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AlphaXpress 8731 Sign Installation and Maintenance Manual (pn 1508610601 rev. A)

Controller plate for 27 x 126 signs

Figure 22.

Typical view of controller plate used for 27x126 signs.

Item

Name

Part #

Description

CONTROLLER #1

15029101

• In two controller sign configurations - controls display and communicates status

information to central communications.

• With three controller sign configurations - Item B (12069003) controls display and

communicates status information to central communications.

CONTROLLER #2

12069003

Auxiliary controller for extra input/output.

AC TERMINAL BLOCK

43201047

Two 8-position terminal blocks for incoming AC power wiring.

120/240VAC SURGE
ARRESTOR

30352001

Transient voltage suppression.

30A BREAKERS

48100013

Two 30Amp breakers are used for 27x126 signs.

AC TO SIGN

43201051

Distributes power to the sign (12-position terminal block).

120V OUTLET

1507500101

Service outlet (GFCI).

COMM OPTION LOCATION N/A

Communication option location.

I/O COM TERMINAL BLOCK 43201054

I/O for controller connections (e.g., power fail signals, power for controllers, light sensor
power, etc.).

Summary of Contents for AlphaXpress 8731

Page 1: ...Manual Part Number 1508610601 rev A AlphaXpress 8731 Front Access Full Matrix Display Signs Installation and Maintenance Manual March 2 2009 ...

Page 2: ...notice Quick Start Guide Mount the sign see Mechanical Installation on page 13 Connect 30amp AC service to input terminal blocks see Electrical installation on page 15 Connect light sensor to controller 2 see Light sensor wiring diagram on page 17 Connect communications to the controller See Sign to ground controller network connection on page 18 for three controller configuration or go to Network...

Page 3: ...Environmental control system 11 Electrical system 11 Installation 13 Mechanical Installation 13 Setting the OPTIONAL tilting brackets before mounting sign 13 Lifting the sign 14 Electrical installation 15 AC wiring 15 Beacon option 16 Light sensor wiring diagram 17 Sign to ground controller network connection 18 Network connection directly to sign 19 Equipment 21 General description 21 Outside vie...

Page 4: ...de of sign 34 Required materials 34 Cleaning procedure 34 Part replacement 35 List of field replaceable parts 35 Opening a sign 36 Controller board replacement 37 Ground controller Controller 3 board replacement 39 Power supply replacement 42 Diode replacement 45 LED driver board replacement 46 Fan replacement 47 Light sensor replacement 48 Appendix 51 AlphaXpress 8731 models single row models 51 ...

Page 5: ...nical personnel so that they can maintain the equipment at the assembly but not the component level Revision history Related documentation Safety information Equipment symbols Warnings and cautions Warnings and cautions are posted in appropriate locations throughout this manual Rev Date Description A March 2 2009 First release Document Number Title Description TechMemo 00 0005 Preventing Electrost...

Page 6: ...ugh power to operate the sign s controller memory not the sign s LED displays 3V lithium backup battery One 3V lithium battery is located on the sign controller board s Figure 1 A 3V lithium battery is located on the sign controller WARNING Danger of explosion if battery is incorrectly replaced Replace only with the same or equivalent type recommended by the manufacturer Dispose of used batteries ...

Page 7: ...y are AC power and Communications Input Output between the sign housing and ground cabinet AlphaXpress 8731 models three row models This manual applies to the following AlphaXpress models For AlphaXpress models other than three row configurations see the Appendix on page 51 for more details AlphaXpress 8731 Height feet Width feet Depth feet Lines Char line Weight lbs Typical Power watts Max Power ...

Page 8: ...2 dimensions Figure 3 AX 8731 27x72 18A 27 x 90 dimensions Figure 4 AX 8731 27x90 18A 159 6 14 25 89 0 34 25 Powerpanel cube Powerpanel cube Controller cube 206 4 89 0 14 25 34 25 Powerpanel cube Powerpanel cube Controller cube Powerpanel cube Powerpanel cube 89 0 253 2 14 25 34 25 Powerpanel cube Powerpanel cube Controller cube Powerpanel cube Powerpanel cube ...

Page 9: ...throughout this manual should help you to gain a general understanding of the LED Variable Message Sign system What is an LED LED based signs are one of the most versatile and visible display systems available We use a cluster of small LEDs to form a pixel The pixels are arranged in various matrices to form alphanumeric characters These characters are then linked together to form an LED display li...

