Supplementary Information ......................................................................................... 48

5.6 DC Relay Kit Installation (F Series only) ................................................................................................. 50

5.7 Polara XAV Controller Kit Installation (F Series only) ............................................................................. 51

5.8 Campbell Guardian Audible Push Button Kit Installation (F Series only) ................................................ 52

6.0 Energy Management System Programming and Testing ............................................................................ 52

6.1 EMS On-Board User Interface Operation ................................................................................................ 52

6.2 R920-E/F Programming ........................................................................................................................... 65

6.3 R820-E/F Programming ........................................................................................................................... 65

6.4 R829-E/F Programming ........................................................................................................................... 65

6.5 R247-E/F Programming ........................................................................................................................... 65

7.0 Commissioning Checklist ............................................................................................................................... 66

8.0 Maintenance and Product Care ...................................................................................................................... 67

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

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

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

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

9.0 Troubleshooting .............................................................................................................................................. 71

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

10.0 Customer Service and Warranty .................................................................................................................. 74

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

10.2 Glossary ................................................................................................................................................... 75

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E / F SERIES USER MANUAL

1.0 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 and F
Series 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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E / F SERIES USER MANUAL

1.0 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.

All Carmanah traffic products use a constant-current LED output circuit. Not all traffic beacons
are compatible with this output. Please contact Carmanah for additional information and
guidance when adding or replacing beacons or other hardware.

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E / F SERIES USER MANUAL

1.0 WARNINGS AND PRECAUTIONS

Solar Engine

Mounting Adapters

RRFB Light Bars, Circular
Pedestrian
Push Button

EMS

Batteries

Solar

Onboard

Antenna

Ambient Light

visible)

1.4 System Components

Sensor (not

User

Interface

(OBUI)

Panels

(E Series shown)

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Beacons, LED Enhanced
Signs

E / F SERIES USER MANUAL

2.0 INTRODUCTION

E-Series
Models

F-Series
Models

Applications

LED type(s)

Radio
Communication

R920-E

R920-F

Pedestrian crosswalks

RRFB or LED Enhanced Signs

Standard

R820-E

R820-F

Pedestrian crosswalks

Circular beacons or LED signs

Standard

R829-E

R829-F

School zones, calendar-based

Circular beacons or LED signs

Optional

R247-E

R247-F

Continuous 24-7 operation

Circular beacons or LED signs

N/A

2.0 Introduction

2.1 About the E and F Series

The Carmanah E and F Series products consist of the following models:

The E Series models all share a common compact solar engine, while the F Series models share a common,
larger solar engine with a more powerful solar panel and higher-capacity batteries. The F Series can also
accommodate third-party devices within its larger solar engine. While all E and F Series products share 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 a system from its original model and configuration. Each system will be described in
full later in this user manual.

E-Series Solar Engine Dimensions

F-Series Solar Engine Dimensions

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E / F SERIES USER MANUAL

2.0 INTRODUCTION

R920-E with Single Light Bar and

R920-E with Dual Light Bar and

R920-E Advance Warning with

Button (uni-directional)

2.2 Radio Communication

Radio communication between products is standard in R820-E/F and R920-E/F systems and is an option in
R829-E/F systems. In addition to the E and F Series, Carmanah also manufactures larger, cabinet-based 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 and F Series products use a low-profile antenna that does not require any special orientation or adjustment
and is immune to vandalism.

2.3 R920-E and R920-F: Pedestrian Crosswalk with RRFB Light Bars

Overview

The R920-E/F solar LED Rectangular Rapid Flashing Beacon (RRFB) products are ideal for uncontrolled
pedestrian-activated crosswalk applications. Multiple R920 units can be combined to create a complete crosswalk
set. Each R920 is radio-controlled, and each synchronizes flashing with the other R820s and R920s in the group.
The system will flash for a pre-set duration (field adjustable) upon activation of the push button. Spread-spectrum
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 R920s require no trenching of cables across the roadway.

