RRFB-XL2™: Solar-powered and AC-powered User Guide...4 2017 Trac Parking Control Company Inc...

RRFB-XL2™: Solar-powered and AC-poweredUser Guide

TAPCO • Traffic & Parking Control Company, Inc.

Solar-Powered Systems Pages & Steps Colored in Green AC-Powered Systems Pages & Steps Colored in Blue

RRFBXL2_ug_14124308_RevEUG-14124308 Rev E

WARNINGWherever AC power is present, electrical installation and servicing must be performed ONLY by a qualified electrician: serious personal injury or death may result from contact with hazardous AC power! Disconnect AC power source AND verify the circuit breaker is ‘OFF’ BEFORE performing any wiring procedures or servicing.

Solar Panels require unobstructed sunlight to charge batteries!

Single Light Bar,No PC-LED

Single Light Bar,Single PC-LED

Single Light Bar,Dual PC-LEDs

Dual Light Bars,No PC-LED

Dual Light Bars,Single PC-LED

Dual Light Bars,Dual PC-LEDs

2 ©2017 Traffic & Parking Control Company, Inc. • RRFBXL2_ug_14124308_RevE

RRFB-XL2™ User Guide: Solar-powered and AC-powered

©2017 Traffic & Parking Control Company, Inc. (TAPCO) All rights reserved. This notice applies to all copyrighted material included with the associated product(s), 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.Warning and Caution Statements and Notes: Read These Prior to Assembly and Installation! Warning, Caution and Note statements are used to emphasize important and critical information in this guide.

If you have any questions that are not answered by this Guide, contact your Distributor or TAPCO Technical Support.TAPCO Technical SupportPhone 866-753-6255 (M-F 8-5 CT)Email [email protected]

NOTE: Notes are used to inform you about beneficial tips, techniques and processes regarding the installation, operation, programming or maintenance of your system: they typically are not hazard-related.

CAUTIONIndicates an unsafe practice which could potentially result in minor or moderate injury. It may also be used to alert against unsafe practices that can cause component damage and void warranties. Understand and heed all Cautions in this document!

WARNINGIdentifies a potentially hazardous situation which, if not avoided, could result in death or serious injury. Warning statements may describe what you should do to avoid the risk of exposure to the hazard, and may include potential consequences of not avoiding the hazard. Understand and heed all Warnings in this document!

WARNINGUse appropriate OSHA-approved Protective Clothing and Devices, Cut-proof Gloves and Safety Glasses while performing all procedures. Failure to do so could result in death or serious injury.

WARNINGBatteries normally produce explosive gases which can cause personal injury or death. Therefore, do not allow flames, sparks or lit tobacco to come near batteries. Always provide ventilation when charging or working near a battery, and wear gloves, goggles and an apron. Batteries contain sulfuric acid which burns skin, eyes and clothing. Disconnect the fuses and/or solar panel leads before removing or replacing any electrical components. To disconnect batteries, always detach the negative terminal first (to prevent arcing). To re-connect, always attach the battery’s positive terminal first and connect the battery’s negative terminal lead last.

Warning, Caution and Note Statements

WARNINGWherever AC power is present, electrical installation and servicing MUST be performed ONLY by a qualified electrician: serious personal injury or death may result from contact with hazardous AC power! BEFORE performing any wiring procedures or servicing, disconnect AC power source and verify the circuit breaker is ‘OFF’.

NOTE: Stored batteries MUST be checked monthly and kept charged to 12V with an approved charger, or your LED devices may not function properly. While charging the batteries you may proceed with other assembly processes.

NOTE: The typical default RRFB-XL LED Flash Duration is 30 seconds, and can be modified following this Guide’s section ‘Adjusting Beacon Flash Duration (Timeout)’. Wireless communication between systems including Timeout, Radio Binding, Testing & Site Survey are included in the separate BlinkerBeam® Radio Operation User Guide: If that guide is unavailable, contact TAPCO to have a PDF emailed to you.

NOTE: If you are considering the use of push buttons NOT supplied by TAPCO, refer to the section ‘TAPCO-Approved Components’ before proceeding to verify that your push buttons will function properly with TAPCO RRFB-XL2 systems.

WARNINGAlthough we’ve included many of the potential hazards you might encounter during the installation and operation of this equipment, we cannot predict all of the possible hazards: these statements should not be a substitute for your judgment and experience.

3©2017 Traffic & Parking Control Company, Inc. • RRFBXL2_ug_14124308_RevE


Warning, Caution and Note Statements ............................................................................. 2-3RRFB-XL2 System Requirements ........................................................................................... 4Light Bar Underground Cable Requirements (optional) ......................................................... 4TAPCO-Approved Components; Pedestrian Confirmation LED Options ..................................... 5Typical 2-Lane Street RRFB-XL2 Layout.................................................................................. 6Typical 4-Lane Street RRFB-XL2 Layouts ................................................................................ 7Solar-Powered System Introduction ...................................................................................... 8Solar-Powered System Installation Outline ........................................................................... 9AC-Powered System Introduction ........................................................................................ 10AC-Powered System Installation Outline ............................................................................. 11Solar-Powered System Site Preparation .............................................................................. 12AC-Powered System Site Preparation .................................................................................. 13Pole Preparation ........................................................................................................... 14-15XAV2-LED Push Button Preparation ..................................................................................... 15Bulldog Push Button Preparation ....................................................................................... 16Cabinet Port Preparation .................................................................................................... 16Solar Panel Cable Feed & Mounting ................................................................................ 16-17Push Button Cable Feed & Mounting ................................................................................... 17Light Bar Cable Feed & Mounting ................................................................................... 18-20Cable Feeds and Cabinet Mounting ..................................................................................... 21Push Button Lead Preparation & Mounting .................................................................... 21-22LED Terminal Connections .............................................................................................. 22-25Push Button & Component Terminal Connections ................................................................ 26AC-Power Connections ........................................................................................................ 27Battery & Solar Connections ............................................................................................... 28Battery Replacement ......................................................................................................... 29Vehicle/Pedestrian LED Synchronization ............................................................................. 29BlinkerBeam® Radio Binding .............................................................................................. 30Adjusting Beacon Flash Duration (Timeout) ........................................................................ 31XAV2E-LED Message Repeat, Locate Tone and Message Type .............................................. ..32XAV2E-LED Volume Adjustments ....................................................................................... ..32XAV2E-LED Push Button Tips and Troubleshooting ............................................................. ..33SunSaver Solar Controller Charging Status & Battery State of Charge ................................... 34SunSaver Solar Controller Parameters ............................................................................... ..35SunSaver Solar Controller Tips and Troubleshooting .......................................................... ..36ProStar Solar Controller Tips and Troubleshooting ............................................................... 37Solar and AC System Tips and Troubleshooting .................................................................. ..38Warranty and Registration ................................................................................................. 39Document & Contact Information ...........................................................................Back Cover

Table of Contents

WARNINGRead and understand ALL Warnings and Cautions in this Guide (including those on the previous page) BEFORE proceeding with assembly, installation or servicing. Read the Notes statements to facilitate installation, operation, programming and maintenance.Changes or modifications to TAPCO equipment not expressly approved in writing by TAPCO could damage the components and voids any warranty.

Solar-Powered Systems Pages and Steps are Colored in Green

AC-Powered Systems Pages and Steps are Colored in Blue


RRFB-XL2™ User Guide: Solar-powered and AC-powered System Requirements; Light Bar Underground Cable Requirements

Universal System Requirements:Light Bar / Controller Connection Limitations:Connect no more than two (2) Dimmable light bars to any Controller; Non-dimming will accommodate up to four.Underground XAV Push Button Cable (if XAV Push Button(s) and underground cable are used):8C 18AWG dedicated direct burial-suitable cable, such as Belden 27601A or equivalent. Cabinet Mounting Hardware:U-Bolts or straight bolts or heavy-duty banding: Snap-lock straps are provided for temporary use only, to hold cabinet in place while permanent mounting hardware is attached.Light Bar Mounting Hardware Kits:Four unique Light Bar mounting brackets have been designed to suit many pole/post mounting options. Refer to steps 11A-11D to determine the best option to use with your supplied mounting brackets. Contact your TAPCO Sales Contact or Distributor if you wish to purchase a different bracket option.Snap-lock banding brackets are to be used only for mounting light bars: they are not suitable for other components. Use heavy-duty banding or bolts to mount other components.

AC-powered System Requirements:AC Power Service Ratings:120VAC 10A minimum; 3-wire grounded circuit.AC Power Feed:Power feed wire type and gauge should match your local codes and engineering specifications. Refer to the powersupply’s label for power input requirements, and contact your local engineer/municipality for more information.

Solar-powered System Requirements:Solar Panel(s) must be located in full unobstructed sunlight. Stored Batteries must be kept charged until installed.

Are My Light Bars Dimmable or Non-Dimming?

Identifying Characteristic Non-Dimming

Light Bar Cable Sheath Color Black

Terminal Block Slots ‘A’ and ‘B’ Not Present

Non-Dimming Light Bar Cable RequirementsCable must be dedicated direct burial-suitable, 4C AWG

Length of Cable Run Minimum Gauge Required

Up to 300 feet 18 AWG or larger (16, 14 etc.)

300-450 feet 16 AWG or larger (14, 12 etc.)


Light Bar Underground Cable (UC) Requirements:If optional UC will be used, identify your type of system: Non-Dimming Light Bars have a black cable sheath, while Dimmable Light Bars have a gray cable sheath. If underground cable runs will be used: Determine your cable gauge requirements listed below.

Are My Light Bars Dimmable or Non-Dimming?

Identifying Characteristic Dimmable

Light Bar Cable Sheath Color Gray

Terminal Block Slots ‘A’ and ‘B’ Present

Dimmable Light Bar Cable Requirements

Cable must be dedicated direct burial-suitable, 4-conductor 18AWG or larger (16, 14, 12 etc.)Light Bar Cable Runs must not exceed 50 feet.No more than two (2) Dimmable light bars may be connected to any Controller.

NOTE: TAPCO’s RRFB-XL2 Systems are to be used only within the constraints as explained on this page and in the next section, ‘TAPCO-Approved Components’. Other usage not approved expressly (in writing) by TAPCO voids any warranty. All components listed below are available from TAPCO, either with your system order or in supplemental quantities.


RRFB-XL2™ User Guide: Solar-powered and AC-poweredTAPCO-Approved Components; Pedestrian Confirmation LED Options

TAPCO-Approved Components:Light Bars: TAPCO’s RRFB-XL2 Light Bars are the only light bars that

are approved for use with these systems. Light Bars are available with one (typically), or two or no Pedestrian Confirmation LED arrays, as shown below. Mounting hardware is covered in the section ‘System Requirements’.

Light Bar Underground Cable Requirements: Refer to previous section ‘Light Bar Cable Requirements’.Batteries: 12V AGM (gel) or VRLA (voltage-regulated lead-acid) with

equivalent ratings to original equipment are the only acceptable battery types to be used with these systems. Stored Batteries must be kept charged monthly until installed, or they may not perform satisfactorily.

Push Buttons and Push Button Cable:TAPCO recommends only the Push Button models and cable types listed below for use with RRFB-XL2 systems. TAPCO cannot verify that other Push Buttons and actuation devices will function properly with these systems.Polara Bulldog III Models BDSP-011 and BDSP-014;Polara XAV2E-LED equipped w/Polara controller card;Low-impedance Mechanical, Normally Open Models.