Page 10: ...dard Using this network connection or I O port the Host issues commands to and requests status information from the LED VMS equipment The controllers monitor and control the entire LED VMS system Communication by the controllers to and from the Host and the VMS is accomplished using industry standard 10 100 Ethernet or RS232 communications circuitry and NTCIP protocol Ethernet does not come standa...

Page 11: ...time of the duty cycle is 75 then the brightness will be at 75 and so on The photocell assembly is constructed in such a manner that adverse weather conditions should have no effect on its performance Light sensor globe mounting Because the function of the photocells depends on ambient lighting the light sensor globe should be mounted in a location where it will receive maximum light exposure thro...

Page 12: ...tors the status of the power supplies See the Appendix on page 51 for power panel locations on sign configurations other than three row models Figure 8 Model AX 8731 27x54 18A All power supply panels are located in the second center row on three row AlphaXpress 8731 sign configurations Refer to Figure 2 Figure 6 for power supply panel locations WARNING Hazardous voltage Multiple power sources may ...

Page 13: ... P R S R O F T N I O P T O V I P T L I T G E D 5 U R H T G E D 1 E T O N R O F W O L E B M A E B G N I T L I T E E S S N O I T A C O L E L O H T O V I P A B C D E F G H J K L E T O N R O F W O L E B M A E B G N I T L I T E E S S N O I T A C O L E L O H T O V I P T L I T D R A W R O F H G U O R H T G E D 1 G E D 0 1 R O F T N I O P T O V I P G E D 0 1 U R H T G E D 0 T L I T D R A W R O F T L I T O...

Page 14: ...lifting guidelines WARNING Crush hazard Do not lift sign with more than a 15 degree tilt Always use lifting bar to lift sign Otherwise eyebolts may fail and sign may fall causing serious injury or death RECOMMENDED Lifting bar Front view Use both eyebolts to lift the sign NOT RECOMMENDED Front view Not less than 60 Use both eyebolts to lift the sign ...

Page 15: ...ll other sizes Figure 12 Terminal block on controller plate for all signs except 27x126 WARNING Hazardous voltage Contact with high voltage may cause death or serious injury Always disconnect power to unit prior to servicing Controller plate Line 1 120VAC 30Amp Service Line 2 120VAC 30Amp Service Ground Neutral Note Terminal block accepts a maximum of 8AWG wire Controller plate Line 120VAC 30Amp S...

Page 16: ... PN Description Field Installed 1508230201 SIGNAL CLOSURE KIT Yes 61910044 SERRATED LOCK RING Yes 64000029 1 5 INCH HEX NIPPLE Yes 64000030 1 5 INCH NOTCHED COUPLING Yes 63320022 NEOPRENE GASKET Yes 64000028 6 INCH THREADED NIPPLE No 634008901 12 INCH BEACON HOUSING WITH LED Yes 64000031 HUB PLATE No Beacon Option Components See below table for details Beacon Option When used one is wired on each ...

Page 17: ... JP9 JP8 JP10 JP11 JP1 JP3 JP2 JP4 JP5 JP6 JP7 JP9 JP8 JP10 JP11 CNTRL 2 CNTRL 1 P1 J1 P4 PORT 3 PORT 0 J2 D OUTPUT J3 J4 D INPUT P1 PORT 0 J5 A INPUT J6 PORT 1 P3 P1 J1 P4 PORT 3 PORT 0 J2 D OUTPUT J3 J4 D INPUT P1 PORT 0 J5 A INPUT J6 PORT 1 P3 MAIN SEE NOTE 2 SEE NOTE 2 SEE NOTE 2 FIRMWARE PART REV CONTROLLER PART CONTROLLER PART FIRMWARE PART MAIN REV GND BLK PWR RED Wire power per label on pl...

Page 18: ...ock on the sign s controller plate see below The other wire run is a spare in case the first run ever fails RED ORANGE WHITE BLACK WHITE ORANGE SHIELD GREEN BLUE WHITE WHITE WHITE BLUE RED BLACK SHIELD GREEN WHITE RED BLACK SHIELD GREEN WHITE Run network wiring conduit into this area If any drilling is required vacuum any metal filings from the sign Otherwise the sign fans could blow these pieces ...