Details on RRFB light bars can be found in Section 2.7 and Section 4.1

As an alternative to light bars, R920 systems can be configured with LED Enhanced Signs. Details on LED
Enhanced Signs can be found in Section 2.9 and Section 4.3

.

.

Typical R920 Configurations

Push Button (uni-directional)

Push Button (bi-directional)

single Light Bar and No Push

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E / F SERIES USER MANUAL

2.0 INTRODUCTION

Typical R920 Configurations, cont’d

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E / F SERIES USER MANUAL

2.0 INTRODUCTION

2.4 R820-E and R820-F: Pedestrian Crosswalk with Circular Beacons

Overview

Multiple R820-E/F units can be combined to create a complete crosswalk set. Each R820 is radio-controlled, and
each synchronizes flashing with the other R820s and R920s 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 circular
beacons, with each pair mounted on poles at opposite ends of the crosswalk. Wireless communication between
units means that R820s require no trenching of cables across the roadway.

R820s can also be wirelessly controlled by an R829 master controller. The R820s and R829 operate together
based on the schedule programmed into the R829’s internal calendar.

Details on circular beacons can be found in Section 2.8 and Section 4.2

As an alternative to circular beacons, R820 systems can be configured with LED Enhanced Signs. Details on
LED Enhanced Signs can be found in Section 2.9 and Section 4.3

.

.

Typical R820 Configuration

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E / F SERIES USER MANUAL

2.0 INTRODUCTION

2.5 R829-E and R829-F: School Zone Flashing Beacon

Overview

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

1) A non-wireless R829 can operate on its own, automatically flashing based on the schedule programmed
into its internal calendar.

2) A non-wireless R829 can also be turned on and off through a hard-wired switch. This switching function
can be provided by an override box, a third-part time switch, or both.

3) A wireless R829 can operate as the master controller in a group of wireless Carmanah E, F, or G Series
traffic products

4) Other Carmanah E, F, or G Series products respond to commands from a wireless R829 master
controller system and operate according to the master’s calendar schedule.

Details on circular beacons can be found in Section 2.8 and Section 4.2

As an alternative to circular beacons, R829 systems can be configured with LED Enhanced Signs. Details on
LED Enhanced Signs can be found in Section 2.9 and Section 4.3

E Series products can also operate with an externally mounted time switch, while F Series
products feature optional time switch kits that allow various third-party products to be mounted
within the solar engine. See Section 2.10 and Section 5.0

.

.

for details.

Typical R829 Configuration

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E / F SERIES USER MANUAL

2.0 INTRODUCTION

Ensure you obtain the latest copy of the calendar software (Version 1.2.0 as of November 2018).

See Section 5.1 for more information about related accessory calendar upload / override

Internal Calendar (Standard on R829, optional on other systems)

The R829 is equipped with an internal calendar that is programmed via USB to automatically activate and
deactivate school zone flashers on a user-defined schedule of up to 512 days. The calendar is programmed
using an intuitive Microsoft Windows-based graphical user interface. Once the program is established for one
system, the settings can be uploaded to other R829 units onsite with a laptop PC. A USB cable is part of the
calendar programming kit and is provided coiled up inside the R829 solar engine.

Eight different day schedule types can be defined (including OFF all day). Each day type can be configured for
up to eight ON periods of adjustable duration. Refer to the support document “R829 School Zone Calendar
Configuration Instructions” for additional information and complete programming instructions.

Older versions of the calendar software will not operate correctly with the newest version of traffic
firmware. Minimum Windows 7 operating system is required (32-bit or 64-bit). The software can
be obtained by contacting Carmanah Traffic Sales. The software is also included on a USB
memory stick in the calendar software programming kit, which also includes a 32-foot active
USB extension harness which can be used to program a system’s calendar from a vehicle.

switch kit.

2.6 R247-E and R247-F: 24-Hour Flashing Beacon

Overview

The R247-E/F 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 and low bridges.

The R247-E can be turned off when required using the optional Override Box kit, see Section 5.1

Details on circular beacons can be found in Section 2.8 and Section 4.2.

