Adaptive P1507 Maintenance Manual Download Page 4 | Manualshive

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Adaptive P1507 Maintenance Manual Download Page 4

AlphaXpress DMS Sign (Texas DOT) Maintenance Manual (pn 1509620301)

March 2, 2006

4

Front Access Full Matrix LED Sign Maintenance Manual (pn 1507610501 rev. A)

Part replacement ....................................................................27

List of field-replaceable parts................................................................................................................... 27

Controlling electrostatic discharge (ESD) ................................................................................................ 27

Opening a sign......................................................................................................................................... 28

Sign controller board replacement........................................................................................................... 32

Power supply replacement....................................................................................................................... 35

Diode module replacement ...................................................................................................................... 37

Relay replacement ................................................................................................................................... 39

LED driver board replacement ................................................................................................................. 41

Fan replacement ...................................................................................................................................... 42

Heater replacement.................................................................................................................................. 43

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Summary of Contents for P1507

Page 1: ...28x96 Front Access Full Matrix LED Sign Maintenance Manual 1 07 inch 1 35 inch and 1 75 inch Pitch Signs with 2 Controllers P1507 P1514 Manual part number 1507610501 rev A Revision date December 10 2007 ...

Page 2: ... Systems 7840 North 86th Street Milwaukee WI 53224 USA 414 357 2020 414 357 2029 fax http www adaptivedisplays com Adaptive is a regisered trademark of Adaptive Micro Systems All other brand and product names are trademarks or registered trademarks of their respective companies ...

Page 3: ...rightness control system 10 Environmental control system sign housing 10 Electrical system 10 Equipment description 13 General description 13 Outside views 1 07 inch pitch sign 14 Outside views 1 35 inch pitch sign 15 Outside views 1 75 inch pitch sign 16 Inside view 1 07 inch pitch sign 17 Inside view 1 35 inch pitch sign 18 Inside view 1 75 inch pitch sign 19 Controller plate 20 Sign controllers...

Page 4: ...anual pn 1507610501 rev A Part replacement 27 List of field replaceable parts 27 Controlling electrostatic discharge ESD 27 Opening a sign 28 Sign controller board replacement 32 Power supply replacement 35 Diode module replacement 37 Relay replacement 39 LED driver board replacement 41 Fan replacement 42 Heater replacement 43 ...

Page 5: ... fans see In ternal view 1 07 inch pitch sign on page 17 or Internal view 1 35 inch pitch sign on page 18 for locations page 26 Figure 15 Door latch locations on 1 07 inch and 1 35 inch pitch signs page 28 Figure 16 Front face frame and prop rod page 28 Figure 17 Fastening LED panels page 28 Figure 18 Removing quick release pin and unfastening LED panels page 29 Figure 19 Door latch locations on t...

Page 6: ...lay page 40 Figure 35 Example of a 1 07 inch 1 35 inch pitch sign The larger 1 75 inch pitch signs have lift arms and winch handles page 41 Figure 36 Fan locations page 42 Figure 37 Screws securing the fan panel housing page 42 Figure 38 Locations of the 6 32 nuts on the fan guard page 42 ...

Page 7: ...aptivedisplays com Safety information Equipment symbols Warnings and cautions Warnings and cautions are posted in appropriate locations throughout this manual Revision Date Notes 1507610501 rev A December 10 2007 Initial release Part Manual title Description 1507650207 Wiring Diagram Sign wiring diagram for the 1 07 inch pitch sign with two controllers 1507650201 Wiring Diagram Sign wiring diagram...

Page 8: ...he sign controller s memory not the sign s LED displays 3V lithium backup battery One 3V lithium battery is located on each of the sign s controller boards Figure 1 Location of the 3V lithium battery on the sign s 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 accordin...

Page 9: ... mentioned systems in general terms for ease of understanding Referring to the drawings 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 four LEDs to form a single pixel The pixels are arranged in various matrices to fo...

Page 10: ... is responsible for maintaining a working environment for the sign display components and communication electronics in the sign display systems The environmental control system consists of the following components Photo temperature sensor Fans Fan filters Fan relay Humidity sensor Fan monitor board Heater strip Heater relay General operation The fans are responsible for exchanging air in the sign ...

Page 11: ... inch and 1 35 inch pitch signs and 20A service for the 1 75 inch pitch sign Electrical distribution DC Attached to the back panels in the sign housing are the power supply boxes that contain two 12VDC switching power supplies The electronic power supplies convert the 120VAC to the required DC voltage to power all of the electronics in the sign DC power to the electronics is redundant and has a pr...