Page 19: ... Ethernet connectivity 1 Connect Ethernet cable to the Ethernet surge suppressor on the controller plate See Item H Controller plate on page 24 or Controller plate for 27 x 126 signs on page 25 2 Set the IP address See To set the IP address for the new Controller 1 board on page 38 for details For RS232 connectivity connect DB9 cable to P3 port on Controller 1 See Item R Controller 1 and 2 on page...

Page 20: ...20 AlphaXpress 8731 Sign Installation and Maintenance Manual pn 1508610601 rev A INSTALLATION THIS PAGE INTENTIONALLY BLANK ...

Page 21: ...e 7 or the Appendix on page 51 Display size see AlphaXpress 8731 models three row models on page 7 or the Appendix on page 51 Character height 18 2 inches nominal Character width 10 4 inches nominal Figure 17 Nominal character heights for model AX 8731 27x54 18A Pitch distance between each LED pixel 2 6 inches Figure 18 Pitch is 2 6 inches 27 LED pixels Character width 10 4 nominal 54 LED pixels C...

Page 22: ...models on page 7 D TIE PLATE Used to secure display mountings together vertically E LIGHT SENSOR CONDUIT 3 4 conduit light sensor opening F COMMUNICATION 3 4 conduit communication opening G AC POWER 3 4 conduit AC power 1 opening H LIGHT SENSOR GLOBE See Light sensor globe mounting on page 11 and Light sensor replacement on page 48 I PIXEL LOUVER Used to improve LED contrast J DOOR PROP Used to se...

Page 23: ...nts C CONTROLLER PLATE Contains sign controller 1 and 2 D POWER PANELS Provides DC power to the display and controller Located in middle row across the width of the sign on three row sign configurations See Appendix on page 51 for single row sign configurations E OPTIONAL CONTROLLER BATTERY BACKUP 12V controller battery backup keeps the controllers operating does not power or backup the sign For a...

Page 24: ...unicates status information to central communications B CONTROLLER 2 12069003 Auxiliary controller for extra input output C AC TERMINAL BLOCK 43201058 12 position terminal block used for incoming AC power wiring D 120 240VAC SURGE ARRESTOR 30352001 Transient voltage suppression E 30A BREAKER 48100013 A single breaker is used for the sizes shown in Figure 21 F AC TO SIGN 43201051 Distributes power ...

Page 25: ...atus information to central communications B CONTROLLER 2 12069003 Auxiliary controller for extra input output C AC TERMINAL BLOCK 43201047 Two 8 position terminal blocks for incoming AC power wiring D 120 240VAC SURGE ARRESTOR 30352001 Transient voltage suppression E 30A BREAKERS 48100013 Two 30Amp breakers are used for 27x126 signs F AC TO SIGN 43201051 Distributes power to the sign 12 position ...

Page 26: ...abinet E TERMINAL BLOCK 43201044 RS422 connection to sign controller 5 position x 2 8 24AWG 600V 50A F GROUND CONTROLLER 15029101 This board is connected to an NTCIP network and works in conjunction with the two sign controller boards to control sign operation G LOCAL REMOTE SWITCH OPTIONAL 41000233 DPDT 20A Set activate diagnostics and messages H POWER SUPPLY 40656304 Meanwell SP 200 12 switching...

Page 27: ...S Controller 1 connects to power supply fail signals and door status Controller 2 connects to power fail signals of power supplies E S1 DIP SWITCHES Serial addressing and sign controller configuration F P1 RS232 PORT RS232 COMM PORT 0 not used because J3 is used G JMP2 TO JMP6 Configures controller for RS422 on J3 for communication between controllers H J3 RS422 PORT Used to interface both sign co...

Page 28: ...ntroller 1 Not used in all applications Controller 2 Not used in all applications LED4 Controller 1 Communications to and from LED display boards Controller 2 Communications to and from light sensors 0 1 and 2 O J5 PROGRAMMING PORT P J4 ETHERNET PORT Communication option available on 15029101 only Q S2 RESET CONTROLLER RESET SWITCH Initiates soft reset on controller board R P3 RS232 PORT Two contr...

Page 29: ...0003LFSP OR PN 30300002SP Diode s allow an electric current to pass in one direction and block the flow of electric current in the opposite direction See Diode replacement on page 45 B N A TERMINAL BLOCK PN 43201077 2 pole terminal block C N A POWER SUPPLY WITH PDMB PN 1509904101 The 1000 watt power supply converts and regulates incoming AC power into DC power protecting electronic sign components...

