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Solar-Powered Sign Installed in Canada — Yes, Canada

Ascent Green Energy, Advanced Lighting Systems Collaborate

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Dov H. Rom is proprietor of Ascent Green Energy (Concord, ON, Canada).

There is tremendous interest in solar-powered signage. As concerns continually grow regarding our finite natural resources, the search continues for alternatives that will reduce electricity consumption. As the sign industry has transitioned from neon and fluorescent illumination to LEDs, this has provided an opportunity to present solar-powered signage as a green alternative. LEDs consume far less power than traditional lightsources, which make setting up a solar-power grid that much more cost-effective. In many cases, power-grid access is nonexistent, and renewable energy is the only source of energy.
To serve this market, Ascent Green Energy (AGE) has developed a dedicated system to operate solar-powered signage. Using renewable energy sources does present a few problems. First, and the most serious, is that, during winter months, solar panels capture insufficient sunlight and are unable to power up the LED sign. Second, the size of the solar panels can cause them to overshadow the sign and ruin its overall appearance.

A bright future
We’ve built a system that includes three main components: solar panels; batteries enclosed in a hermetically sealed box, usually buried underground, which restricts exposure to the elements; and a charger/controller that allows us to alter the LED load profiles through a cellular Internet connection to reduce the percentage of LED light. This will reduce the energy requirements to power up the LEDs in wintertime.
Before a project begins, our sophisticated software system looks at the geographic area and makes calculations based on a minimum 10 years’ historical data of the sun’s radiation, especially in winter months. Depending on the circumstances, we may introduce a small wind generator and/or a dual-access, sun-tracking system for the solar panels, for added efficiency, to increase the energy generated by the system.
As a renewable energy system provider, we must understand how to manage LED energy consumption. For example, integrated-dimmer technology is essential for conserving energy. A cloud-based system is needed to manage the power profile as it adjusts to seasonal conditions.Also, our potentially extreme climate necessitates a large backup-battery storage system, to compensate for consecutive days without sunshine. Of course, as with any significant project, familiarity with UL and/or CSA listings is a necessity.
A solar-sign fabricator can use any type of LED, but this system further reduces power consumption and power requirements, and minimizes the solar system’s footprint. Putting this technology to work, AGE has partnered with Advanced Lighting Systems (ALS), a Toronto-based sign fabricator, for the past two years, and now solar-powered signage represents 15% of its business. Together, the two companies developed a freestanding sign for Chartright, a private aircraft-maintenance company that operates at Toronto’s Pearson Intl. Airport.
Chartright had few alternatives to a solar-powered sign. Electricians’ estimates to dig trenches and run power lines to the freestanding sign were expensive and would require filing for permits. The upfront costs of solar energy approximated installing trenched lines, and having a free energy source enabled the customer to get a return on their initial investment within a few years. In general, as solar-power technology becomes more sophisticated, and the price of conventional energy sources increases, sun- and wind-power electricity will become increasingly competitive.
Based on AGE’s engineering layout, ALS determined that AGE-specified LEDs would provide optimal energy efficiency. The slender, 10 x 5-ft., freestanding, double-face pylon sign was positioned facing north and south. To make energy collection more efficient, AGE recommended using Axis solar panels that also faced south and tilted 60° in the direction which provides the greatest sun-ray intensity and prevents snow accumulation.

Fabrication
The client provided the logo for the signage as a vector file. ALS handled pre-production using a combination of Illustrator, SA Intl.’s FlexiSign® Pro, AutoCAD® drafting software and EnRoute® 4 3-D production software. Discussions with the customer determined the sign would be a “push-through” type. ALS routed out the copy on 0.080-in.-thick aluminum using its 6 x 16-ft. CNC router that was custom-built in the Far East with an automatic tool changer. Routed second-surface letters were fabricated using ¾-in.-thick, impact-modified acrylic. The aluminum interior structure was welded with Miller Weldmaster Millermatic 252 and Lincoln MIG-welding systems with SignComp extrusion profiles.
ALS built a custom, 8-ft.-deep concrete foundation using several augers. Large anchor bolts joined the cabinet to the foundation. A 30-ft.-reach JLG bucket lift, standard installation power tools and a generator were required to transport and construct the sign components. Also, holes were dug into the foundation to bury the battery containers and safely remove them from exposure to the elements.
Aesthetics were a key consideration. For highway signs, a large solar panel being visibly prominent is not problematic. However, for commercial signage, branding is far more important; therefore, solar panels must be more carefully chosen and positioned.
As mentioned above, an effective controller is essential to operating an effective solar-powered sign. If levels of energy collection are not managed, or if the sign operates at unnecessarily high levels of brightness at certain times, the modules will not perform sufficiently during cold or overcast periods when less solar energy is collected. Wind power provides an effective backup, but, as with solar, your energy source waxes and wanes.

Equipment and Materials
Foundation: Auger and accessory equipment, from such manufacturers as Falcon Industries (Medina, OH), (330) 723-0099 or www.falconindustries.com; quick-forming concrete and anchor bolts, available at building-supply stores
Installation: Thirty-ft. bucket lift, from JLG (McConnelsburg, PA), (877) 554-5438 or www.jlg.com; power tools and generator, available at home-improvement or building-supply stores
LEDs: Proprietary, 24VDC modules, from Ascent Green Energy (Concord, ON, Canada), (800) 927-5107 or www.ascentgreenenergy.com
Router: Six x 16-ft., customized CNC router, produced by an Asian manufacturer
Software: Illustrator® software, produced by Adobe (San Jose, CA), www.adobe.com; EnRoute® 4 3-D fabrication software, from SA Intl. (Salt Lake City, UT), (800) 229-9066 or www.thinksai.com; AutoCAD® drafting software, from Autodesk (San Rafael, CA), (415) 507-5000 or www.autodesk.com
Welding: MIG welders, from Miller Electric Mfg. Corp. (Appleton, WI), (920) 734-9821 or www.millerwelds.com, and Lincoln Electric (Cleveland), (888) 935-3876 or www.lincolnelectric.com

More About Ascent Green Energy and Advanced Lighting Systems
Ascent Green Energy (Concord, ON, Canada) produces solar- and wind-energy-powered products for such markets as freestanding and pylon, LED-illuminated signs; bus stops and ATM lights; closed-circuit TVs; billboards and related installations. According to the company, the system, in addition to eliminating electrical-grid usage, eliminates the need for trenched power lines or having licensed electricians onsite, and reduces maintenance requirements.
In business since 1987, Advanced Lighting Systems (Concord, ON, Canada) fabricates UL and Canadian Standards Assn. (CSA)-recognized channel letters, sign cabinets, pylon signs, post-and-panel systems, cut-out letters and other types of sign projects. Additionally, the company also provides design, survey, installation and shipping services.
For more information, visit www.ascentgreenenergy.com and www.wholesalesignpro.com.

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