BlinkerBeacon™ Single-Head LED Beacon · 2013-07-16 · The Solar Panel Cable is tagged, showing the correct connections: Brown Solar + Blue Solar – CAUTION Solar panels produce

Blinker™ Division

Solar LED Solutions

BlinkerBeacon™ Single-Head LED Beacon24/7 Flash, Solar Powered, Post or Pole Mount

User Guide

BBEAC_Single_Solar_guide_130419TAPCO • Traffic & Parking Control Company, Inc.

The Route To Safety, One Solution At A Time

2TAPCO • Traffic & Parking Control Company, Inc. 5100 West Brown Deer Road, Brown Deer, WI 53223

legal use; instructions; warning, caution and notes

use of this guide; product record

Thank you for your purchase of TAPCO-made productsThe BlinkerBeacon™ Solar-powered LED Beacon Assembly from TAPCO represents the latest technology in the field of LED-enhanced traffic control, and is designed to provide you with years of trouble-free service. Please take a few moments to record the model and serial numbers below, and keep this document in a safe place for future reference.Please Register your Warranty: on-line instructions are included later in this document.MODEL NAME: BlinkerBeacon™ Solar-powered LED Beacon Assembly SERIAL NUMBER(s): ___________________________________________________________DATE OF PURCHASE: _________________________________OPTIONS PURCHASED: _______________________________INSTALLATION LOCATION: ____________________________OTHER NOTES: ______________________________________

For Technical Support• Phone 866-753-6255• Email [email protected]

©2013 Traffic & Parking Control Company, Inc. (TAPCO)

All rights reserved. This notice applies to all copyrighted material included with this product, including but not limited to this manual and software embodied within the product. This User Guide is intended for the sole use of the persons to whom it was provided, and any unauthorized distribution of the manual or dispersal of its contents is strictly forbidden. This manual may not be reproduced in whole or in part by any means whatsoever without the express written permission of TAPCO.These instructions are for guidance only. Please read and fully understand them before proceeding. They are not to be construed as engineering-approved documents. You should consult a licensed professional engineer for approval of your site and erection plans.

Warning, Caution and Note statementsWarning, Caution and Note statements are used throughout this guide to emphasize important and critical information. Read these statements prior to assembly to help ensure safety and to prevent product damage. The statements are defined below.

NOTE: Used to notify you about information on installation, operation, programming or maintenance that is important but not hazard-related.

CAUTIONIndicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury. It may also be used to alert against unsafe practices.

WARNINGIndicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

3TAPCO • 800-236-0112 • www.tapconet.com BBEAC_Single_Solar_guide_130419

Recommended Tools and SuppliesVoltage MeterTape MeasureSocket/Deep Socket setsOpen end/box wrench setElectrician’s Fish tapeScrewdrivers: Large Flat bit and Phillips cross headDriver to mate with pin-type allen bitMultiMeter with VDC and Ohm scales

Optional Tools for 41⁄2" Pole Mounting:Drill motor (110V model recommended)Arbor drill bitsHole Reamer (to remove drilling burs)

Thank you for your purchase! The solar-powered BlinkerBeacon™ LED Beacon Assembly from TAPCO represents the latest technology in the field of LED-enhanced traffic control, and is designed to provide you with years of trouble-free service. Parts List (per assembly)Please examine all parts before assembly and installation. Check your Packing List for actual shipped components:Contact TAPCO immediately if anything is missing or damaged.Qty Description1 13-Watt Solar Panel with pole-top Bracket1 BlinkerBeacon™ LED Beacon Assembly (amber shown) Beacon Enclosure and Visor (detached for shipping) Mounting Arms: Aluminum (typical)1 Control Cabinet with Circuitry1 4.8VDC 14Ah Battery1 110VAC Battery Charger1 T100 Allen Wrench1 Pin-type Allen BitOptional: Sign(s); Pole; Base; Pushbutton; Hardware

parts list and recommended tools

WARNING

Use Cut-proof Gloves; Safety Glasses; and OSHA-approved Protective Clothing and Devices. Failure to do so could result in death or serious injury.


site selection

On straight segments, orient the beacon and sign face’s angle to maximize the vis-ibility to oncoming traffic. On curved road segments (both horizontal and vertical), larger adjustments may be necessary to provide the optimal visibility of the LEDs and retroreflectivity of the sign face.