Page 30: ...ates the incoming voltage is below 90VAC LD2 DC BAD On Indicates DC output is below 12 3VDC LD3 AC GOOD On Indicates the incoming voltage is above 90VAC LD4 DC GOOD On Indicates DC output is greater than 12 3VDC LD5 FAULT On PDMB Power Distribution Monitor Board detected a power fault condition has occurred LD6 COMM Flashing PDMB is receiving communications from the controller on the RS422 bus LD7...

Page 31: ...D driver board if in normal operating mode LD3 COMM On There is NO communication from sign controller Off There is communication from the sign controller LD4 RUN Flashing LED driver board processor operating B BIN LABEL Information on the intensity and wavelength of the LED lamps C P3 DATA Connects to Controller 1 via a ribbon cable D P5 Programming port for the LED driver board processor E P2 LED...

Page 32: ...THIS PAGE INTENTIONALLY BLANK 32 AlphaXpress 8731 Sign Installation and Maintenance Manual pn 1508610601 rev A EQUIPMENT ...

Page 33: ...ign for general cleanliness Make sure all fans are operational see Fan test on page 47 for details on testing fan operation Make sure the sign s drain holes are not plugged Front lens cleaning outside of sign Required materials Cleaning brush with very long and soft bristles Mild nonabrasive liquid detergent liquid glass cleaner Soft cloth or soft paper towels Cleaning procedure 1 Mix the detergen...

Page 34: ...THIS PAGE INTENTIONALLY BLANK 34 AlphaXpress 8731 Sign Installation and Maintenance Manual pn 1508610601 rev A MAINTENANCE ...

Page 35: ...s page 42 Diode module page 45 LED driver board page 46 Fans page 47 Light sensors page 48 Notice This equipment contains components that may be damaged by static electricity or electrostatic discharge To prevent this from happening be sure to follow the guidelines in Adaptive Tech Memo 00 0005 Guidelines for Controlling Electrostatic Discharge Damage available at Adaptive s web site at http www a...

Page 36: ...ex screw locations on the front face frame 3 Lift up the front face frame and fully engage both prop rods until they lock into position Note On older sign models a screw was used for securing the door open For newer models automatic engaging prop rods are used Figure 28 Prop rods on the front face frame WARNING Hazardous voltage Contact with high voltage may cause death or serious injury Always di...

Page 37: ...ard to be replaced 5 Remove the four screws circled and remove the controller board from the sign Figure 30 Screw locations on the controller board 6 Fasten the new controller board to the sign 7 Reconnect all the cables to the new controller board 8 If Controller 1 is Ethernet controller pn15029101 go to To set the IP address for the new Controller 1 board on page 38 If Controller 1 is non Ethern...

Page 38: ...eved Figure 31 Setting the IP address for the controller 4 Click Set to set the IP address each sign must have a unique IP address 5 After the IP address is set detach the computer from the controller board and reset the controller 6 Close the sign and apply power Verify communications and ensure proper operation Get retrieves IP information from the sign Set assigns IP information to the sign Get...

Page 39: ...ers on the replacement board to match the DIP switches and jumpers on the board being replaced At least one dip switch must be on for the controller to function See Figure 32 Figure 32 DIP switch settings for the ground controller 4 Disconnect all the cables from the ground controller board WARNING Hazardous voltage Contact with high voltage may cause serious injury or death Always disconnect powe...

Page 40: ...8610601 rev A 5 Remove the four screws circled below that hold the ground controller board to the panel Remove the controller board from the sign Figure 33 Ground controller screw locations 6 Fasten the new ground controller board to the plate and reconnect all the cables to the new board 7 Apply power to the ground controller plate ...

Page 41: ...f the controller is operational LED 1 is normally flashing use Get to verify if the sign s IP address can be retrieved Figure 34 Setting the IP address for the controller 4 Click Set to set the IP address each sign must have a unique IP address 5 After the IP address is set detach the computer from the controller board 6 Reset the controller and verify operation of controller Note If battery is lo...

Page 42: ...the AC power input connector DC power output connector addressing plug and communication RS422 wiring from the power supply Note Metal cover plate that protects the PDMB is removed for a better view of the connection points You do not have to remove the cover plate in order to disconnect the cables Figure 35 Disconnecting power supply cables WARNING Hazardous voltage Contact with high voltage may ...