XAV Push Button Cable (if XAV Push Button is used):8C 18AWG dedicated direct burial-suitable cable, such as Belden 27601A or equivalent.Bulldog / Mechanical Push Button Cable:2C 18AWG dedicated direct burial-suitable cable.

Single Light Bar,No PC-LED

Single Light Bar,Single PC-LED

Single Light Bar,Dual PC-LEDs

Dual Light Bars,No PC-LED

Dual Light Bars,Single PC-LED

Dual Light Bars,Dual PC-LEDs

Pedestrian Confirmation LED (PC-LED) Options: If any side-mounted PC-LED does not sync with its large LED array, remove the cover from the light bar enclosure; disconnect both sets of Deutsch connectors; swap and re-connect them; re-attach the cover onto the enclosure.

FHWA Memorandum IA-11: 6e states ‘A small light directed at and visible to pedestrians in the crosswalk may be installed integral to the RRFB or push button to give confirmation that the RRFB is in operation.’ PC-LED options are illustrated below.

NOTE: TAPCO’s RRFB-XL2 Rectangular Rapid Flashing Beacon Systems must be used only with the TAPCO-Approved components listed on this page and in the sections ‘System Requirements’ and ‘Light Bar Underground Cable Requirements’. The use of any other components not approved expressly (in writing) by TAPCO voids any warranty. All components listed below are available from TAPCO, either with your system order or in supplemental quantities.



©2014 TAPCO

RRFBXL_2Lane_draw_1412

OR

OR

P U S HB U TT O N T OT U R N O NWAR N I N GL I G H T S



PUSHBUTTON TOTURN ONWARNINGLIGHTS

RRFB-XL2™ Rectangular Rapid-Flashing Beacon Suggested RRFBs, Signage and Pavement Markings for 2-lane Roads

OTHER TYPICAL CROSSWALK MARKINGS

A

30'

SPEED A30 MPH 140'35 MPH 183'40 MPH 234'A=distance from Advance sign to crosswalk

YIELD LINESA YIELD line is a series of white isosceles triangles, pointing toward approaching vehicles, and extending across a lane or lanes. It is used at midblock crosswalk locations where it supple-ments R1-5 ‘Yield Here To Pedestrians’ signs. See MUTCD Section 3B.16.

BlinkerSign® LED SignsThese signs can be linked wirelessly to flash once per second for the same flash duration of the RRFB.

MUTCD Section 2A.20 Sign Orientation Guidance:01 Unless otherwise provided in the manual, signs should be vertically mounted at right angles to the direction of, and facing, the traffic that they are intended to serve...On curved alignments, the angle of placement should be determined by the direction of approaching traffic rather than by the roadway edge at the point where the sign is located.

Align the signage and RRFB properly to maximize driver yielding compliance. Keep this in mind when mounting the components to the poles. First, align the RRFB housing to aim the Near Lane LED arrays toward approaching traffic in lanes nearest to that assembly, then tighten. Second, aim the Far Lane LED Arrays toward approach-ing trafficin lanes across from that assembly, then tighten.

Advance RRFB are allowed only in conjunction with crosswalk RRFB.

R1-5 signs and yield lines provide additional guidance to yield.

R1-6, R1-6a signs provide additional guidance to yield.R1-6a (STOP...) are allowed only in States where approved

Fixed Arrays

Far Lane

Near Lane

TOP VIEW TOP VIEW

Pedestrian Array Far Lane

Near Lane

Pedestrian Array

Pedestrian LEDs

Typical 2-Lane Street RRFB-XL2 Layout



©2014 TAPCORRFBXL_4Lane_draw_1412






OR

OR

A

OR OR

30'





RRFB-XL2™ Rectangular Rapid-Flashing Beacon Suggested RRFBs, Signage and Pavement Markings for 4-lane Roads

Undivided 4-lane

Pedestrian LEDs

Divided 4-lane

Typical 4-Lane Street RRFB-XL2 Layouts


RRFB-XL2™ User Guide: Solar-powered and AC-poweredSolar-Powered System Introduction

Solar-Powered System IntroductionTAPCO’s Solar-Powered RRFB-XL2 Rectangular Rapid Flashing Beacon products are ideal for pedestrian-activated crosswalk applications with unobstructed sunlight, where an AC power source is not already present. The next two pages provide instructions on assembling and installing a solar-powered system: please review completely before proceeding, as well as the section ‘Pedestrian Confirmation LED Options’.

System ComponentsTAPCO’s RRFB-XL2 Rectangular Rapid Flashing Beacons can be configured to meet a variety of crosswalk requirements. The following components make up the solar-powered configurations, shown at right:

Solar Panel AssemblyFlashing LED Light Bar(s)Control Cabinet (size/type varies)Battery (1 or more)Pedestrian Push Button(s): low impedance requiredOptional: Cabinet Mounting Hardware (cabinets require heavy-duty banding or u-bolts)

Optional: Poles and BasesCabinet Mounting Hardware: NOTE that snap-lock straps are for temporary use, only to aid in mounting cabinets

Recommended Tools/Supplies (not supplied)Lifetime Silicone Sealant and Duct SealMarking Pen and Tape Measure Voltmeter/MultimeterFor XAV2E-LED Push Button:

Torx T15 pin-type star bit (also fits LED heads)Self-tapping screws (or) #7 or 13⁄64" bit and 1⁄4"-20 tap

Pole Strap Wrench (for threaded poles)Corded Hand-held Drill, preferably with side handle2" Step Bit (Unibit) or arbor (hole saw) bitsHole Reamer (to remove drilling burs)Fish Tape/Hook to pull cables/wiring out of poleScrew DriversTorque Wrench, Open/Box Wrenches Ratchet/Driver, Extension, Sockets/Deep SocketsWire Stripper/Terminal Crimper

RRFB-XL2 with single Light Bar and Push Button (Uni-directional)

RRFB-XL2 with dual Light Bars

and Push Button (Bi-directional)

RRFB-XL2 with single Light Bar

and no Push Button (Uni-directional)

TAPCO’s Solar-Powered System Overview:Various RRFB-XL2 configurations are combined to create a complete crosswalk set. When actuated, the BlinkerBeam® radios in each linked assembly communicate wirelessly to flash the RRFB-XL2 light bar LEDs for a programmable duration (timeout). Within each solar-powered RRFB-XL2 assembly, the solar panel and solar controller interact to charge the battery (or batteries) during daylight hours. The controller also regulates the flow of power from the battery to the Flashing LED Light Bar(s).

TAPCO’s Solar-powered Configurations: Optional Poles/Bases/Mounting Hardware sold separatelySolar Panels require unobstructed sunlight to charge batteries!


RRFB-XL2™ User Guide: Solar-powered and AC-poweredSolar-Powered System Installation Outline

Basic steps to install a Solar-Powered LED RRFB-XL2 Assembly: For more in-depth details and images/illustrations of each step below, refer to the like-numbered sections following this page.1. Site Prep: Prepare your site(s) for mounting the assemblies. Note due southerly direction for solar panel alignment.2. Sign Mounting Prep: Mark the pole where the signs will be mounted: mark the location of the warning sign's bottom and its mounting holes, and the location of the plaque's top and its mounting holes.3. Light Bar Porting Prep (Right side of street): See 10B and 11B for more information and images. Mark the pole at the midpoint between the sign's bottom edge and the plaque's bottom edge, and for the opposite-facing light bar if used.4. Light Bar Porting Prep (Left side of street): See 10B and 11B for more information and images. Mark the pole at the midpoint between the sign's bottom edge and the plaque's bottom edge, and for the opposite-facing light bar if used. 5. Light Bar Port Drilling: See steps 10 and 11 for more info. Use step bit or arbor bit to drill ports. Ream off all burs.6. Push Button Prep (varies): (XAV) Mark mounting/port holes; remove cover; strip and connect the wires; replace the cover. (Bulldog): Remove cover. Mark and drill a cable port. Ream off all burs. Drill/tap mounting holes. Mount base onto pole.7. Cabinet Port Marking & Drilling: Mark the cabinet port location, then drill the port. Ream off all burs.8. Solar Panel Porting Cable Feed & Mounting: Feed the Solar Panel cable through its mounting cap, and through the pole to the pole’s cabinet port; place the Solar Panel onto the pole and rotate it so it will face southward. Tighten allen screws. Adjust panel tilt per your latitude, and tighten bolts. 9. Push Button Mounting & Cable Feed (varies): Fish the push button cable through its port to the pole’s cabinet port; (XAV) Remove the plaque and mount the push button frame to the pole. Re-install the plaque. (Bulldog) Strip, crimp and connect leads. Secure the cover onto the base. 10. Light Bar Cable Feed (varies): Verify all light bar Pedestrian Confirmation LED locations and align accordingly; (Straps) Use a fish tape to pull the cables through their respective ports to the pole’s cabinet port hole. (U-bolts) Remove the light bar covers. Use a fish tape to pull the cables through their ports to the pole’s cabinet port hole.11. Light Bar Mounting (varies): Verify all light bar Pedestrian Confirmation LED locations; (Straps) Feed straps through the bracket slots, wrap them around pole and secure. Trim straps if desired. (U-bolts) Place a pair of u-bolts onto the pole and secure each light bar onto them. Replace the light bar covers. 12. Cable Feeds and Cabinet Mounting: Based on quantity, determine which step (15, 16 or 17) you will use. Terminalize and feed cables into the cabinet (order varies). Mount cabinet to pole. Seal openings with lifetime silicone caulk/duct seal.13. RRFB-XL2 LED Lead Prep: Strip and terminate* RRFB-XL2 LED leads (splice and solder if connecting 3-4 light bars). *If using a Bulldog Push Button, strip leads to exact length and connect to terminal block.14-16. LED Terminal Block Wiring: Choose Correct Step, based on number and type (A= Non-Dimmable, B= Dimmable):

14. Connect Single Light Bar leads to the Terminal Block. 15. Connect Dual Light Bar leads to the Terminal Block.16. Connect Triple or Quadruple Light Bar leads to the Terminal Block.

17. Connect Push Button Leads In Cabinet: On terminal block (Bulldog) or printed circuit board (XAV). See instructions.18. Connect Optional Components. Verify polarity.19. Haul Assemblies to site, and Install: Signs can be mounted at your shop or on-site. 20. Insert & Connect Battery: Insert battery into cabinet. Verify Polarity, then connect positive battery cable first, then negative cable to corresponding battery terminals. If using multiple batteries, press polarized connectors together.21. Connect Solar Panel Leads: Verify Polarity, then connect the solar leads to corresponding terminal block slots.