SIDE VIEW

300’

VIEW FROM ABOVE

300’

SIDE VIEW

300’

VIEW FROM ABOVE

300’

Shade from trees, buildings, poles, etc. will reduce the solar panel’s effectiveness, so select a site where the solar panel can receive the maximum amount of sunlight throughout the day. The collector typically needs to face due south to receive maximum sunlight, but may be adjusted slightly if doing so increases solar collection (due to partial solar obstruction). Site selection should be based on MUTCD standards and engineering practices. Visit the FHWA’s MUTCD web site for further guidance on sign location and orientation: http://mutcd.fhwa.dot.gov/pdfs/2009/part2a.pdf

MUTCD 2A.20 ...signs should be vertically mounted at right angles to the direction of, and facing, the traffic that they are intended to serve. Where mirror reflection from the sign face is encoutered to such a degree as to reduce legibility, the sign should be turned slightly away from the road. Signs that are placed 30 feet or more from the pavement edge should be turned toward the road. On curved alignments, the angle of placement should be determined by the direction of traffic rather than by the roadway edge at the point where the sign is located...On grades, sign faces may be tilted forward or back from the vertical position to improve the viewing angle.

NOTE: These instructions are guidelines only, and are not to be construed as engineering-approved documents. You should consult the MUTCD and a licensed, professional engineer for approval of your site and erection plans.

Once you’ve determined an appropriate location for the assemblies, prepare an appropriate foundation to which you’ll mount the base(s). Allow any new concrete to cure fully before erecting the assemblies. Proceed with assembly.

battery charging

It is imperative that the battery is fully charged prior to installation. The system may not function properly unless the battery is fully charged.The battery is located in the cabinet behind the beacon, so take your unmounted assembly to an area near a 110VAC outlet. If already installed, remove the battery and take it to where it can be charged. Locate the battery charger and remove it from its cardboard box.Open the cabinet located behind the beacon. Take the unplugged MALE battery connector and plug it in to the supplied battery charger’s connector. You will feel and hear them click when they are connected properly. Pull gently on the connectors to ensure the connection is secure.Plug the battery charger into a standard 110V wall outlet. Allow the battery to charge overnight, at least eight hours, before proceeding with installation. You may now proceed with assembly.Once the battery has been fully charged, unplug the battery charger from the wall outlet used to charge the battery. Unplug the battery charger’s connector from the battery’s connector by pressing on the spring tab. You may then proceed with assembly and installation.


Solar Panel

Beacon Assembly:Pole/post Mounting

components will vary

Control Cabinet

Sign (if used)

Post or Pole:Various Options

Optional Pole Base

42" max.

15"typ.

84"

Varies

Typical Sign Heights:

Rectangle Diamond30" 30"= 41" high36" 36"=49" high48" 48"=66" high

*2009 FHWA MUTCD 2A.18The minimum height, measured vertically from the bottom of the sign...where parking or pedes-trian movements occur...shall be 7 feet.

Crosswalk Plaque (Optional)

Optional Pushbutton: If used, mount Pushbutton

for easiest access by pedestrians, bicyclists &

the disabled: For more ADA guidelines refer to

www.access-board.gov/ada

To determine the minimum overall height of pole + base you’ll need, sum up the heights of:

Ground to bottom of Sign; Sign Height (varies, see heights above, as well as FHWA requirement below)

typical single blinkerbeacon™ configuration


attaching led and solar panel leads

solar panel attachment & adjustment

Locate the Terminal Block inside the control cabinet. The Beacon and Solar Panel cables’ spade terminals should already be connected to the Terminal Block. If they are connected, as shown at right, proceed to the next step. If they are not, as shown below-right, connect them according to the instructions below.

