RetroFlex Installation Manual LT1.02

RetroFlex
Installation Manual

Version LT1.02

Welcome!

On behalf of ClearWorld’s team we would like to welcome you and thank you for your interest in
our unique and innovative patented Solar LED Lighting and Micro-Grid Systems. The RetroFlex
system is designed to be Retrofit onto existing or new infrastructure. This aesthetically pleasing
solution can be attached to any size pole or diameter, whether round, squared, oval, tapered, wood,
concrete or metal. Using our Universal adjustable banding process, it’s perfect for all light pole
applications.
This innovative approach to street lighting is changing the market’s mind-set, being more than just
a light, ClearWorld’s Retroflex systems offers a bundled set of technologies and opportunities that
benefits the global industry.
ClearWorld has taken the Solar LED technology market to another level by providing advanced
solutions which is the backbone to any Smart City initiative. Whether Off or On-grid, we can
provide you with layered services that integrate within your existing infrastructure. In the event
of natural disasters, ClearWorld’s solutions provides public safety and a resilient measure
when the grid goes down.
Thank you again and welcome to ClearWorld’s team, we look forward for a fruitful and long
lasting relationship with you!

Better World! - Safer World! - Healthy World! - ClearWorld!

ClearWorld RetroFlex - Installation Manual 2

Abstract

ClearWorld would like to share this great installation manual with you to facilitate the installation
process of your RetroFlex systems. This installation manual demonstrates step-by-step procedures
to properly install ClearWorld’s RetroFlex systems onto your new or existing infrastructures.
Please read the entire manual carefully before proceeding to install or handling any of our
RetroFlex systems.
In addition, this manual also states safety precautions you must take before and during the
installations.
It is important to follow all procedures listed in this manual to avoid invalidation of Warranty
provided by ClearWorld.
ClearWorld is not responsible for any damages caused by mishandling equipment or inappropriate
installation of the RetroFlex systems.

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Table of Contents

Welcome….…………………………………………………………………….………Page 2
Abstract...….………………………………………………………………...….………Page 3
Table of Contents….………………………………………………………...….………Page 4
Safety......….………………………………………………………………...….………Page 5
RetroFlex Box Contents......………………………………………………...….………Page 6
Installation Tools….………………………………………………………...….………Page 7
Installation Guide….………………………………………………………...….………Page 8-19
*More to be included…Alex

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Safety

All installation procedures must be performed by trained and licensed electricians, with PV system
experience. You must understand and follow all applicable local, state, and federal regulations and
standards for building construction, electrical design, fire, and safety, and must check with local
authorities to determine applicable permitting requirements before attempting to install any
RetroFlex systems.
Note: The installation procedures of this manual is a two-man operation with an estimate
completion time of one-hour per pole.

 For the safety of the installers, use the proper bucket truck for the installation and personal
protective equipment listed in this manual.

 DO NOT perform any installation of our systems during inclement weather conditions.

 Take caution when installing and connecting electrical components
to prevent the risk of electric shock.
 Use insulating tools and DO NOT wear metallic jewelry while
performing installations.

 TWO man lifting and carring operation.
 DO NOT drop package.
 Keep away from wet areas.
 Keep packages stored under-roof.

During this installation processes ensure to wear minimum the following safety protection
equipment:

Safety Glasses
Helmet
Gloves

Reflective Vest
Safety Harness

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RetroFlex Box Contents

Components Qty.

1 Aluminum Array + Solar Panels 1
2 Battery Cases 2
3 Inner Filler (Silver) 1
4 5.5" Filler Trim (Black) 1
5 Array Middle Bracket Fillers 2
6 Array Bottom Bracket Filler 1
7 Crescent Fillers 2
8 Plastic Cap 1
9 Cap Bracket 1
10 Adjustable Metal Clamps 2
11 1/2" Rivets 50

Figure 1 illustrates all components.

Figure 1
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Installation Tools

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Installation Guide

Reminder!
A. This is a two man operation. Installer 1 in bucket truck to affix the solar array to the pole
and installer 2 at the bottom to stabilize and ensure Retroflex is leveled.

B. Identify the assigned location of the RetroFlex unit by using the enclosed Site Summary
Sheet and match with the Serial Number stamped on the RetroFlex system. Each RetroFlex
unit is programed to specific coordinates as determined at the time of purchase.