RRFB-XL2™ User Guide: Solar-powered and AC-poweredAC-Powered System Introduction

AC-Powered System IntroductionTAPCO’s AC-powered RRFB-XL2 Rectangular Rapid Flashing Beacon products are ideal for pedestrian-activated crosswalk applications where an AC power source is available. The next two pages provide instructions on assembling and installing an AC system: before proceeding, please review completely.Power Service Ratings:120VAC, typical 10A minimum; 3-wire grounded circuit.Light Bar Cable Requirements:Refer to the section ‘Light Bar Cable Requirements’ to determine your cable type and gauge requirements based on length of underground cable runs and your type of light bars (dimming or non-dimmable).System Components

TAPCO’s RRFB-XL2 Rectangular Rapid Flashing Beacons can be configured to meet a variety of crosswalk requirements. The following components make up the AC-powered configurations, shown at right:Flashing LED Light BarsPedestrian Push Button(s)Control Cabinet (size/type varies)

Optional: Poles and BasesCabinet Mounting Hardware: Snap-lock straps are for temporary use only)

Recommended Tools/Supplies (not supplied)Lifetime Silicone Sealant and Duct SealMarking Pen and Tape Measure Voltmeter/MultimeterFor XAV2E-LED Push Button:

Torx T15 pin-type star bit (also fits LED heads)Self-tapping screws (or) #7 or 13⁄64" bit and 1⁄4"-20 tap

Pole Strap Wrench (for threaded poles)Corded Hand-held Drill, preferably with side handle2" Step Bit (Unibit) or arbor (hole saw) bitsHole Reamer (to remove drilling burs)Fish Tape/Hook to pull cables/wiring out of poleScrew DriversTorque Wrench, Open/Box Wrenches Ratchet/Driver, Extension, Sockets/Deep SocketsWire Stripper/Terminal Crimper

TAPCO’s AC-powered System Overview:Various RRFB-XL2 configurations are combined to create a complete crosswalk set. The LED light bars in the set can be either wired together or wirelessly linked by BlinkerBeam® radios, to flash each synchronously when actuated for a programmable duration (timeout). Within each AC-powered RRFB-XL2 assembly, the power supply and controller regulate the flow of power to the light bar(s).

RRFB-XL2 with single Light Bar and Push Button (Uni-directional)

RRFB-XL2 with dual Light Bars

and Push Button (Bi-directional)

RRFB-XL2 with single Light Bar

and no Push Button (Uni-directional)

TAPCO’s AC-powered Configurations: Optional Poles/Bases/Mounting Hardware sold separately

NOTE: For more info on RRFB-XL2 layout and orientation, refer to this Guide’s sections ‘Pedestrian Confirmation LED Options’, ’Typical 2-Lane Street RRFB-XL2 Layout’ and ’Typical 4-Lane Street RRFB-XL2 Layout’.

XAVCU2 Controller to Push Button Station Cable: Must be dedicated direct burial-suitable cable with 8C 18AWG stranded conductors and matching color coding, such as Belden 27601A or equivalent, available from TAPCO.Bulldog & Manual N/O Push Button Cable: 2C 18AWG.


RRFB-XL2™ User Guide: Solar-powered and AC-poweredAC-Powered System Installation Outline

Basic steps to install an AC-Powered LED RRFB-XL2 Assembly: For more in-depth details and images/illustrations of each step below, refer to the like-numbered sections.Electrical Power Prep (Qualified Electrician Only): Prepare your site for power feeds and other cable runs.1. Site Prep: Prepare your site(s) for mounting the assemblies and for any cable runs.2. Sign Mounting Prep: Mark the pole where the signs will be mounted: mark the location of the warning sign's bottom and its mounting holes, and the location of the plaque's top and its mounting holes.3. Light Bar Porting Prep (Right side of street): See 10B and 11B for more information and images. Mark the pole at the midpoint between the sign's bottom edge and the plaque's bottom edge, and for the opposite-facing light bar if used.4. Light Bar Porting Prep (Left side of street): See 10B and 11B for more information and images. Mark the pole at the midpoint between the sign's bottom edge and the plaque's bottom edge, and for the opposite-facing light bar if used.5. Light Bar Port Drilling: See steps 10 and 11 for more info. Use step bit or arbor bit to drill ports. Ream off all burs.6. Push Button Prep (varies): (XAV) Mark mounting/port holes; remove cover; strip and connect the wires; replace the cover. (Bulldog): Remove cover. Mark and drill a cable port. Ream off all burs. Drill/tap mounting holes. Mount base onto pole.7. Cabinet Port Marking & Drilling: Mark the cabinet port location, then drill the port. Ream off all burs.8. Not applicable: for Solar-Powered Systems only. Skip to step 9.9. Push Button Mounting & Cable Feed (varies): Fish the push button cable through its port to the pole’s cabinet port; (XAV) Remove the plaque and mount the push button frame to the pole. Re-install the plaque. (Bulldog) Strip, crimp and connect leads. Secure the cover onto the base.10. Light Bar Cable Feed (varies): Verify all light bar Pedestrian Confirmation LED locations and align accordingly; (Straps) Use a fish tape to pull the cables through their respective ports to the pole’s cabinet port hole. (U-bolts) Remove the light bar covers. Use a fish tape to pull the cables through their ports to the pole’s cabinet port hole.11. Light Bar Mounting (varies): Verify all light bar Pedestrian Confirmation LED locations and align accordingly; (Straps) Feed straps through the bracket slots, wrap them around pole and secure. Trim straps if desired. (U-bolts) Place a pair of u-bolts onto the pole and secure each light bar onto them. Replace the light bar covers. 12. Cable Feeds and Cabinet Mounting: Based on quantity, determine which step (14, 15 or 16) you will use. Terminalize and feed cables into the cabinet (order varies). Mount cabinet to pole. Seal openings with lifetime silicone caulk/duct seal.13. RRFB-XL2 LED Lead Prep: Strip RRFB-XL2 LED leads, (splice and solder if connecting 3-4 light bars) and terminate.14-16. LED Terminal Block Wiring: Choose Correct Step, based on number and type (A= Non-Dimmable, B= Dimmable):

14. Connect Single Light Bar leads to the Terminal Block. 15. Connect Dual Light Bar leads to the Terminal Block.16. Connect Triple or Quadruple Light Bar leads to the Terminal Block.

17. Connect Push Button Leads In Cabinet: On terminal block (Bulldog) or printed circuit board (XAV). See instructions.18. Connect Optional Components. Verify polarity.19. Haul Assemblies to site, and Install: Signs can be mounted at your shop or on-site. 20. Power Feed and Connection: Qualified Electrician Only.21. Turn OFF Circuit Breaker.22. Power Feed and Connection: Qualified Electrician Only. Attach power leads: system must be properly grounded. Turn on circuit breaker.


RRFB-XL2™ User Guide: Solar-powered and AC-poweredSolar-Powered System Site Preparation

Solar-Powered System Site Preparation: Prepare your site for mounting the assemblies according to your engineering plans, as well as your State, Federal and local regulations: while the forms are setting, you may proceed with assembly at your shop, reducing your time exposed to traffic/potential risks. For solar alignment, note due southerly direction in rela-tion to the assembly locations. Note: the use of a locking collar or allen screw is recommended to allow for on-site pole rotation adjustment and locking.

1

SAMPLE


RRFB-XL2™ User Guide: Solar-powered and AC-poweredAC-powered System Site Preparation

Qualified Electrician Only: AC Power Service Ratings: 120VAC 10A minimum; 3-wire grounded circuit. AC Power Feed: Power feed wire type and gauge should match your local codes and engineering specifications. Refer to the power supply’s label for power input requirements, and contact your local engineer/municipality for more information. Run power feeds to site and cable runs according to Federal, your State and local regulations, as well as your engineering plans. Coordinate procedures with Installer to ensure the proper power feeds.

AC-Powered System Site Preparation: Prepare your site for mounting the assemblies and for any cable runs according to your engineering plans, as well as your State, Federal and local codes/regulations: while the forms are setting, you may proceed with assembly at your shop, reducing your time exposed to traffic and to potential risks. Note: the use of a threaded allen screw or locking collar is recommended to allow for on-site pole rotation adjustment and locking pole posi-tion after adjustment.

1

SAMPLE

Non-Dimming Light Bar Cable Length > GaugeCable must be dedicated direct burial-suitable, 4C AWG

Length of Cable Run Minimum Gauge Required

Up to 300 feet 18 AWG or larger (16, 14 etc.)


450-700 feet 14 AWG or larger (12 etc.)

Dimmable Light Bar Cable Requirements

Cable must be dedicated direct burial-suitable, 4-conductor 18AWG or larger (16, 14 etc.)Light Bar Cable Runs must not exceed 50 feet.No more than two (2) Dimmable light bars may be connected to any Controller.



RRFB-XL2™ User Guide: Solar-powered and AC-poweredPole Preparation

Sign Mounting Prep: Mark the pole locations for the warning sign and plaque tops and bottoms, and make cross-marks where the top-center of the plaque and the bottom-center of the sign will be mounted. Allow at least 6 inches between them for light bar clearance. If sign/plaque mounting bolts will be used, mark pole for their mounting hole locations.

Light Bar Porting Prep for Right side of street: refer to this Guide’s sections on Typical...RRFB-XL2 Layout. Mark the cable port hole for the Near Lane light bar at the midpoint between the marks for top of the plaque and bottom of the sign. If an opposing light bar will be used, make a mark on the back side of the pole, rotated slightly counter-clockwise so the Far Lane light bar aims toward the lane(s) across the street. On a 41⁄2" pole, offset it about 1⁄2" for 2-lane streets or 3⁄4" for 4-lane streets: see illustrations below. For u-bolt Light Bar mounting only, the second hole must also be staggered 1" above or below the first hole to allow vertical staggering of light bars: see 10B and 11B for more information and images.

2

3

(For RIGHT side ofstreet)

TopView,InsidePole

NOTE: The next 2 steps explain light bar wiring port placement. If used, center median light bars can be mounted directly opposite of each other with their LED arrays aimed counter-clockwise from the street’s path so they will be directed toward the drivers approaching from that direction. For more median-mounted light bar information and illustration, refer to this Guide’s section ’Typical 4-Lane Street RRFB-XL2 Layout’.

Far Lane

Near Lane

PED Array PED Array

Light Bar Orientation For Left Side of Street

Light Bar Orientation For Right Side of Street

Traffic Flow

Traffic Flow

Near Lane

Far Lane

PED Array

PED Array

Far Lane

Near Lane

PED Array PED Array


RRFB-XL2™ User Guide: Solar-powered and AC-poweredPole Preparation (continued); XAV2E-LED Push Button Preparation

Light Bar Porting Prep for Left side of street: Mark the cable port hole for the Far Lane light bar at the midpoint between the top of the plaque and bottom of the sign, but rotated slightly counter-clockwise so the Far Lane light bar aims toward the lane(s) across the street. On a 41⁄2" pole, offset it about 1⁄2" for 2-lane streets or 3⁄4" for 4-lane streets. For a Near Lane light bar, make a mark on the opposite side of the pole so it will aim toward traffic approaching from that direction: see illustrations below. For u-bolt Light Bar mounting only, the second hole must also be staggered 1" above or below the first hole to allow vertical staggering of light bars: see 10B and 11B for more information and images.

4

XAV2E-LED Push Button Prep: (For Bulldog Push Button, skip to 6B: ‘Bulldog Push Button Prep’) Read the complete instructions in the XAV2E-LED push button’s shipping box. Use its Mounting Hole Diagram to mark the pole for mounting holes and cable porting. Remove the bottom cover of the push button frame by removing the two screws with a Torx T15 pin-type star bit. Carefully strip about 11⁄2" off of the push button cable’s outer jacket, then strip 1⁄4" of the insulation off of each wire. Insert just the stripped portion of each lead into its corresponding terminal port (see images and table below) and tighten the screw to secure it, then pull gently on each lead to ensure a secure connection. Replace the cover and tighten it securely. Drill the cable port in the pole per XAV2E-LED instructions and ream off all burs.

5

6A

Light Bar Port Drilling: See steps 10 and 11 for more information and images to help ensure proper porting placement. Using a step bit or an arbor (hole saw), drill 1" or larger porting holes: larger ports allow for greater rotation of light bars. Ream off all burs inside and outside of the porting holes to help prevent cable damage.