Page 43: ...ten the new power supply to the sign 6 Reattach cables to the new power supply refer to Figure 35 for details Verify that the wires in P1 terminal block DC power output are tight before attaching it to the PDMB 7 Apply power to the sign and verify the new power supply LEDs indicate normal operating function Note When the power supply powers on all LEDs will be lit for a few moments before returnin...

Page 44: ...pade connector 3 Loosen but do not remove the 4 screws that hold the power supply to the ground controller plate Then remove the power supply Figure 38 Screw locations on the power supply 4 Fasten the new power supply to the sign and then reconnect all the wires to the new power supply 5 Close the sign and then apply power to the sign If the replacement power supply does not have a ground spade co...

Page 45: ...pn 30300003LFSP or 30300002SP 7 Bolt the replacement diode module to the power panel plate Module 30300002SP will mount to 1 4 20 x 3 4 PEM studs Module 30300003LFSP will mount to 8 32x1 screws 8 Reconnect wiring to the diode module and tighten the screws Figure 40 Diode module connections WARNING Hazardous voltage Contact with high voltage may cause serious injury or death Always disconnect power...

Page 46: ...he driver board up and slide off to remove Figure 42 hook locations on driver boards 6 Attach the new LED driver board to the LED mounting panel Slide the driver board on the hooks ensuring they are all fully engaged and then push down Reattach the anchor screw 7 Reconnect the cables to the LED driver boards P1 P2 and P3 8 Reapply power to the sign close the door and verify operation WARNING Hazar...

Page 47: ...ew fan into the frame pointing in the correct direction Figure 44 Fan air flow 7 Reattach the fan and fan guards with the 6 32 screws and nuts 8 Secure the fan to the fan mounting in the case and tighten the two 10 32 nuts 9 Connect the fan wire harness 10 Apply AC power to the sign Fan test Use a heat gun directed at the fan thermostat to verify fan operation The thermostat must be heated to 122º...

Page 48: ...ase of the light sensor globe Remove the attachment bracket and glove to access the light sensor boards Figure 45 Light sensor screws base bracket globe and addressing 3 Locate the light sensor board to be replaced WARNING Hazardous voltage Contact with high voltage may cause death or serious injury Always disconnect power to unit prior to servicing 3 screws per side Light sensor boards Address 0 ...

Page 49: ...all flat blade screwdriver to remove the wire connector form the light sensor that is being replaced Then remove the four screws circled that hold the board to the base of the light sensor globe Figure 47 Light sensor board representative view 6 Attach the replacement light sensor board and screw down the wire connector 7 Reattach the attachment bracket and globe to the base with the 12 screws see...

Page 50: ...THIS PAGE INTENTIONALLY BLANK 50 AlphaXpress 8731 Sign Installation and Maintenance Manual pn 1508610601 rev A PART REPLACEMENT ...

Page 51: ...0 3 6 21 5 1 2 1 18 1050 333 1002 1 AX 8731 9x108 3 6 25 1 2 1 21 1250 366 1169 1 AX 8731 9x126 3 6 29 1 2 1 25 1450 400 1337 1 Pixel center to center spacing is 2 6 66 mm horizontally and vertically Character count is based on a 7 x 4 single stroke font with single column spacing A 7 pixel high character is 18 460 mm tall Line count based on a 7 x 4 font with two pixel row spacing Approximate cab...

Page 52: ...x 126 dimensions Figure 54 AX 8731 9x126 207 0 43 0 Controller cube Power panel cube Fan only cube Fan only cube 14 25 34 25 43 0 254 0 14 25 34 25 Controller cube Fan only cube Power panel cube Fan only cube Fan only cube 43 0 300 0 Controller cube Fan only cube Fan only cube Power panel cube Fan only cube Fan only cube 14 25 34 25 43 0 347 0 Controller cube Fan only cube Fan only cube Power pane...

Page 53: ...APPENDIX ALPHAXPRESS 8731 MODELS SINGLE ROW MODELS AlphaXpress 8731 Sign Installation and Maintenance Manual pn 1508610601 rev A 53 ...

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Page 55: ...THIS PAGE INTENTIONALLY BLANK 55 AlphaXpress 8731 Sign Installation and Maintenance Manual pn 1508610601 rev A APPENDIX ...

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