How to Install Top of Pole Solar Power Kit (SPTOP)

MUTCD Sign Rings: If your controller is running firmware 401N or >, adjust brightness from 100% to 60%. Failure to do so will result in higher power draw and solar systems may fail.

Is my ring MUTCD?
There is a -M at the end of the model number for MUTCD compliant rings

How to Install Top of Pole Solar Power Kit (SPTOP) Guide

Overview
This guide provides step-by-step instructions for installing and connecting a TraffiCalm Top of Pole Solar Power Kit. These kits are designed to be used with TraffiCalm Flashing Sign Systems, providing a reliable and sustainable power source for enhancing visibility and safety.

Applicable Models

M75-SPTOP-030W
M75-SPTOP-060W
M75-SPTOP-100W
M75-SPTOP-150W

Important Information
These solar panel systems integrate seamlessly with our Z-Series Slimline Controller and Collaborators. Ensure you have all the necessary components before starting the installation.

Included Components

Solar panel (30W, 60W, 100W, or 150W, depending on order)
NPT/SAE threaded 1-1/2” post extension
Single threaded 1-1/2” support pipes (x2)
X-pipe fitting
Pelco end caps (x2)
X-pipe threaded cap (aluminum)
Standard drilled channel brackets (x2)
NPT threaded lock rings (x3)
Serrated pipe clamp assemblies (x2)
Post Top Hub with lock ring
Assorted assembly hardware
Wiring harness, panel to controller
Weather tight wiring seals (x2)
Solar Controller (for 100W and 150W models only)

Required Maintenance
Periodically inspect and clean the solar panel. Prune local vegetation that may shade the panel.

Assembly Instructions

Step 1: Assemble the Post Top Bracket

Ensure all set screws and lock rings are loosened or removed to avoid thread damage.
Install lock rings on the straight cut threads (SAE) of all three pipe extensions.
Fully thread the two single threaded pipes to the x-pipe fitting, directly across from one another.
Fully thread the straight threaded (SAE) side of the double threaded pipe to the x-pipe fitting at a 90° angle to the other pipes.
Install the reducing coupler upside down on the non-threaded side of the x-pipe.
Tighten the lock rings and set screws.

Step 2: Panel Preparation

Remove one full “tap-out” from the bottom of the junction box with a flat screwdriver and hammer.
Open the panel’s junction box to access the wiring terminals.
Install one side of the length of conduit to the box.
Connect the black wire to the negative terminal (-) and the red wire to the positive terminal (+).
Allow the harness to hang loosely.

Step 3: Mounting Structure Assembly

Option 1

Assemble toothed clamps to universally drilled cross supports with 3” long x 1/4” bolts and nuts.
Assemble the two universally drilled supports across the height of the panel.
Secure the cross support bolts to the solar panel frame.

Option 2

Align the Unistrut U Channel on the backside of the solar panel along the pre-drilled holes.
Place a Washer fender on the Unistrut side at the aligned holes.
Assemble using a 3/4" Hex Bolt, 1/4" flat washer, 1/4" split washer, and Nut.
Insert the channel spring nuts into the U channel at the desired hinge point.
Attach the clamps to the spring nut using 3 1/4" Bolts and a flat washer

Step 5: Assemble to Post

Complete as much assembly as possible on the ground before hosting the assembly onto the pole

Attach the mounting structure to the pole top hub (Controller or Collaborator).
Thread the assembly onto the Hub and secure the structure.
Slide the serrated clamps onto the mounting structure and tighten bolts.
Adjust the panel for optimal solar exposure:
1. Angle should equal the geographical latitude.
2. Face the panel geographical south.
3. Adjust angle for heavy snow cover if needed.
4. Rotate the panel for best sunlight exposure.
Securely tighten all clamps and screws.

Conclusion
Your solar panel system is now ready to be connected to the Z-Series Slimline Controller or Collaborator Hub. Ensure to create a drip loop in the cable and trim or stow excess cabling after assembly and testing.

TC SPTOP Installation Guide