(For LEFT

side ofstreet)

TopView,InsidePole

Terminal Label / Lead Insulation Color*PWR+ PWR– BTN LED MUTE MIC AUD1 AUD2

Red Black Orange Yellow Brown Blue Red/Black Blue/Black

*XAV2E-LED Push Button Cable: Dedicated direct burial-suitable cable with 8C 18AWG stranded conductors and matching color coding, such as Belden 27601A or equivalent, available from TAPCO.

Near Lane

Far Lane

PED Array

PED Array



Bulldog Push Button Prep (two different bases shown below): Unscrew and remove the push button cover from its mounting base. Use the mounting base as a template to mark the porting hole and the two push button mounting holes. Drill and ream out a push button cable porting hole in the pole, 3⁄8" diameter or more. Drill mounting holes with a #7 or 13⁄64" bit, then thread with a 1⁄4"-20 tap (self-tapping screws could be used here). Mount the push button base to the pole.

6B

Mounting Hole

Mounting Hole

Porting HoleMounting Hole

Mounting Hole

Porting Hole

Side-Mount Solar Panel Porting, Cable Feed & Mounting (For Top-Mount, skip to 8B: ‘Top-Mount Solar Panel Cable Feed & Mounting’): Mark the solar panel porting hole location on the (when installed) southern side of pole, in line with the bracket hole shown below. Drill and ream out a cable porting hole in the pole, 3⁄8" or more in diameter. Mount bracket onto pole/mast arm so collector faces upward and toward the equator (southward). Feed the cable into the pole through the bracket, into the pole’s porting hole, and back out through the cabinet porting hole. Adjust the tilt to 45º above horizontal in southern U.S. latitudes, to a steeper 55º in northern U.S. latitudes. Tighten the bracket hardware securely.

Cabinet Port Marking & Drilling: Mark the cabinet porting hole location on the pole: varies according to your engineer’s plans. Use a 2" step bit or a 2" arbor bit (hole saw) to drill the cable feed porting hole, just large enough to accept the cabinet stub. Ream off all burs inside and outside of the porting hole to help prevent cable damage.

7

8A

NOTE: TAPCO cannot verify the compatibility of push buttons not supplied by TAPCO: high-impedance push buttons will not function with these systems. Refer to the section ‘TAPCO-Approved Components’ for RRFB-XL2-compatible push button models.

Bulldog Push Button Preparation; Side Mount Solar Panel Port/Cable/Mount



B

Bulldog Push Button Cable Feed/Mounting: Fish the push button cable through its port into the pole, and back out through the cabinet porting hole. Strip the ends of the push button leads (typically Blue and Brown) and crimp a spade terminal onto each. On two-terminal push buttons, polarity does not matter: connect the leads to the two push button terminals in any order. If you use a different push button with three terminals, connect the typically Blue lead to the push button’s ‘COM’ terminal and the typically Brown lead to the ‘NO’ terminal: you will terminate them identically on the cabinet’s terminal block. Do NOT use the ‘NC’ terminal. Place the push button cover onto its base and secure with screws.

9

Top-Mount Solar Panel Cable Feed & Mounting: Feed the solar panel cable through its mounting cap’s porting hole, into the pole and back out through the cabinet porting hole. Place the solar panel/bracket onto the pole, then tighten the allen set screws evenly. Adjust the panel’s collector facing toward the equator (southward), tilted to 45º above horizontal in southern U.S. latitudes to a steeper 55º in northern U.S. latitudes. Tighten the bracket tilting hardware securely.

8B

XAV Push Button Cable Feed/Mounting (For Bulldog Push Button, skip to 9B: ‘Bulldog PB Cable Feed/Mounting’): Fish the push button cable through its port into the pole and back out through the cabinet porting hole. Unscrew the plaque’s four screws with a Torx T15 pin-type star bit; remove plaque. Mount the push button frame onto the pole, then secure it with the supplied bolts fed through lock washers and washers. Replace and secure the plaque.

9A

NOTE: TAPCO cannot verify the compatibility of push buttons not supplied by TAPCO: High-impedance push buttons will not function with these systems. Refer to the section ‘TAPCO-Approved Components’ for RRFB-XL2-compatible push button models.

Solar Panel Cable Feed & Mounting; Push Button Cable Feed & Mounting



Light Bar Cable Feeds when using Bolts or U-bolts: Verify Pedestrian Confirmation LED array locations on each light bar. Remove the four screws on each Light Bar cover (Torx T15 pin-type star bit), then remove covers. Feed a fish tape through from the cabinet porting hole. Attach the Near Lane Light Bar cable end to it. Feed the cable from the Far Lane light bar (if used) through its port and back out of the Near Lane port. Attach the second cable end to the fish tape, then pull both of the cables through the pole and out of the cabinet porting hole. Proceed to step 11D to mount light bars.

10B

Light Bar Cable Feeds when using Snap-lock Straps or your Heavy-duty Banding: (if using bolts, skip to step 10B)Verify the Pedestrian Confirmation LED array location on each light bar: see images and illustrations below, as well as ‘Pedestrian Confirmation LED Options’ section. Fish each Light Bar cable into pole through its corresponding porting hole, and back out through the pole’s control cabinet porting hole. Pull the remaining slack cable through the pole.

10A

NOTE: For more RRFB-XL2 layout and orientation info, refer to this Guide’s sections ‘Pedestrian Confirmation LED Options’, ’Typical 2-Lane Street RRFB-XL2 Layout’ and ’Typical 4-Lane Street RRFB-XL2 Layout’.

PED Array

All cable ports need to be reamed and/or grommeted

to protect cable.

Both RRFB cables can be fished thru the pole at once.

Light Bar Orientation For Left Side of Street

Light Bar Orientation For Right Side of Street

Traffic Flow

Traffic Flow

Near Lane

Far Lane

PED Array

PED Array

Far Lane

Near Lane

PED Array PED Array

Light Bar Cable Feeds and Mounting



Light Bar Mounting when using W-Bracket and Snap-lock Straps: (Other bracket options following) Trim the Snap-lock bracket straps to a length sufficient for your pole: trim after mounting if desired. Feed the straps through the slots of the light bar mounting brackets. Verify that the all light bars are oriented so all Pedestrian Confirmation LED Arrays will face desired direction: see ‘Pedestrian Confirmation LED Options’ section. Then, feed the strap ends around the pole and through the buckles. Adjust the bars and tighten the straps so the light bars are securely attached to the pole.

11A

Straps can be trimmed before or after attaching to pole.

Cables to be fed into pole as illustrated in Step 10.

Single Light Bar Dual Light Bars

PED Array PED Arrays

Light Bar Mounting with Extended Brackets, using either Snap-lock Straps or your own Banding: Pedestrian Confirmation LED Arrays must face desired direction: see ‘Pedestrian Confirmation LED Options’ section. If you wish to feed the RRFB cables through the pole after mounting the brackets you may do so: feed the straps* through

the slots of the extended light bar mounting brackets, and then wrap them around the pole and through the buckles. *If you use your own banding you may attach one snap-lock strap to position the brackets/bars while attaching the first band; then remove the snap-lock strap and attach the second band.

With the bars aimed in the desired direction, tighten the straps or banding so the light bar brackets are securely attached to the pole. Carefully trim any excess strap/banding.

If you've removed the light bars, feed the cable(s) through the pole and then re-mount the light bar(s) onto the bracket(s).

11B

NOTE: Four unique RRFB-XL2 Light Bar mounting brackets have been designed to suit many pole/post mounting options. Refer to steps 11A-11D below and on the next page, to determine the best option to use with your supplied mounting brackets. Contact your TAPCO Sales Contact or Distributor if you wish to purchase a different bracket option.

NOTE: While the illustrations below show the Extended mounting brackets with the Light Bars detached, you do not need to detach them for assembly. If you feed the cables through the pole before installing the Light Bars and Brackets, it is recommended that you leave the Light Bars attached to the Extended brackets.

Light Bar Cable Feeds and Mounting (continued)

Brackets do not need to be detached from Light Bars, but if you wish to do so, then use the supplied Torx T27 star bit.



Light Bar Mounting using U-bolt Brackets (following step 10B): Place a u-bolt onto the pole (or a bolt through square post) for each light bar. With Pedestrian Confirmation LED arrays aligned as illustrated below, place each light bar onto its bolt or u-bolt. Add a washer and nut with rubber face toward pole, adjust the bars and tighten the nuts evenly. Replace each light bar cover and secure with four screws: to help prevent cross-threading, turn each screw counter-clockwise until you hear/feel a click, then tighten clockwise.

11D

PED Array PED Array

Light Bar Mounting with Articulating Brackets (advisable when mounting onto square posts): With the inner (post-side) bracket portions aligned as shown in the images below, place your bolts through the first bracket's top and bottom holes, then through the post, and, if used, through a second bracket. Add a lock washer and/or locking nut, and tighten the nuts securely. If the cables have not yet been fed into/through the post, do so now.If you have detached the light bar(s) or the bracket(s), re-attach them now. When properly aligned, tighten both bracket bolts sufficiently so the light bars will not pivot. These brackets allow you to easily rotate the light bars on-site, to aim them precisely toward approaching vehicles.

11C

Pedestrian Confirmation LED Arrays must face desired direction: see ‘Pedestrian Confirmation LED Options’ section. NOTE: If using Articulating Brackets, you may feed the cables through the post before or after mounting the Light Bars, whichever order is preferable. The light bars do not need to be detached from articulating mounting brackets, but they have been detached in the illustrations below. You may either detach the light bars from the outer brackets, or the outer brackets from the inner brackets: both options are shown in the image below, third from the left. If desired, you may wish to use a step bit and reamer to enlarge the post's porting hole(s) before attaching brackets.

Enlarge porting hole in post before attaching bracket, if so desired.

Light Bar Cable Feeds and Mounting (continued)



RRFB-XL2 LED Lead Prep / Cabinet Mounting: Review steps 14-16 to determine which step to follow, based on the number of light bars connected to one terminal block. Each Substep A explains Non-Dimming Light Bar terminations (light bars with BLACK cable);Each Substep B explains Dimmable Light Bar terminations (light bars with GRAY cable).If not done already, strip 3⁄8" off of the unterminated RRFB-XL2 LED leads that are fed into the cabinet. Crimp a spade connector onto the exposed portion of each LED lead or, if connecting multiple light bars, onto each spliced set of identical leads: see step 16 or 17). Proceed to the correct step to complete the RRFB-XL2 LED connections.

13

Cable Feeds and Cabinet Mounting: Review steps 14-16 to determine which step to follow, based on the number of light bars connected to one terminal block (Step 14=Single, 15=Double, 16=Triple or Quadruple; Substep A=Non-Dimming, B=Dimmable). If you are connecting three or four light bars to one terminal block, see Step 16 before proceeding to simplify splicing cables, either inside the pole or inside the cabinet. Otherwise, feed all cable(s) into the cabinet through its port. Secure the cabinet onto the pole: hardware varies with cabinet mounting type, and may or may not be provided. Snap-lock straps are provided ONLY for temporary use, to support cabinet while permanent banding, u-bolts or standard bolts are installed. Tighten the hardware (heavy-duty banding or bolts/nuts) securely.

12

Use a torque wrench to tighten these four nuts to ≤16ft-lbs., and use the Snap-lock brackets ONLY for temporary mounting!

Caulk around cabinet port stub before feeding into pole port.