Step 1. Safety First! Wear all safety protective gear before starting the installation process. Refer

to page 4.

Step 2. Once equipment is at installation site, carefully open the RetroFlex box and layout all

components. Leave Solar array in the box until ready to install to pole. Refer to page 5 to see all
contents of the RetroFlex system.

Note: Do Not use box cutters as they may damage the Solar array.

Step 3. Determine the South direction by utilizing a compass and mark a reference.

Note: The solar array 3.5” filler must face South.
Determine the Solar array mounting height and mark.
Installer 2 hands the Solar array to installer 1 to start the installation. Ensuring the 3.5” filler is
facing South direction and MC-4 Solar panel cables on top, begin by placing the Solar array on
the pole. Install the temporary adjustable metal clamp on the top bracket (upper bracket arms) in
order to hold the Solar array. See Figure 2.

Top

Adjustable Metal Clamp

Figure 2

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Step 4. Level array by placing a 4’ level vertically on the

inside of the array as shown in Figure 3. Make adjustments as
needed. Visually inspect also.

Figure 3

Step 5. Ensure all the bolts and nuts of each array bracket / support arms are tight.

Step 6. Insert the Bandit strap into

the buckle as shown in Figure 4 and
then shift the buckle towards the far
left side.
See important notes below
regarding the top buckle position.

Figure 4

Note: Do not tighten the
Bandit strap in the middle of
the pole as the battery case will
be inserted and slid from the
top on this section of the pole.

Figure 5 Place the buckle on the far
side as shown in Figure 6.

Figure 6

ClearWorld RetroFlex - Installation Manual 9

Step 7. Once the top buckle is in the Figure 7

proper position, use a Bandit tool to
tighten the strap to correct tension and
cut. See Figures 7.

Note: Do not bend the strap backwards as it will
loosen the strap and the process will need to start
over with another Bandit strap.

Figure 8

Step 8. Hammer the Bandit strap tip Locking teeth

forward until flat then hammer the two Locking teeth
locking teeth towards the strap to lock Figure 9
and secure. See Figure 9.

Step 9. Double check the Solar array is still leveled then repeat steps 6-8 for the other three Bandit

straps. The buckles can be in the middle of the pole for the other straps.

Step 10. Remove the temporary adjustable metal strap installed in Step 3 and save for later use.

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Step 11. Install and tighten the middle and bottom brackets fillers. Refer to the RetroFlex contents

list to identify each bracket filler to be installed on the correct array bracket. See Figure 10.
Middle Bracket Fillers

Bottom Bracket Filler

Figure 10

Step 12. Intall and tighten adjustable metal clamp on both middle

brackets (on lower arms) as shown in Figure 11.

Figure 11
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Step 13. Using a 1 1/8” step-down drill 1” to 2” Top

bit, drill a 1” hole on the far left of the Figure 12
pole linear with the top buckle as shown
in Figure 12.

The distance from the top of the array to
the hole should be 1” to 2”.

Note: This hole will be used for running
the LED wire through the inside of the
pole. The next steps will explain this
process.

Step 14. Place the inner (silver) filler on the array and level the filler to have a 1/2” overlap on

each side of the filler in order to fit the rivets. See Figure 13.

Top 1/2” overlap

Bottom

1/2” overlap

Figure 13

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Top Step 15. Using a 3/16” drill bit, drill a hole on the
Figure 14
top right corner of the inner filler (through the array).

Note: Ensure the filler is still leveled on the top and
on the bottom.

Install one of the 1/2” rivets provided by ClearWorld as
shown in Figure 14.

Ensure the filler is still leveled on the top and on the
bottom. Repeat same step on top left corner.

Now the inner filler is secured on the array and ready to
start installing the rest of the rivets.

Step 16. Repeat step 15 and install the rivets as follows:

 10 rivets on the left side
 10 rivets on the right side
 6 rivets in the middle (2 rivets per inner bracket as shown in Figure 15)

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Install the first 4 rivets every 6”.

Install 2 rivets on middle
bracket, 4” apart from center.

Install 2 rivets on middle Install a rivet every 1.5’ until
bracket, 4” apart from center. bottom. Repeat same steps
for left side also.
Install 2 rivets on bottom
bracket, 4” apart from center. Note: Once all rivets are
installed, visually check that
filler is secured and fully flat
against the array.
If a section of the filler has a
bump, proceed to add an extra
rivet.