The BlinkerBeacon™ Cable is tagged,showing the correct connections: Brown LED 1+ Blue LED 1–

The Solar Panel Cable is tagged, showing the correct connections: Brown Solar + Blue Solar –

CAUTIONSolar panels produce live current, so use caution when handling any wires attached to the solar panel. Do not do any assembly near standing water. Attach all wires in the exact order listed. Failure to do so will void TAPCO warranty.

Take the cable connector from the solar panel mount and plug it into the connector in the tube above the beacon. You will feel and hear them click when they are connected properly. Pull gently on the connectors to ensure the connection is secure.

Place the solar panel support tube onto the beacon assembly’s tube so that it is fully seated. After aligning the solar panel so that it is directed properly toward the mid-day sun (south), use the supplied pin-type T-shaped allen wrench to tighten each of the allen screws.


attaching the assembly to your pole

For a 21⁄2" or 2" SQUARE post: The adapter should already be attached to the assembly. If not, thread it onto the bottom of the assembly. Place the assembly with adapter attached onto your post. Insert and tighten nuts and bolts to secure the assembly onto the post. Rotate the assembly at the adapter thread until it is directed properly toward oncoming traffic, then use an allen head bit to tighten the top set screw to secure the positioning.Once the assembly is secured onto the pole or post: Open the control cabinet and connect the battery connectors. The beacon should begin to flash. If it does not, go to Tips and Troubleshooting procedures.

For a 27⁄8" round post: The adapter should already be attached to the assembly. If not, thread it onto the bottom of the assembly. Place the assembly with adapter attached onto your post. Rotate the assembly until it is directed properly toward oncoming traffic. Use an allen head bit to tighten the lower six set screws equally, to secure the assembly onto the post. If necessary, rotate the assembly at the adapter thread until the assembly is directed properly toward oncoming traffic, then use an allen head bit to tighten the top set screw to secure the assembly positioning.

For a 4½" pole: Use a 3/8" open-end wrench, crescent wrench or 3/8" square socket to loosen all six square-headed set bolts sufficiently that the assembly base seats fully over the signal pole. After aligning the assembly so that the beacon is directed properly toward oncoming traffic, tighten all six of the square bolts to secure the assembly onto the pole. DO NOT overtighten the bolts, as it could crack the base.

For a 4" or 3" round post: Slide the sleeve over the top of the post so that the sleeve top is flush with the top of the post. Use an allen head bit to tighten the six set screws equally and securely. Use a 3/8" open-end wrench, crescent wrench or 3/8" square socket to loosen all six square-headed set bolts sufficiently that the assembly base seats fully over the signal pole. After aligning the assembly so that the beacon is directed properly toward oncoming traffic, tighten all six of the square bolt heads to secure the assembly onto the pole.

Visor assembly

To reduce the potential for damaging the visor, do not install it until on-site. Make sure the beacon enclosure door wing nuts are tight. With the visor screw heads loosened sufficiently, place the visor onto the beacon face, aligning the visor’s tabs slightly counterclockwise of the screws.

Rotate the visor clockwise so that the tabs seat fully under the screw heads. Tighten the screws with a large flat or phillips bit. Do not overtorque, as it could break the plastic tabs.


testing battery Voltage and continuity

WARNING

NiMH batteries must be disposed of according to local code: DO NOT INCINERATE!

Testing the Battery for Voltage (VDC setting).Push 2 large paper clips’ ends (or solid wire) into the MALE battery connector’s BLACK & RED leads, either into the pin holes or into the back side of the plug. Meter should read at least 4.8VDC. If less, follow the charging procedures below.

Testing the Battery for Continuity (OHMS Ω setting). Push 2 large paper clips’ ends (or solid wire) into the MALE battery connector’s WHITE & BLACK leads, either into the pin holes or into the back side of the plug. Use meter on highest Ohm Ω scale to test across clips: if it displays ‘OL’ , replace with new battery. Otherwise, proceed to testing for voltage.