Tighten the post bolts & nuts to securely mount the cabinet

Cable Feeds and Cabinet Mounting

Note: If you have a Solar-powered system equipped with Bulldog Push Buttons, refer to the Terminal Block and Panel instructions in the section Instructions for Solar-powered Systems with Bulldog Push Buttons on the next page. If you have an AC-powered and/or XAV Pushbutton-equipped system, it will utilize the terminal blocks shown in steps 14-16.



Note: This Terminal Block and Panel are used with Solar-powered systems equipped with Bulldog Push Buttons.

1. Fish all component leads into the cabinet, either through the port (shown at right) or through conduit.

2. Measure and strip between 3/8" and 1/2" (9mm–12mm) off of each lead that will be connected to the terminal block. Then twist each stranded lead to ease feeding into its slot.

IMPORTANT NOTE: The amount of insulation you strip is criti-cal: if you strip less than the minimum, the wire’s insula-tion could prevent a solid connection; if you strip more than the maximum, the exposed wires could short out against each other, potentially causing damage that will require component replacement at your expense.

3. BEFORE connecting leads, verify that the load fuse is removed: it may be in the pouch mounted inside the cabinet door.

IMPORTANT NOTE: Removing the load fuse prior to making connections will help protect the Solar Controller and the components’ LEDs from damage. Failing to perform this procedure may potentially cause damage that will require replacement at your expense.

4. Attach the LED leads first, because attaching LEDs to an en-ergized circuit could destroy them, requiring replacement at your expense. Feed each stripped and twisted lead fully into its slot, then tighten the screw using a 1/4" to 5⁄16" wide, flat-bit screwdriver, which may have been provided with your ship-ment. Check in the pouch on the inside of the cabinet door.

5. Attach the other leads to their proper slots, and tighten them snugly. Test each by gently tugging on each.

6. Insert the battery into the cabinet. Attach the ring terminals to the battery, properly polarized, and tighten snugly.

7. Replace the fuses into their proper slots: fuses may be in the pouch mounted inside the cabinet door.

8. Close and latch the cabinet door.

This Terminal Block eliminates the need to crimp terminals onto each lead, reducing the time to make your connections. This page explains the preparation and connection of the system’s component leads. Consult the steps following this page to determine the proper connections for leads, as well as to clarify any questions that are not answered herein.

Strip off between 3/8" and 1/2" (9mm–12mm) of insulation

Feed each stripped and twisted lead fully into its proper open slot below the label, and then tighten screw snugly. Pull each lead gently to verify a secure connection.

Terminal Connections for Solar-powered Systems with Bulldog Push Buttons



To connect a SINGLE Non-Dimming light bar (models with a black-sheathed cable) to one terminal block:Connect the Light Bar’s White lead ‘LED1+’ connector to the ‘LED1+’ slot; connect its Black lead ‘LED1–’ connector to the ‘LED1–’ slot; connect its Brown lead ‘LED2+’ connector to the ‘LED2+’ slot; connect its Blue lead ‘LED2–’ connector to the ‘LED2–’ slot. Tighten each terminal screw sufficiently to ensure a secure connection.

To connect a SINGLE Dimmable light bar (models with a gray-sheathed cable) to one terminal block:Connect the Light Bar’s White lead ‘LED1+’ connector to the ‘LED1+’ slot; connect its Black lead ‘LED1–’ connector to the ‘LED1–’ slot; connect its Brown lead ‘LED2+’ connector to the ‘LED2+’ slot; connect its Blue lead ‘LED2–’ connector to the ‘LED2–’ slot. The ‘A’ and ‘B’ slots are not used. Tighten each terminal screw sufficiently to ensure a secure connection.

14

14

Sing

le R

RFB

Ligh

t Bar

Si

ngle

RRF

B Li

ght B

ar

Sing

le R

RFB

Ligh

t Bar

Sing

le R

RFB

Ligh

t Bar

Sing

le R

RFB

Ligh

t Bar

Sing

le R

RFB

Ligh

t Bar

Sing

le R

RFB

Ligh

t Bar

Sing

le R

RFB

Ligh

t Bar

A

B

NOTE: Non-Dimming RRFB-XL2 light bars have a black-sheathed cable (see substep ‘A’ below). Dimmable RRFB-XL2 light bars have a gray-sheathed cable (see substep ‘B’ below). If in doubt of your type, look in your control cabinet and check the terminal block’s label for the presence or lack of ‘A’ and ‘B’ terminals. Dimmable systems have ‘A’ and ‘B’ terminals, while non-dimming systems do not.

Note: If you have a Solar-powered system equipped with Bulldog Push Buttons, see the Terminal Block and Panel on the previous page. If you have an AC-powered and/or XAV Pushbutton-equipped system, it will utilize the terminal blocks shown below.

How to determine if your Light Bars are Dimmable or Non-Dimming

Identifying Characteristic Dimmable Non-Dimming

Light Bar Cable Sheath Color Gray Black

Terminal Block Slots ‘A’ and ‘B’ Present Not Present

LED Terminal Connections



15A

15B

NOTE: Verify LED circuits are not energized. Non-Dimming RRFB-XL2 light bars have a black-sheathed cable (see substep ‘16A’ below). Dimmable RRFB-XL2 light bars have a gray-sheathed cable (see substep ‘16B’ below). If in doubt, look in your control cabinet and check the terminal block’s label for the presence or lack of ‘A’ and ‘B’ terminals. Dimmable systems have ‘A’ and ‘B’ terminals, while non-dimming systems do not.

To connect TWO Non-Dimming light bars (models with a black-sheathed cable) to one terminal block, identical RRFB-XL2 LED leads must be wired in parallel. EITHER: 1) Stack the identical lead connectors on the terminal block slot as illustrated below and explained in Step 14A, or else 2) Splice the identical leads, terminate and connect to the appropriate terminal as illustrated below and explained in Step 14A.

RRFB

Lig

ht B

ar 2

RRFB

Lig

ht B

ar 2

RRFB

Lig

ht B

ar 2

RRFB

Lig

ht B

ar 2

RRFB

Lig

ht B

ar 1

RRFB

Lig

ht B

ar 1

RRFB

Lig

ht B

ar 1

RRFB

Lig

ht B

ar 1

RRFB

Lig

ht B

ar 1

RRFB

Lig

ht B

ar 1

RRFB

Lig

ht B

ar 1

RRFB

Lig

ht B

ar 1

RRFB

Lig

ht B

ar 1

RRFB

Lig

ht B

ar 1

RRFB

Lig

ht B

ar 1

RRFB

Lig

ht B

ar 1

RRFB

Lig

ht B

ar 2

RRFB

Lig

ht B

ar 2

RRFB

Lig

ht B

ar 2

RRFB

Lig

ht B

ar 2

RRFB

Lig

ht B

ar 2

RRFB

Lig

ht B

ar 2

RRFB

Lig

ht B

ar 2

RRFB

Lig

ht B

ar 2

To connect a TWO Dimmable light bars (models with a gray-sheathed cable) to one terminal block:RRFB Light Bar #1: Connect the BLUE lead’s spade terminal to the ‘LED2–’ slot; Connect the BROWN lead’s spade termi-nal to one side of the open ‘B’ slot; Connect the BLACK lead’s spade terminal to the ‘LED1–’ slot; Connect the WHITE lead’s spade terminal to one side of the open ‘A’ slot; tighten screws; next, complete RRFB Light Bar #2 connections (below)

RRFB Light Bar #2: Connect the BLUE lead’s spade terminal to the other side of the ‘B’ slot; Connect the BROWN lead’s spade terminal to the ‘LED2+’ slot; Connect the BLACK lead’s spade terminal to the other side of the ‘A’ slot; Connect the WHITE lead’s spade terminal to the ‘LED1+’ slot. Tighten each terminal screw sufficiently to ensure a secure connection.

LED Terminal Connections (continued)



To connect THREE or FOUR Non-Dimming light bars (models with a black-sheathed cables) to one terminal block, identical RRFB-XL2 LED leads must be wired in parallel. To do so, splice together each group of leads with identical labels/colors: LED1+ (white leads); LED1– (black leads); LED2+ (brown leads); and LED2– (blue leads). Splice them wherever it is most convenient, either inside the pole or inside the cabinet. Solder (recommended) and insulate each spliced group separately to isolate them. Terminate each like-colored spliced group in the control cabinet with a spade connector. Keep any altered leads and cables correctly labeled to ensure the proper terminations.Connect the white leads’ ‘LED1+’ connector to the ‘LED1+’ slot.Connect the black leads’ ‘LED1–’ connector to the ‘LED1–’ slot. Connect the brown leads’ ‘LED2+’ connector to the ‘LED2+’ slot.Connect the blue leads’ ‘LED2–’ connector to the ‘LED2–’ slot.With the light bar connections made, complete other connections.

16

RRFB

Lig

ht B

ar 4

RRFB

Lig

ht B

ar 3

RRFB

Lig

ht B

ar 2

RRFB

Lig

ht B

ar 1

A

16B

NOTE: Non-Dimming RRFB-XL2 light bars have a black-sheathed cable (see substep ‘17A’ below). Dimmable RRFB-XL2 light bars have a gray-sheathed cable (see substep ‘17B’ below). If in doubt of your type, look in your control cabinet and check the terminal block’s label for the presence or lack of ‘A’ and ‘B’ terminals. Dimmable systems have ‘A’ and ‘B’ terminals, while non-dimming systems do not.

Connecting THREE or FOUR Dimmable light bars to one terminal block is not recommended: contact TAPCO Technical Support before proceeding with this type of wiring.

LED Terminal Connections (continued)


RRFB-XL2™ User Guide: Solar-powered and AC-poweredPush Button & Component Terminal Connections

A

Connect Bulldog / Mechanical Normally Open (N/O) Push Button Leads in Cabinet: (See step 17B for XAV2E-LED Push Button) For two-terminal push buttons, polarity does not matter: connect the blue and brown leads to the two push button terminals in any order. If you use a different push button with three terminals, connect the blue lead to the push button’s ‘COM’ terminal and the brown lead to the Normally Open ‘NO’ terminal. Do not use push button’s N/C terminal.

17

Bulld

og P

ush

Butt

on

NOTE: TAPCO cannot verify the compatibility of push buttons not supplied by TAPCO. High-impedance push buttons will not function with these systems. Refer to the section ‘TAPCO-Approved Components’ in this Guide before proceeding to verify push button models that are compatible with TAPCO RRFB-XL2 systems.

Optional Component Connections: If there are additional components that require power connections, connect them to their corresponding terminal block positions. The ‘12V+/0V–’ terminals provide for a constant source of 12VDC.

Haul Assemblies to site, and Install: The assemblies can now be hauled to the installation site(s) and installed: your signs can be mounted either at your shop or on-site.

17

18

19

Terminal Label / Lead Insulation Color*AUD2 AUD1 MIC MUTE LED BTN PWR– PWR+

Blue/Black Red/Black Blue Brown Yellow Orange Black Red

Connect XAV2E-LED Push Button Leads in Cabinet: Locate the green circuit board inside the cabinet, as shown below at left. There are eight pairs of push button terminals: two slots with screws are provided for each terminal, in the event you are connecting two push buttons. Carefully strip about 4" off of the cable’s outer jacket and then strip 1⁄4" of the insulation off of each wire. Insert just the bare, stripped portion of each color-coded push button wire lead into either corresponding terminal slot on the circuit board: see image and table below. Tighten each terminal screw onto the lead’s stripped portion, securing each lead to its terminal. Pull each lead gently to ensure a secure connection.

B

*XAV2E-LED Push Button Cable: Dedicated direct burial-suitable cable with 8C 18AWG stranded conductors and matching color coding, such as Belden 27601A or equivalent is required, available from TAPCO.