As an alternative to circular beacons, R247 systems can be configured with LED Enhanced Signs. Details on
LED Enhanced Signs can be found in Section 2.9 and Section 4.3

.

Typical R247 Configuration

.

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R247-E with Integrated Signal Head

E / F SERIES USER MANUAL

2.0 INTRODUCTION

Three (3) circular beacons in a system must be either wired in parallel or use a “Unison” flash

while flashing and therefore produce the same brightness.

Dual Confirmation Light

Single Confirmation Light

2.7 RRFB Light Bars: Overview

E Series and F Series products support up to four (4) RRFB light bar fixtures. The FHWA Interim Approval 21
March 20
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 push
button. Opaque adhesive covers are included to optionally cover the confirmation LED if desired.

See Section 4.1

th

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

for information on installing and aiming light bars.

– No Opaque Cover

– Using Opaque Cover

2.8 Circular Beacons: Overview

E Series and F Series products support up to 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 solar engine are specially reinforced for 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.

pattern to avoid current imbalance and ensure all fixtures receive the same amount of current

All Carmanah traffic products use a constant-current LED output circuit. Not all traffic beacons
are compatible with this output. Please contact Carmanah for additional information and
guidance when adding or replacing beacons or other hardware.

See Section 4.2

for information on installing circular beacons.

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E / F SERIES USER MANUAL

2.0 INTRODUCTION

Do not mix different sizes or LED counts of LED Enhanced Signs or mix LED Enhanced Signs

based G Series.

2.9 LED Enhanced Signs: Overview

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

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

If powering three (3) LED Enhanced Signs in a system, 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.

See Section 4.3

for information on installing LED Enhanced Signs.

2.10 Third-Party Devices: Overview

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

• The E/F Series provide 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/F Series (e.g. time switch, passive pedestrian detection, water level
detectors)

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

The F Series is available with several optional 3PD kits which allow the installation of the 3PD within the F Series
solar engine:

• The F Series RTC/IDC time switch kit option allows the installation of an RTC or IDC time switch and

includes a mounting plate, switch mounting hardware, and a pre-wired harness with a connector that plugs
into the time switch. (Time switch not included.) For installation information see Section 5.2, Section 5.3

Section 5.5.

• The F Series Applied Information modem kit option allows the installation of an AI time switch and cellular

modem. It includes mounting hardware, an antenna, and a prewired, connectorized harness to interface

and

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E / F SERIES USER MANUAL

2.0 INTRODUCTION

Contact Carmanah for additional support in connecting and configuring the above the devices or
other third-party devices.

between the F Series and the AI time switch and modem. (AI time switch/modem not included). For
installation information see Section 5.4 and Section 5.5

• The F Series Relay kit option comes with a 10A DC relay prewired to the F Series EMS. For installation

information see Section 5.6

.

• The F Series Polara XAV controller kit option includes the Polara XAV controller prewired for the Polara

XAV2E audible push button. Push button station harness length options are 16ft, 36ft, or 75ft. For installation
information see Section 5.7

.

• The F Series Campbell Guardian audible push button kit includes a prewired harness for a Campbell

Guardian audible push button. For installation and more information see Section 5.8

.

.

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E / F SERIES USER MANUAL

3.0 SOLAR ENGINE INSTALLATION

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

examination and solar simulations for your site.

3.0 Solar Engine 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

3.1 Tools and Materials Required

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

a. Imperial socket set
b. Crescent wrench
c. Tap set
d. Imperial Allen-Wrench set
e. Fish tape
f. Level
g. Compass or pre-determined equatorial

direction

h. Drill and drill bits
i. Fine-tip felt marker
j. Multi-bit screwdriver
k. Pelco Roger-Wrench (some configurations)
l. Hook spanner wrench, 1-1/2” trade size