Figure 15

Step 17. Use 91% Isopropyl alcohol and a clean towel to completely wipe the aluminum array,

top to bottom. This step will allow the Solar panels to adhere better on the aluminum array.

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Step 18. Peel the paper of the Solar panels, both

Sides. See Figure 16.

Figure 16

Step 19. Warm-up entire aluminum array by using a

heat gun. Use the heat gun 6” away from array and warm
evenly. See Figure 17.

Do Not heat the Solar panels as it could damage.

Note: This process is needed if ambient temperature is
< 80F.

If > 80F, skip step 19 and continue to step 20.

Figure 17

Step 20. Stick the Solar panels onto

aluminum array. Start in the middle section
of the array and pull from the back of the
array to the front as tightly and securely as
possible to ensure that the adhesive sticks.
Hold for 15 seconds to ensure that it has
adhered to the array.

Both installers must perform this process
using both hands.

Use hands to smooth out any kinks or
bubbles that may appear and ensure the
Solar panel is flat to the array.

Figure 18
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Step 21. Repeat step 20 for the bottom section then repeat again for top section. Ensure all is

evenly adhered.

Step 22. Install the 5.5” filler trim to cover the Top

remaining aluminum array. Start by placing the Figure 19
filler in position and level at the top and bottom.
See Figure 19.

Level the filler to have a 1/2” overlap on each side
of the filler trim in order to tight and secure the
Solar panels.

Note: The filler trim has pre-drilled holes.

Using a 3/16” drill bit, drill a hole through the pre-
drilled holes of the filler trim – through the
aluminum array.

Install one of the 1/2” rivets provided by
ClearWorld on the top right. Ensure the filler is
still leveled on the top and on the bottom. Repeat
same step on top left.

Now the filler is secured on the aluminum array
and ready for the rest of the rivets.

Note: Have caution to accidentally drill though the
Solar panel.

Figure 20 shows the filler trim installed.
Solar panels are now secured.

Figure 20
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At this point, aluminum array and Solar panel installation is complete.

Reminder!
A. Do not unplug the battery connections. (Will need to be reset if accidently unplugged)
B. There are two battery cases: One case with electronics + battery – One case with battery only.
B. Take extreme caution with the antenna.

Step 23. Insert the battery only case from the top as shown in Figure 22. Insert until top of battery

case is flat on the array. Careful not to pinch any wires.

Top Battery only case

Battery +
Electronics case

Figure 21

Figure 22

Step 24. Insert the battery + electronics case from the top

as shown in Figure 23. Insert until top of battery case is flat
on the array Careful not to pinch any wires.

Do not unplug the battery connections.

Careful with the antenna.

Figure 23

Step 25. Pass the LED wire through the pole hole drilled

on step 13 and feed into the inside of the pole and out.
See figure 24.

Figure 24 ClearWorld RetroFlex - Installation Manual 17

Step 26. Connect all MC-4 connectors.

Step 27. Carefully insert all cables and wires inside the array as shown in Figure 25, except the

LED wire.

Figure 26 shows a clean view once all the cables and wires are inserted in the array.

Insert cables and wires LED light wire

Figure 25 Figure 26
Figure 27
Step 28. Install the plastic cap. Raise the

antenna and ensure it is placed inside the cap
hole as shown in Figure 28.
Note: Careful with the antenna.
Pull the LED wire through the cap.

Cap hole for
antenna

Figure 28

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Figure 29 Step 29. Apply 100% waterproof Silicone in the

gap between the pole and the cap as shown in
Figure 29.
Apply evenly around the pole to prevent water or
dust from going inside the array.

Step 30. Install the cap bracket and tighten

securely.

Figure 30

Step 31. Install the LED light and connect wires.

-----------------

At what point the crescent fillers are installed?
-
I was thinking to continue by including:

1. Steps 1-31 are for Off-Grid applications.
2. Roadway vs Residential (include the details of the different setps)
3. For On-Grid applications follow Steps 1-22 (Skip Steps 23-25). As soon as we know the

process for this installation…we can include in this manual
4. Including communication / wireless installation (Cimcon or other)
5. Also include the hand held user guide.
6. Include basic troubleshooting table.

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