NOTE: These instructions are for AC-powered systems only. Proceed to the next page for Solar-powered systems.

Power Feed and Connection: Qualified Electrician ONLY! If power leads are fed directly to the cabinet at this time, ONLY a qualified electrician should proceed with assembly from here forward. Run power feeds and connect to the power cable extension in the bottom of the pole. If using a pedestal base with access door, the main power feeds can be connected to the extension leads after wiring and erecting are completed.

20

Turn OFF Circuit Breaker: CAUTION: Verify that the circuit breaker is switched to ‘OFF’ prior to making any wiring connections. Always attach the RRFB-XL2 LED Leads prior to applying power to them: attaching them with power applied can destroy the LEDs, requiring replacement at your expense. Once ALL RRFB-XL2 LED and other component connections have been made and with power applied, you may turn the circuit breaker to the ‘ON’ position.

Power Connections: Qualified Electrician ONLY! Switch circuit breaker to the OFF position. Attach Power leads: System MUST be properly grounded!Attach your (typically black) ‘Line’ lead to the terminal block’s ‘Line In’; tighten screw.Attach your (typically white) ‘Neutral’ lead to the terminal block’s ‘Neutral In’; tighten screw.Attach your (typically green) ‘Ground’ lead to the terminal block’s ‘Ground’; tighten screw.Switch circuit breaker to the ON position. The system should now be ready to test.To adjust beacon flash duration, either refer to the ‘BlinkerBeam Radio Menus’ and ‘Adjusting Flash Duration (Timeout)’ sections included in this Guide and in the separate BlinkerBeam Radio Operation User Guide.

21

22


AC-power Connections


RRFB-XL2™ User Guide: Solar-powered and AC-poweredBattery and Solar Connections

Insert & Connect MULTIPLE Batteries: (See step 20A for Single Battery) RRFB-XL2 LEDs must be connected prior to this step! With the light bar LEDs connected, open the control cabinet. Remove the battery cables from the pouch on the inside of the door. For each battery: attach the red-wired ring terminal to the Positive (+) battery terminal, and then the black-wired ring terminal to the Negative (–) battery terminal by feeding each bolt through a lock washer, a washer, ring terminal and second washer; then thread bolt into battery and tighten securely with wrench. Place each battery on the bottom of the control cabinet. Locate the battery cable cluster attached to the terminal block. Matching red to red and black to black, press each of its connectors together with one of the battery’s connectors. Pull gently on each pair of connectors to verify they are all locked together.

20B

Insert & Connect SINGLE Battery: (See step 20B for MULTIPLE Batteries) With the light bar LEDs connected, open the control cabinet. Move the battery cables to the side so they will be accessible. Center the battery on the bottom of control cabinet so its Negative terminal is to the left and the Positive terminal is to the right (typically with label facing inward). First, attach the ring terminal of the battery cable tagged ‘Positive +’ to the ‘+’ terminal on battery. Last, attach the ring terminal of the battery cable tagged ‘Negative –’ to the ‘–’ terminal on the battery.

20A

Connect Battery Leads, Solar Panel Leads: With battery leads properly connected, attach the solar panel cable’s leads: Attach ‘Solar–’ lead to ‘Solar–’ on the terminal block, and ‘Solar+’ lead to ‘Solar+’ on the terminal block.

21

Solar Leads

Battery Leads


RRFB-XL2™ User Guide: Solar-powered and AC-poweredBattery Replacement; Vehicle/Pedestrian LED Synchronization

Single Battery Replacement: (See step A2 for MULTIPLE Batteries) Batteries should provide years of use, but will eventually require replacement. Actual battery life will depend on climate, flash duration and LED intensity. With a replacement battery from TAPCO and heeding the Warning and Caution statements, first remove the fuses: this is necessary to protect the solar controller. Then, detach the negative ring connector from the battery terminal; last, detach the positive ring connector. Remove the old battery. Then, follow the ‘Insert & Connect Battery’ procedures in step 20A to complete the replacement process. Always detach the negative terminal first, and always connect the negative terminal after connecting the positive terminal. AFTER the battery is connected, re-insert the fuse(s). Upon activation the LEDs should begin to flash. Dispose of old batteries per local code. Do NOT incinerate.

A1

Multiple Battery Replacement: Batteries should provide years of use, but will eventually require replacement. Actual battery life will depend on climate, flash duration and LED intensity. With the load fuse or all fuses removed, pull apart the battery cable connectors. Remove each battery from the cabinet and detach the leads from the terminals. Then, follow the ‘Insert & Connect Battery’ procedures in step 20B to complete the replacement process. AFTER the batteries are connected, re-insert the fuse(s). Upon activation the LEDs should begin to flash. Dispose of old batteries per local code. Do NOT incinerate.

A2

A3 LED Synchronization: After installing and activating the light bars, if any Pedestrian Confirmation LED is not flashing in sync with its corresponding vehicle LED array, you may rectify it by removing the light bar cover, disconnecting and swapping the Deutsch connectors (circled at right); test if desired and then replace the cover. If there are any other issues, refer to the Tips and Troubleshooting sections in this Guide. PED Array

Vehicle Array


RRFB-XL2™ User Guide: Solar-powered and AC-poweredBlinkerBeam Radio Binding

B I N D I N G

* TA P C O

* TA P C O

TA P C O

M A S T ER

2. If no text is showing on the Master Radio’s LCD display, press either button to wake it, then triple-click its Right Button in rapid succession: while in Binding Mode its LCD screen will alternately display ‘BINDING’, and ‘MASTER’ continuously, and its LEDs will alternately flash red (left, right, left, right, etc.) continuously.

3. Go to every Child (Slave/Repeater) Radio and triple-click its Right Button. The screen will alternately display ‘BINDING’, then ‘SLAVE’ or ‘REPEAT’ repeatedly until bound. When bound, LEDs will both light up solid red, then flash red four times. Until you end the Master’s binding mode, the left LED will slowly flash red and its screen will scroll the TAPCO menu.

5. Now each of the Child Radios’ LEDs should light in this sequence: Left solid red; Right solid amber; Right solid red (these first 3 LED patterns may repeat); Left solid green. Finally the Radio’s Left LED flashes green once every 8 seconds repetitively, indicating the Binding of this Radio has been successful!

NOTE: If radios do not bind using this process, binding codes may be incompatible or there may be a different issue. If they do not bind, refer to the separate ‘BlinkerBeam Radios Operation’ User Guide. Contact TAPCO Technical Support and a PDF can be emailed to you.

1. To communicate and to bind properly, BlinkerBeam® Radios need to be activated and at least 10 feet apart. Identify the Master BlinkerBeam® Radio, typically housed in the cabinet with a label that shows a Binding Code Number (BC: xxxxxx_) ending in ‘G’.*

Power up the Master Radio and proceed to Step 2.

*If label is unavailable or if you are introducing a new radio into the network, the radio type is also displayed in its *DINFO and *FCTRY menus: refer to the separate ‘BlinkerBeam Radios Operation’ User Guide. If the display is dark, click either of the buttons: the Radio wakes and defaults to the TAPCO Autoscrolling Menu.

Child’s (Slave or Repeater) Right Button 3X

Master’s Right Button 3XR

RR R

RR R

RR R

RR R

BINDING

BOUND

MASTER

*TAPCO...

*TAPCO...

*TAPCO...REPEAT OR

SLAVE/BINDINGRR RTriple Right Click

RR RTriple Right Click

Master’s Right Button 2XR R

B I N D I N G

B O U N D

TA P C O

TA P C O

NOTE: TAPCO binds your Radios before shipping, so the system should bind automatically upon powering up all radios. Verify the cabinet label’s 6-numeral portion of ‘BC:’ numbers (BC: xxxxxx_) all need to be identical : if not you may need to modify the code for them to bind. The Master Radio’s cabinet label’s Binding Code Number (BC: xxxxxx_) ends in ‘G’(as shown on label at right) while the other (Child) radios’ cabinet labels Binding Code Number (BC: xxxxxx_) ends in ‘N’.

4. After all radios are bound as explained in step 3, return to the Master Radio. Double-click the Master Radio’s Right Button in rapid succession, thus terminating the Binding Mode. The Master screen will then scroll through the TAPCO menu, and its left LED will flash green once every 8 seconds. Double Right Click R R



L

Adjusting RRFB Beacon Flash Duration (Timeout)

TIMOUT

######

*CONFG

+LOCAL +NETWRK

SAVING

Hold 2 seconds to save Timeout valueR

*TAPCO

L

R

R R

R R R R

R RR RR RR R

R

L

L

R = Single Right Click

= Double Right Click

= No Click: Automatic Scroll

= Single Left ClickKEY FOR MENU NAVIGATION:

R R

1. From the Autoscrolling Mode of the *TAPCO Menu, click the Left Button. 2. When *CONFG is displayed, click the Right Button once to display ‘+LOCAL’.3. The ‘+LOCAL’ submenu affects only the devices wired to that radio. 4. From ‘+LOCAL’ click the Left Button to display ‘+NETWRK’ if you wish to

affect ALL bound networked radios/devices, which must be already bound. Additional Left Button clicks toggle between the Local & Network menus.

5. From either ‘+LOCAL’ or ‘+NETWRK’, click the Right Button once to enter the Timeout menu. When ‘TIMOUT’ is displayed, click the Right Button once to set the flash duration using a combination of the Left and Right Buttons.

6. With the six-digit time displayed in seconds, click the Right Button to advance to the TIMOUT digit you wish to modify. While the desired digit is flashing, increase its value by clicking the Left Button. To set the duration to 45 seconds for example, set display to ‘000045’ and then save as explained next.

7. When all digits are at the desired value, displayed in seconds, press and hold the Right Button for 2 seconds until the display reads ‘SAVING’. It will then read out the saved Timeout value once more: you’re done! The procedure is now complete: LCD display will reset once it is in sleep mode. Close the cabinet.

Optional: If you want to perform other functions, rapidly double-click the Right Button R R to return the radio to higher menu levels:

From Duration [6], R R to return to TIMOUT, Test† or ResetFrom Timeout [5], R R to return to +Local or +NetworkFrom +Local [3] or +Network [4], R R returns you to Configuration [2].

Step TIMOUT Flash Duration User Action Display Notes

1 With the Display reading *CONFG, click the Radio’s Right Button. The display will read +LOCAL. At this level, click the Left Button to toggle between the +Local and +Network menus.

*CONFG+LOCAL (or)+NETWORK

Choose the level which you want to view and to modify or test: +Local or +Network level. Then proceed to the Timeout or Test menu.

2 Click the Right Button to enter the Timeout menu. With the Dis-play reading TIMOUT, click the Radio’s Right Button. The display will read ######. At this level, click the Right Button to advance through the digits and the Left Button to increase the value of the selected (flashing) digit to program the number of seconds that the device(s) will flash. When the desired value is reached, press and hold the Right Button for two seconds to Save your settings. The saved value is displayed; procedure is completed.

TIMOUT######SAVING

######

Timeout is the Flash Duration of the Device(s). The readout indicates the present flash duration setting in seconds. If you simply want to test the LED(s), See the separate BlinkerBeam Operation User Guide section ‘Device LED Testing’ for procedures. Once the TIMOUT Flash Duration has been saved, nothing more is required. The radio LCD display will automatically reset once in sleep mode.

3 Rapid double-clicking the Right Button returns the Radio Display to a higher Menu level.

TIMOUT See Flow Chart above.