Charging the BatteryAn easy-to-use charger is typically shipped in a box, bagged and taped to the back of the solar panel. Disconnect the battery’s plugs (red, white and black wires) by pressing on the tab, as shown at right. If you have no 110VAC source on-site, remove the battery from the cabinet following the procedures below, then take the battery to where it can be charged. Plug the charger into a live 110-volt socket and charge for at least 8 hours. A full initial charge is essential for proper functioning.

Continuity (Ohms - Ω) Test

Voltage (VDC)Test

BlinkerBeacon® LED Beacon batteries should provide years of use, but will eventually require replacement. Actual battery life will depend on climate, flash duration and LED intensity. After purchasing a replacement BlinkerBeacon® LED Beacon battery from TAPCO, follow the charging procedures above, prior to installing the battery into the cabinet.After charging the new battery, unplug the battery connector plug from the charger plug by pressing on the spring tab.Remove the three phillips head screws that support the battery bracket. Take the old battery out of the bracket and replace it with the newly-charged battery. With the wiring facing bottom-right, put the battery and bracket back into place. Insert and tighten the three support screws. Connect the battery connector. You will feel and hear it click when connected properly. Pull gently on the connector to ensure it is secure. The beacon should begin to flash.

remoVing and replacing the battery


The Solar Panel, Battery and LED Beacon Leads should already be connected to the terminal block’s solar panel, battery and LED terminals, respectively. With adequate sunlight shining on the solar panel collector face, the Green LED marked “CHARGING STATUS” should be STEADY ON if charging, as shown below at left. If the LED is FLASHING INTERMITTENTLY the solar panel is not charging the battery.

Note the Solar Controller’s three Battery Status LEDs, shown below at right: If Red LED is lit, the battery charge is too low for the Solar Controller to function: disconnect the battery leads and charge it using a 12VDC charger to a level of 12.6V. In the absence of a 12VDC charger, you may charge the battery using the solar panel in full sunlight: this procedure may require a full day or more of unfiltered sunlight.

Battery Status LED Error Indications: <> = LEDs flash, back and forth

LED Pattern Error Type and Possible Causes

R <> G High Voltage Disconnect

R <> Y High Temperature Disconnect

R&G <> Y External Wiring Error; Current Overload; Load Short-circuit

R <> Y <> G Self-test Error

‘battery status’ ledsThis STATUS LED is STEADY ON when it is charging the battery. The LED is FLASHING when not charging the battery.

If the Green LED is not steadily lit, charge or rectify any error before using the system.

solar controller charging and battery status

Individual Beacon Doesn’t

Flash

LEDBeacons

Don’t Flash

Loose wiring

Inoperative LED(s)

Loose connections or broken wires

Battery is not fully charged, or will no longer hold a charge (replace with new battery)

Insufficient solar charging

Make sure all leads are connected and tight, then reactivate. Contact TAPCO or TAPCO distributor for replacement part(s), or repair authorization (TAPCO RMA required).

Gently test each connection to ensure they are tight: if loose, tighten screw or nut. If a wire is broken, strip and splice it with a shielded connector, or contact TAPCO or distributor for replacement part(s).

Test with a multi-meter as shown on previous page. If viable, charge battery for 8 hours and retest. If not functioning, replace with new, fully charged TAPCO battery. Dispose of old battery per local code.

Align solar collector so it faces south (toward mid-day sun). If obstructed by trees, trim or remove them to allow more sunlight to reach the collector. If obstructed by immovable object (such as a building, mountain or hillside), rotate so collector receives the maximum amount of solar energy (daily sunlight).

With the collector in full sunlight, unplug connector and test leads with voltmeter to ensure a charging voltage of at least 5VDC.

SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION

tips and troubleshooting

‘charging status’ led


BlinkerBeacon™ LED Beacon heads typically last for many years, depending on flash rate and intensity. After purchasing a replacement beacon from TAPCO, open the control cabinet, usually mounted behind the beacon. Locate and disconnect the battery by detaching the connector plugs.

