Power Maintenance Guide - CTL2/3 & CLB2/3

Overview

This guide is designed to help you identify and resolve power-related issues in your TraffiCalm Flashing Sign System. It includes steps for checking system fuses, testing battery voltages, and ensuring proper solar panel connections.

Applicable Models

This troubleshooting guide addresses power issues related specifically to 20/30w solar engine controllers and collaborators. It applies to the following TraffiCalm devices involved in these setups:

1. M75-SA300-CTL2
   
2. M75-SA300-CLB2
   
3. M75-SA300-CTL3
   
4. M75-SA300-CTL3
5. M75-DE0TS-CTL3
   

Tools Needed

1. Multimeter or voltmeter
   
2. Screwdriver (Phillips-head)
   

---

Checking and Replacing Fuses

Blade Fuse (5 amp)

• Location: Located on the electronics tray inside the solar engine.
• Action: Check and replace, if necessary, with a standard 5-amp blade fuse. Barrel Fuse (5 amp)
  

• Location: Located on the outside of the solar engine.
• Action: Check and replace, if necessary, with a slow blow 5-amp glass fuse.

---

Battery and Solar Voltage Checks

Battery Voltage Levels

• Normal Range: 12.4 - 14.2V DC.
• Low Voltage Threshold: Below 10.4V may prevent system recovery without recharging to at least 12.4V.
• To test individual batteries, disconnect one wire from the battery terminal and use a voltmeter to measure. This prevents the combined voltage from affecting the reading.

Solar Panel Output

• Expected Output: 17-21V on sunny days; above 14V even on cloudy days.
• Connection Check: Ensure the positive and negative are correctly connected. A negative reading indicates reversed connections.

---

Battery Replacement

Accessing the Battery

To access the battery, open the battery compartment located on each side of the solar engine housing. 

Removing the Battery

Note:  There are 2 batteries so be sure to pull the fuses or disconnect the pigtail wire from both before removing a battery.  This would prevent shorting wires together.  If you disconnect only 1 battery and the wires touch together, they are still HOT from the other battery and will short and blow the fuses.

Wiring: The two 6vdc batteries are wired in series to 12vdc

Terminals: pull the tab terminals from both the positive and negative side

Remove Battery: Carefully remove the batteries.

Installing the Battery

NOTE:  Be sure you pull fuses or disconnect both battery wire pigtails so when the first set of wires are connected the other set of wires are not HOT and shorting together.

Position New Battery: Place the new battery into the compartment, ensuring it is correctly oriented.

Connect Terminals: Attach the positive and negative terminals and securely latch the battery compartment

Final Checks

After replacing any parts or making adjustments:

• Ensure all connections are secure.
• Power on the system to check operational status.
• Monitor the system for any irregularities during initial reactivation.

---

Replacement Parts

Here’s a table of common replacement parts you might need:

Part	Description	Part Number
Battery	Battery AGM 6 Volt 12.0 AH	<029-05162-0000>
Blade Fuse	FUSE-BLADE TRM & SPECIAL 32V 5A	<029-03590-0000>
Barrel Fuse	FUSE MINI SLOW BLOW 5A 250V	<029-05285-0000>

---

• 🔋 Battery Maintenance & Life Cycle

  Proper maintenance of the system batteries ensures reliable operation and long service life. Although these batteries are sealed, maintenance-free AGM types, they still benefit from regular inspection and voltage checks.

  ⚙️ Expected Service Life

  Under typical conditions (temperatures near 77 °F / 25 °C, regular charging, and moderate cycling), the expected life span of the Power Sonic 6 V AGM batteries used in the CTL/CLB controllers is 3 to 5 years.
  In higher-temperature or high-load environments, expect 2 to 3 years.

  End-of-life indicators:

  • Resting voltage falls below 12.0 V after full charge.

  • Voltage drops rapidly under load (below 11.5 V within a few minutes).

  • Excessive heat during charging or discharging.

  • Visible swelling or corrosion at terminals.

  When two or more of these conditions are present, schedule replacement of the battery pair
  

---

• 1. 🧾 Recommended Maintenance Intervals

Interval	Task	Details
Every 3 Months	Voltage Check/Visual Inspection	Check terminals for corrosion or loose fittings. Confirm wiring is secure and strain-relieved. Clean as needed. Measure resting voltage after at least 4 hours of inactivity. Healthy readings: 12.4 – 13.2 V. Note results in maintenance log.
Every 12 Months	Load Test & Cabinet Inspection	Verify voltage stability under system load for at least 15 minutes. Inspect enclosure for heat damage or moisture ingress.
As Needed	Battery Replacement	Replace when voltage cannot be sustained above 11.5 V under normal load or physical wear is observed.

Images

Test Battery & Solar voltage as seen here.

This guide should provide you with the necessary steps to troubleshoot and fix power issues in your flashing sign system. If the problem persists, it may be advisable to contact TraffiCalm technical support for further assistance.

---

Other Power Maintenance Guides

CTL2/CTL3

E-Box

S-Box

• Related Articles

• CTL2/CTL3 Controller Setup Guide

  Overview This guide provides step-by-step instructions for installing CTL2 and CTL3 models, which are Solar Engine-Integrated Controllers or Collaborators. These systems are designed for easy mounting to poles or existing infrastructure, featuring an ...

• Power Maintenance Guide - CTLS & CLBS

  Overview This guide is designed to help you identify and resolve power-related issues in your TraffiCalm Flashing Sign System. It includes steps for checking system fuses, testing battery voltages, and ensuring proper solar panel connections. ...

• Flashing Sign Systems Troubleshooting Guide

  Trafficalm Flashing sign system are used in variety of ways. Push 2 Cross, Curve Warning Systems, Stop Rings, Conflict Intersections, Highwater Warning, or School Zone Beacon Flashers are just a few ways the systems can be setup to operate. ...

• Flashing Sign Systems Quickstart Guide

  System Overview TraffiCalm Flashing Sign systems are available in multiple configurations to suit diverse project requirements. Typically, systems include a Flash Controller (also known as a solar engine), a Sign Ring, and an input device such as a ...

• Installation Guide for Polara iNX Push Button

  Overview The Polara iNX/iDX Push Button Station is designed for easy integration with pedestrian crossing systems, enhancing accessibility with features like an audible direction indicator and customizable settings. This modular device consists of ...