In the Configuration (*CONFG) Menu you can view, modify and/or test† your Flash Duration (Timeout) settings on two levels: ‘+LOCAL’ Submenu, affecting only the devices wired to that radio, OR:‘+NETWRK’ Submenu, affecting ALL radio-networked devices. NOTE: Network-level settings can be performed from any radio, but all radios need to be bound before changing Network settings. NOTE: Timeout settings are independent of LED TEST† settings.

† Partial Menu of Functions: Refer to the separate BlinkerBeam® User Guide’s section ‘Device LED Testing In Configuration Menu’ for LED device testing, which is independent of Timeout.

To advance through TIMOUT digitsTo increase the value of the selected (flashing) TIMOUT digit value: cycles through1,2,3,4,5,6,7,8,9,0,1,2, etc.

L

R

[1]

[2]

[3]

[5]

[6][7]

[4]

Left ButtonL

Right ButtonR

T I M O U T

######

No Click: AutomaticR



WARNINGTo reduce the risk associated with electric shock injury, including death resulting from contact with hazardous AC voltage, all AC-powered systems must be serviced by a Qualified Electrician with previous training or certification to safely work on high voltage equipment.

The XAV2E-LED Push Button Control Unit, XAVCU2, has two LED indicators, shown below at right. The red PWR LED flashes once per second, indicating that the board has operating power and that the on-board microcontroller is functioning. The red BUTTON LED indicates whenever the associated push button is pressed and activated.Message Repeat, Locate Tone and Message Type: Dip switch positions 1 and 2 (SW1, SW2) are used to select the number of message repeats whenever flashing starts. If any of the message repeats (1, 2, or 3) is selected, then any button push during the flashing will restart the message count.

SW1 SW2 Message RepetitionsOFF OFF 1 RepeatON OFF 2 RepeatsOFF ON 3 RepeatsON ON Continuous while flashing

Locate Tone Frequency: Dip switch positions 3 and 4 are used to configure the PBS locating tone.

SW3 SW4 ResultOFF OFF No Locate ToneON OFF Locate tone every 2 secondsOFF ON Locate tone every 3 secondsON ON Locate tone every 4 seconds

Message Type: Dip switch position 5 selects the message type.SW5 ResultOFF English Language OnlyON English message followed by Spanish message

VOLUME Control: The output volume from the XAV2E-LED system self-adjusts automatically based over a wide range of ambient noise levels received by the microphone. ‘MIC SENS’ microphone sensitivity control: adjusting can increase or decrease the relative

volume change resulting from a change in ambient noise. ‘VOL MIN’ and ‘VOL MAX‘ controls, for both the voice message and locate tones, restrict the

volume range chosen by the microphone control. The ‘VOL MIN’ control sets the lower limit for the volume, while the ‘VOL MAX‘ control sets the upper limit. If both controls are set the same, or the ‘VOL MAX‘ is set below the MIN, the volume will remain fixed. The ‘VOL MAX‘ control takes precedence over ‘VOL MIN’.

‘FL TIME’ Control: DO NOT adjust this setting! To modify Flash Duration of the LED arrays (from the typical 30-second default), refer to the section ‘Adjusting Flash Duration (Timeout)’.

Volume Adjusters

Volume Adjusters

PWR LED

BUTTON LED

XAV2-LED Message Repeat, Locate Tone, Message Type and Volume

Dip Switches



The following are descriptions of the XAV2E-LED Push Button’s Circuit Board terminals to help identify sources of trouble. For more detailed information in addition to the table below, refer to the section ‘XAV2E-LED Push Button Message, Tone and Volume Adjustments’. For additional system troubleshooting refer to the section ‘System Tips and Troubleshooting’.

PWR+ TERMINAL ‘RED’

This point should always have a DC voltage present. This voltage should be 13 to 15 volts most of the time. It will typically fluctuate some if the voice message is currently playing. For DC model, the voltage should match the DC INPUT voltage. This voltage is measured between PWR+ and PWR-.

PWR- TERMINAL ‘BLACK’ This is the circuit ground for the XAV2E-LED system.BTN TERMINAL ‘ORANGE’

Connecting this terminal to ground (PWR-) should cause the BUTTON LED to light and cause the BUTTON OUT terminals to change to a low resistance state between them. Pressing the PBS button should cause the voltage at the BTN terminal to drop to near zero.

LED TERMINAL ‘YELLOW’ This is an open collector type output from the Control Unit to the PBS. It connects to ground to turn on the PBS LEDs. This output should turn on the LEDs whenever the voltage is present at the LTS IN input.

MUTE TERMINAL ‘BROWN’ This is an output signal which switches the audio amplifier in the PBS between operate and standby modes. It should go to ground whenever a sound is to be played.

MIC TERMINAL ‘BLUE’ This is a low voltage signal from the PBS which represents the ambient noise level. It is generally less than 1 volt above ground and can range from 0 to 1.5 volts. It should change as the ambient noise changes.

AUD1 ‘R/BK’; AUD2 ‘BL/BK’ This is a balanced audio signal which provides the input signal to the audio amplifier.FLSH COM, FLSH1, FLSH2 Output signals for driving external flash relays.BUTTON; OUT Solid state opto-relay contact closure while BUTTON terminal is grounded.LTS IN*: COM and 10-35 VDC inputs are used

Input from LED flash circuit. For the Control Unit, this signal must be present in order to trigger the voice message and also to flash the PBS LEDs. *This input is required to trigger the voice message. See note below at right.

WARNINGTo reduce the risk associated with electric shock injury, including death resulting from contact with hazardous AC voltage, all AC-powered systems must be serviced by a Qualified Electrician with previous training or certification to safely work on high voltage equipment. Turn OFF power BEFORE performing any servicing, maintenance or troubleshooting.

XAV2E-LED Push Button Tips and Troubleshooting

To manually activate the voice message output, connect a separate jumper lead between the BROWN ‘MUTE’ and BLACK ‘Power–’ terminals.



Charging Status WarningsThe Charging Status LED (above, left) indicates charging status and any existing solar input error conditions. The Status LED flashes red whenever an error condition or conditions exist. For further explanation of warnings, refer to ‘Protections’ section.

Charging Status LED

Charging Indication LED Characteristics

Operating State

None Off, with ON heartbeat1 NightGreen On Solid, with OFF heartbeat2 ChargingRed Flashing ErrorRed On Solid, with OFF heartbeat2 Critical Error1 Status LED heartbeat indication flickers ON briefly, once every 5 seconds 2 Status LED heartbeat indication flickers OFF briefly, once every 5 seconds

SOC LEDs Indication Battery Status Load StatusGreen Fast Flashing3

(2 Flashes/Second)Full Battery: Equalize Charge

Load On

Green Medium Flashing3

(1 Flash/Second)Full Battery: Absorption Charge

Load On

Green Slow Flashing3

(1 Flash/2 Seconds)Full Battery:Float Charge

Load On

Green On Solid Battery Nearly Full Load OnYellow On Solid Battery Half Full Load OnRed Flashing3

(1 Flash / Second)Battery Low LVD Warning

(Load On)

Red On Solid Battery Empty LVD (Load Off)None No LEDs On Battery Missing Load Off3 Multiple flashing SOC LEDs = Error Condition. See Error Indications.

SOC (State Of Charge) Warnings The three battery State Of Charge LEDs (above, right) indicate the level of voltage in the battery. The SOC indication is based solely on battery voltage setpoints, which provides only an approximation of the battery charge state. The amount of time between a green SOC indication and load disconnect will depend on many factors including: Rate of discharge (amount of load draw); Capacity of the battery; Health of the battery and LVD set point.As the battery discharges, the Battery State Of Charge SOC LEDs (top, right) will transition from green to yellow and then from yellow to flashing red. A flashing red SOC LED indication is a warning that a low voltage disconnect (LVD) event is imminent: if the battery discharges to the LVD set point, the load will disconnect and a solid red Battery Status LED indication will be displayed. Remove fuses, then disconnect battery and recharge.

Battery Voltage State Of ChargeThe Controller’s three LEDs (top, right) indicate the battery’s voltage state. If the Red SOC LED is lit, the battery charge is too low for the Solar Controller to function. In this event, remove the fuses, then disconnect the battery leads and use a 12VDC charger to charge it to a level of 12.6V. If you don’t have a 12VDC charger, you may charge the battery with the solar panel in full sunlight without operation, but this procedure may require one or more full day’s worth of sunlight.

With devices connected and adequate sunlight shining on the solar panel, the LED marked “CHARGING STATUS” indicates the Controller Charging Status and any error indications.

These three LEDs indicate the battery’s State Of Charge (SOC). The Green SOC LED should be lit before initially using the system. If yellow or red LED is lit, remove fuses, then disconnect and charge the battery before using.

When charging during the day, the Charging Status LED is on with an off ‘heartbeat’ flicker once every 5 seconds. The Charging Status LED is off at night, with an on ‘heartbeat’ flicker once every 5 seconds. These LED patterns indicate normal operating conditions.

SunSaver Solar Controller Charging Status & Battery State of Charge

Controller ‘CHARGING Status’ LED Battery State Of Charge LEDs

PV–Batt–

Load–PV+

Batt+Load+



Battery State Of Charge LEDs

PV–Batt–

Load–PV+

Batt+Load+

Low Voltage Disconnect (check/replace Solar fuse)(Battery Status LEDs sequencing green&red – yellow) If the solar panel/circuitry is not supplying sufficient voltage, use a voltmeter to test output/continuity.

Solar Overload(Charging Status LED flashing Red) If the solar current exceeds the maximum solar rating, the Controller will stop charging until the solar current returns to within its operational rating.

Load Overload(Battery Status LEDs sequencing green&red – yellow) If the load current exceeds the maximum load current rating, the Controller will disconnect the load. It will then attempt to reconnect the load two (2) times approximately ten seconds apart. If the overload remains after the first two (2) attempts, the fault must be cleared by removing and reapplying power.

Solar Short Circuit(Charging Status LED off) The solar input power wires are short-circuited. Charging automatically resumes when the short is cleared.

Load Short Circuit(Battery Status LEDs sequencing green&red – yellow) Fully protected against load wiring short circuits. After two (2) automatic load reconnect attempts (10 seconds apart), the fault must be cleared by removing and reapplying power.

PV (Photovoltaic) Reverse Polarity(Charging Status LED off) Fully protected against reverse solar connection. No damage to the controller will result. Correct the mistake to resume normal operation.

Battery Reverse Polarity(Battery Status LEDs sequencing green&red – yellow) Fully protected against reverse battery connection. No damage to the controller will result. Correct the mistake to resume normal operation.

Damaged Local Temperature Sensor(Battery Status LEDs sequencing red – yellow – green; Charging Status LED on solid red) The local ambient temperature sensor is short circuited or damaged. Charging stops to avoid overcharging or undercharging. This is a critical error. Contact TAPCO Technical Support for service.

Damaged Internal Temperature Sensor(Battery Status LEDs sequencing red – yellow – green; Charging Status LED on solid red) The internal heatsink temperature sensor is damaged. This is a critical error. Contact TAPCO Technical Support for service.

High Temperature(Battery Status LEDs sequencing red – yellow) The heatsink temperature has exceeded 85ºC (153ºF); the solar and load is disconnected. The controller will automatically reconnect when the heatsink cools to 80ºC (144ºF).

High Voltage Disconnect(Battery Status LEDs sequencing red – green) The battery voltage has exceeded the controller’s maximum regulation limit. The solar and load will be disconnected until the battery voltage decreases to the high voltage reconnect threshold.