On the beacon enclosure, loosen the two wing nuts securing the cover: the nuts need to be loosened only enough to swivel the retaining bolts outward. Swing open the beacon enclosure’s cover. Locate the two wires leading from the back of the beacon to the terminal block. Loosen the two beacon wire screws on the terminal block and detach the wires.

Inside the enclosure cover, remove the phillips screws and tabs holding the beacon in place. Note the orientation of the tabs holding the beacon in place: the bent portion of each tab faces inward. Remove the beacon from the enclosure cover.

Place the new beacon into the enclosure cover, making sure that the indication ‘TOP’ is oriented at the top, as shown at right circled in red. Put the tabs into place with the bent portion of each tab facing inward and tighten all four screws.

Locate the two wires leading from the back of the beacon and connect them to the terminal block: the yellow or red lead must be attached to the screw corresponding to the brown lead, and the white lead must be attached to the screw corresponding to the blue lead, as shown at right circled in red. Close the housing cover, swivel the bolts forward and tighten the wing nuts.

In the control cabinet, reconnect the battery charger’s connector plugs. You will feel and hear them click when they are connected properly. Pull gently on the connector ends to ensure the connection is secure. The beacon will begin to flash. Close the cabinet.

beacon head replacement

CAUTIONDisconnect the battery connector before removing or replacing any electrical components.


warranty

Follow the instructions below to Register your Warranty.Amended April 10, 2013

Traffic & Parking Control Company, Inc., (TAPCO), warrants to each purchaser of a BlinkerBeacon® LED Beacon (Product) for other than personal, family or household use, that the Product will be free from defects in material and workmanship for a period of two (2) years after the date of original purchase. TAPCO warrants accessories, service parts and components purchased separately to be free from defects in material and work-manship for a period of one (1) year after the date of original purchase. If within such warranty periods any part thereof is proved to TAPCO’s satisfaction to be defective, such part shall be repaired by TAPCO or its authorized distributor or, at TAPCO’s option, replaced f.o.b. TAPCO’s factory without charge, including labor costs at its standard rate incurred while repairing said Product. TAPCO’s obligation hereunder shall be limited to such repair or replacement and shall be further considered upon TAPCO’s receiv-ing written notice of any alleged defect and proof of original purchase within ten (10) days after its discovery and, at TAPCO’s option, the return of the allegedly defective part to TAPCO f.o.b. its factory or to its authorized distributor. This warranty shall not apply to any parts not furnished by TAPCO as well as any damage caused by such parts, or to parts which shall have been repaired or altered by others than TAPCO so as, in TAPCO’s judgment, to adversely affect the same; or which shall have been subject to other than normal use or service, negligence, accident or improper installation, care or storage. TAPCO will not be responsible for any expense related to parts or labor which is unrelated to defects in material or workmanship of TAPCO Product, including but not limited to acts of God (Force majeure).The foregoing warranties are exclusive and in lieu of all other express and implied warranties.TAPCO’s liability is limited expressly to the repair and replacement of defective parts as provided herein. TAPCO shall not be liable for any consequential, incidental, or contingent damages whatsoever, whether for breach of contract, breach of warranty, negligence or other tort, or on any strict liability theory.

John KugelPresidentTraffic & Parking Control Company, Inc.

Please register your BlinkerBeacon® System Warranty on-line at:www.tapconet.com/warrantyRecord the serial number from the label on each of your cabinet(s), then log on.Registration is simple and will take just a few moments of your time.Thank you!

warranty registration


For technical support:• Phone 866-753-6255 E-mail [email protected]

©2013, Traffic & Parking Control Company, Inc. (TAPCO)US Patent Nos 6,943,698; 6,693,556; Other Patents Pending.

TAPCO Logo and other trademarks are the property of Traffic & Parking Control Company, Inc.Document: BBEAC_Single_Solar_guide_130419; Reference 13041035

blinkerbeacon™ single-head solar beacon

Documents

BlinkerBeacon™ Single-Head LED Beacon · 2013-07-16 · The Solar Panel Cable is tagged, showing the correct connections: Brown Solar + Blue Solar – CAUTION Solar panels produce