(some configurations)
m. Ladder or lift device
n. Lithium grease

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E / F SERIES USER MANUAL

3.0 SOLAR ENGINE INSTALLATION

3.2 Solar Engine Mounting to Round Post

1. Install supplied longer set screws into mount, if required.

2. Thread mount onto solar engine and tighten.

3. Tighten set screw or clamp bolt at top of mount, if present.

4. Install on post and orient solar engine to face south (for Northern Hemisphere locations).

5. Tighten set screws onto post.

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E / F SERIES USER MANUAL

3.0 SOLAR ENGINE INSTALLATION

3.3 Solar Engine Mounting to Square Post with Universal Cast Mount

1. Obtain lock nut included with solar engine. Fully tighten against bottom of solar engine.

2. Thread solar engine fully onto mount.

3. Install mount onto square post and tighten bolts onto post.

4. Loosen less than one turn until solar engine faces south (for Northern Hemisphere locations).

5. Tighten top bolt on mount.

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E / F SERIES USER MANUAL

3.0 SOLAR ENGINE INSTALLATION

1. Install mount onto square post using suitable fasteners (not supplied). On 2" square posts, mount goes

3.4 Solar Engine Mounting to Square Post with Steel Mount

over post. On 2.5" square posts, mount goes inside post. Leave enough room between top of post

and bottom of mount for solar engine nipple and octagonal nut.

2. Orient two serrated lock rings so the teeth mesh and place onto mount. Align tabs on bottom lock ring

with slots in mount.

3. Install solar engine through lock rings and onto mount. Align tabs on top lock ring with slots in solar

engine.

4. Thread octagonal nut onto solar engine nipple.

5. Orient solar engine to face south (for locations in Northern Hemisphere).

6. Tighten octagonal nut and set screw.

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E / F SERIES USER MANUAL

3.0 SOLAR ENGINE INSTALLATION

3.5 Solar Engine Mounting to Side of Post

\

1. Obtain lock nut included with solar engine. Fully tighten against bottom of solar engine.

2. Thread octagonal nut with set screw onto bottom of solar engine.

3. Insert other octagonal nut into channel in side of post mount so it lines up with hole in top of mount.

4. Thread solar engine all the way onto nut in channel. Loosen less than one turn until solar engine faces

south (for Northern Hemisphere locations).

5. Tighten top octagonal nut down against mount, then tighten two set screws within octagonal nuts.

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E / F SERIES USER MANUAL

3.0 SOLAR ENGINE INSTALLATION

8" Reinforced Signal Head

12" Reinforced Signal Head

3.6 Reinforced Signal Head for Integrated Solar Engine / Signal Head

The following sections describe mounting options in which 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 for E Series, and 12” only for F
Series.

For systems with multiple circular beacons, ensure the solar engine gets mounted to the beacon
assembly with the internal reinforcement bracket(s). The following two diagrams show how a
reinforced signal head can be identified by its stiffening plate(s).

and Load Spreader Plate

12” reinforced signal heads also include a trapezoidal “load spreader” plate which provides additional strength.
To install the load spreader plate, place it in the bottom of the 12” signal head prior to installing the hex nipple.

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

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E / F SERIES USER MANUAL

3.0 SOLAR ENGINE INSTALLATION

The above steps can also be used on square steel posts if using the universal round &
square cast mount kit.

3.7 Integrated Solar Engine with Signal Head – Round Post

1. Install supplied longer set screws into mount, if required (see mount contents above).

2. Align serrated lock ring so that tabs fit into slots in bottom of solar engine.

3. Obtain signal housing with reinforcement bracket(s). Install solar engine through top signal housing hole

and into octagonal nut with set screw.

4. Install nipple through load spreader plate (12" signal housings only), bottom signal housing hole, serrated

lock ring, and tighten onto mount after aligning lock ring tabs with mount slots.

5. Tighten screw at top of mount, if present.

6. Install on post, adjust the rotation of the signal head if required and adjust the rotation of the solar engine

to face south (for Northern Hemisphere locations).

7. Tighten mount screws onto post, then tighten octagonal nut and nut set screw.

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E / F SERIES USER MANUAL

3.0 SOLAR ENGINE INSTALLATION

Integrated Solar Engine with Signal Head – Round Post diagram

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