SunSaver Solar Controller Parameters

Controller ‘CHARGING Status’ LED



Charging Status LED flashes red

Charging Status LED solid red

Battery Status LEDs sequence

green&red–yellow


red–yellow


red–green

Charging Status LED off

Charging Status LED flashes

intermittently

Charging Status LED off;


green&red–yellow


red–yel–green; Charging Status

LED solid red

Solar Overload or impending Low Voltage Disconnect event

Load Overload

High temperature disconnect

High voltage disconnect

Solar Short Circuit

Solar Fuse Removed or Blown

Solar Fuse Removed or Blown

Solar Panel Defective

Solar Panel Wiring

Damaged Local Temp Sensor

Load Short Circuit

PV Reverse Polarity

Damaged Internal Temp Sensor

Battery Reverse Polarity

Controller will stop charging until solar current returns to normal rating limits.

Disconnect Solar Circuit fuse, then remove and reapply power. Re-insert solar fuse.

Correct the solar panel connections on the terminal block.

Critical Error. Contact TAPCO Technical Support for service.

Disconnect Load fuse; correct the battery connections on battery or terminal block.

Disconnect Solar Circuit fuse, then remove and reapply power. Re-insert solar fuse.

Controller automatically reconnects when temperature reaches acceptable limit.

Controller automatically reconnects when voltage reaches acceptable limit.

Charging automatically resumes when the short is cleared.

With battery and components connected to circuitry, insert or replace solar fuse.

With battery and components connected to circuitry, insert or replace solar fuse.

Use voltmeter to test panel polarity/output; rectify or replace solar panel.

Use voltmeter to test continuity; rectify or replace wiring connections.

Critical Error. Contact TAPCO Technical Support for service.

SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION: *REMOVE SOLAR FUSE FIRST

SunSaver Solar Controller Tips and Troubleshooting

LVD: Low Voltage DisconnectDisconnect Load fuse; disconnect & then re-connect the negative battery terminal. Charge battery to 12.6V or above for reconnect, or it will default to LVD event.


RRFB-XL2™ User Guide: Solar-powered and AC-poweredProStar Solar Controller Tips and Troubleshooting

NOTE: The ProStar controller is used ONLY with 85-watt or larger solar panels. The typical, SunSaver controller is covered in other sections. The ProStar is assembled with automated equipment, tested with computers, and is protected from faults. Since the ProStar will generally not be the cause of a problem, it is usually worthwhile to troubleshoot the entire system for faults. Most problems will be caused by wiring connections, faulty loads or batteries unable to hold a charge.

IF BATTERY IS NOT CHARGING:• Check the green CHARGING LED above the Solar input: With sunlight directly on the solar collector, this LED should be lit.• Check that the proper approved Battery Type has been selected.• Check that all wire connections in the system are correct and tight. • Check the polarity (+/–) of the connections.• Measure the solar array open-circuit voltage (disconnected from the

controller) and confirm it is normal. If the array voltage is low or zero, repair or replace the fault in the array.

• Confirm that the load is not drawing more energy than the solar array can provide.

• Check the condition of the battery. Determine if the battery voltage falls at night with no load. If the battery is unable to maintain its voltage, it may be failing. If so, replace with approved battery.

• Measure the solar input voltage (during daytime) and battery voltage at the ProStar terminals. If the voltages at the terminals are the same (within about 0.5 volts), the solar array is charging the battery. If the solar voltage is close to open-circuit (about 20V), and the battery voltage is low, the controller is not charging the battery and may be defective. Make sure the ProStar is not in Pulse Wave Modulation (PWM) regulation for this test. NOTE: If the battery is not being fully recharged, measure the voltage at the battery terminals on the ProStar, and then at the terminals on the battery. This should be done at midday with full charging from the solar array (and not in PWM regulation). If the ProStar terminals are 1 volt higher than the battery terminals, for example, this voltage drop will cause the battery to regulate 1 volt below its desired regulation (PWM) voltage, and it will take longer to recharge. In this case, the SENSE terminals should be connected to the battery for accurate charging.

NOTE: A Solar Controller other than a ProStar (right) may be installed with your SOLAR RRFB-XL2 system. Utilize only the instructions, tips and troubleshooting for your installed Controller.

IF BATTERY VOLTAGE IS TOO HIGH:• First check the operating conditions to account for temperature

compensation (59°F temperature will increase PWM regulation by 0.3V for a 12V battery) and automatic equalizations.

• Check that the proper battery type has been selected.• Disconnect the solar array, and remove the battery wire from the

ProStar’s battery positive (+) terminal. Wait a few seconds and reconnect the battery positive terminal (leaving the solar array disconnected). After start-up, the green CHARGING LED should not be on. Measure the voltage at the SOLAR terminals (with the array still disconnected). If battery voltage is measured at the SOLAR terminals and the green LED is on, the controller may be defective.

IF LOAD IS NOT OPERATING PROPERLY:• Check that the load is connected and turned on. Confirm that no fuses

or circuit breakers in the cabinet are tripped (there are no fuses or circuit breakers inside the ProStar Controller).

• Check all connections to the load, and battery connections. Make sure voltage drops in the system are not too high (a voltage drop to the load will reduce the voltage at the load).

• Check the Controller LEDs: if the red status LED is on, the load has been disconnected due to low battery voltage (LVD). This is a normal protection function; the load will automatically reconnect when the battery is charged by the solar array, or manually (fastest method).

• If the LEDs are blinking, the load may have been disconnected due to: 1) Red/Green–Yellow sequencing = short circuit or overload: After 3 automatic retries, the fault must be located/cleared and

the load must be switched off or disconnected for 10 seconds or longer to restore power to the load terminals.

2) Red–Yellow sequencing = high temperature disconnect.3) Red–Green sequencing = high voltage disconnect. 4) Red/Green/Yellow blinking together =battery select fault.

Measure the voltage at the BATTERY terminals. If it is above the LVD level and no faults are present, the load should have power. Measure the voltage at the LOAD terminals: if there is no voltage present, the controller may be defective. Contact TAPCO Technical Support.



LED Array doesn’t flash: this could also be caused by

Solar Controller issues, covered

on previous pages.

Individual LED doesn’t flash

Pedestrian LEDs out of synch w/large LED arrays

Battery is not fully charged or will no longer hold a charge: if fuses are inserted, remove them prior to proceeding with corrective action(s).

BlinkerBeam® antenna is loose

Fuse Removed or Blown*

BlinkerBeam® Master is down

BlinkerBeam® not synching

BlinkerBeam® signal is too weak

Insufficient Solar Charging: Make certain that collector face is facing south, tilted 45-55º, and is clear of debris, snow and any other obstruction that prevents sunlight from reaching the collector face. In cabinet, make certain that white lead from solar panel is connected to the Solar+ terminal and the black lead is connected to the Solar– terminal.

Loose connections or broken wires: remove fuses prior to corrective action(s).

Loose wiring/circuitry

Circuitry / Light Bar Orientation

Inoperative LED

Remove Load fuse or All fuses. Test battery voltage across terminals: if below 12V, disconnect, remove and charge battery fully: then re-test with a battery load tester, available at some automotive parts stores. If battery will not hold a charge, replace with new, fully charged TAPCO replacement battery or equivalent (see ‘TAPCO-Approved Components’. Then, re-insert fuse(s). Discard old battery per local code.

Extend radio antennas straight out from radios and twist clockwise P until snug.

*If Blown, rectify short; If missing, replace fuse with one of equivalent amp value.

Check power and function of BlinkerBeam® Master Radio.

Refer to BlinkerBeam® Operation Guide to perform diagnostic tests.

Refer to BlinkerBeam® Operation Guide to perform diagnostic tests.

Align solar collector so it faces due south, towards mid-day sun. If obstructed by trees, trim or remove them to allow more sunlight to reach collector. If obstructed by immovable object, such as a building, mountain or hillside, rotate so collector receives the maximum amount of sunlight. If obstruction is immovable or cannot be altered, consider replacement with larger solar panel or AC-powered system.

Remove Solar Circuit Fuse, then (in full sun) test with a DC voltmeter across the terminal block’s ‘Solar+’(with white lead connected) and ‘Solar–’(with black lead connected) to ensure a charging voltage is present, typically 18-22VDC in full sunlight. If no voltage is present, open the junction box cover on back of solar panel. Inside the panel’s junction box, test the voltage across the ‘+’ and ‘–’ terminals. If sufficient voltage is present, repair or replace the cable running from the solar panel to the cabinet. If no voltage is present there, replace solar panel.

*Gently test each connection to ensure each is tight. If loose, tighten screw or nut until snug. If a wire is broken, strip and splice it with a insulated connector, or contact TAPCO or distributor for replacement part(s).

Contact TAPCO or distributor for replacement part(s).

*Make sure all leads are properly connected and tight, then reactivate.

Remove the cover from the light bar you wish to change. Disconnect both sets of Deutsch connectors. Swap and re-connect them. Place the cover onto the light bar. Rotate each screw counter-clockwise until it clicks, then screw in clockwise.

SYMPTOM POSSIBLE CAUSES Corrective Action: *Remove Load Fuse/Trip Circuit Breaker First!

Solar and AC System Tips and Troubleshooting



Registration:The RRFB-XL2 Rectangular Rapid Flashing 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 serial number(s) below, and keep this document in a safe place for future reference. Registration is simple and will take just a few moments of your time. Please register your warranty on-line at: www.tapconet.com/warrantyMODEL NAME: RRFB-XL2 Rectangular Rapid Flashing LED Beacon Assembly SERIAL NUMBER(s): ________________ ________________ _______________DATE OF PURCHASE: _________________________________OPTIONS PURCHASED: _______________________________INSTALLATION LOCATION: ____________________________OTHER NOTES:

Please follow the instructions below to Register your Product Warranty.Warranty amended September 1, 2013: not applicable to systems delivered prior to that date. The use of components not supplied (or approved in writing) by TAPCO, or for use other than stated in this document voids any warranty.Traffic & Parking Control Company, Inc., (TAPCO), warrants to each purchaser of an RRFB-XL2 Rectangular Rapid Flashing 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 three (3) years after the date of original purchase. TAPCO warrants accessories, service parts and components purchased separately to be free from defects in material and workmanship for a period of one (1) year after the date of original purchase. If within such warranty periods any part thereof is proven 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 receiving 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. (TAPCO)

Warranty and Registration

©2017, 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.

For technical support:Phone 866-753-6255 (M-F 8-5 CT)E-mail [email protected]

RRFB-XL2™: Solar-powered and AC-poweredUser Guide

TAPCO • Traffic & Parking Control Company, Inc. RRFBXL2_ug_14124308_RevEUG-14124308 Rev E

Safe travels.™

Solar-Powered Systems Pages & Steps Colored in Green AC-Powered Systems Pages & Steps Colored in Blue

WARNINGWherever AC power is present, electrical installation and servicing must be performed ONLY by a qualified electrician: serious personal injury or death may result from contact with hazardous AC power! Disconnect AC power source AND verify the circuit breaker is ‘OFF’ BEFORE performing any wiring procedures or servicing.

Solar Panels require unobstructed sunlight to charge batteries!

RRFB-XL2™: Solar-powered and AC-powered User Guide...4 2017 Trac Parking Control Company Inc...

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Transcript of RRFB-XL2™: Solar-powered and AC-powered User Guide...4 2017 Trac Parking Control Company Inc...