Page 12: ...Introduction 12 Front Access Full Matrix LED Sign Maintenance Manual pn 1507610501 rev A THIS PAGE INTENTIONALLY BLANK ...

Page 13: ...50 60Hz 15A for the 1 07 inch and 1 35 inch pitch signs and 20A for the 1 75 inch pitch sign Typical current draw is approximately 5 8A Display Full matrix 28 x 96 pixels Figure 2 5x7 font dimensions Pitch distance between each LED pixel 1 07 inch 1 35 inch and 1 75 inch pitch Figure 3 LED pitch 5x7 Font Character width nominal 1 07 inch pitch 6 1 35 inch pitch 7 1 75 inch pitch 9 5x7 Font Charact...

Page 14: ...LTS Used to lift sign These should NOT be used to mount the sign C FRONT PHOTO CELL Used for controlling LED brightness D LEDS Used to display messages E FRONT FACE FRAME LATCH Used to fasten sign front face frame F DRAIN HOLE Allows water that may accumulate inside the sign to escape G EXHAUST VENT OUTLET WITH HOOD Permits hot air from inside sign to exit H BACK PHOTO CELL Used for controlling LE...

Page 15: ...sed to lift sign These should NOT be used to mount the sign C FRONT PHOTO CELL Used for controlling LED brightness D LEDS Used to display messages E FRONT FACE FRAME LATCH Used to fasten sign front face frame F DRAIN HOLE Allows water that may accumulate inside the sign to escape G EXHAUST VENT OUTLET WITH HOOD Permits hot air from inside sign to exit H BACK PHOTO CELL Used for controlling LED bri...

Page 16: ...be used to mount the sign C FRONT PHOTO CELL Used for controlling LED brightness D LEDS Used to display messages E FRONT FACE FRAME LATCH Used to fasten sign front face frame F DRAIN HOLE Allows water that may accumulate inside the sign to escape G EXHAUST VENT OUTLET WITH HOOD Permits hot air from inside sign to exit H BACK PHOTO CELL Used for controlling LED brightness I INTAKE AIR VENT Allows c...

Page 17: ... filters E LOAD CENTER Principal AC power for sign 120VAC 20A service required F POWER PANEL 3 Convert AC power from load center to DC power G POWER PANEL 2 H POWER PANEL 1 I HEATER 1 Used to control humidity inside sign J INTAKE FAN FAN 1 Draws in air from outside K LIGHT SENSOR 0 FRONT The address number of a light sensor is set via SW1 and is the same as the light sensor number To replace light...

Page 18: ...ing board and fan heater control relays E POWER PANEL 3 Convert AC power from load center to DC power F POWER PANEL 2 G POWER PANEL 1 H HEATER 1 Used to control humidity inside sign I INTAKE FAN FAN 1 Draws in air from outside J LIGHT SENSOR 0 FRONT The address number of a light sensor is set via SW1 and is the same as the light sensor number To replace light sensor board remove the four nuts atta...

Page 19: ...A service required F POWER PANEL 3 Convert AC power from load center to DC power G POWER PANEL 2 H POWER PANEL 1 I HEATER 3 Used to control humidity inside sign J HEATER 2 K HEATER 1 L INTAKE FAN FAN 1 Draws in air from outside M LIGHT SENSOR 0 The address number of a light sensor is set via SW1 and is the same as the light sensor number To replace light sensor board remove the four nuts attached ...

Page 20: ...pen D 120V OUTLET 64000024 Service outlet GFCI E FAN THERMOSTAT 30670752 Normally open Closes when temperature 120ºF and fans are activated F FAN MONITORING BOARD 1509110301 Monitors fan speed Sends alert via NTCIP if fan speed falls below a specified RPM G RELAY 1 48000004 Fan relay This relay is used to control AC power being applied to the fans H RELAY 2 48000009 Heat strip relay The relay is u...

Page 21: ...S Controller 1 connects to humidity sensor Controller 2 no connection D J4 D INPUT DIGITAL INPUTS Controller 1 connects to power supply fail signals door status and fan monitor board Controller 2 connects to power fail signals of power supplies E P1 RS232 PORT RS232 COMM PORT 0 Not used J3 is used F S1 DIP SWITCH Serial addressing and sign configuration G JMP2 TO JMP6 Configures RS232 or RS485 for...

Page 22: ... Communications from P3 laptop computer Controller 2 Communications from Controller 1 LED3 LED4 Controller 1 Communications to and from LED display boards Controller 2 Communications to and from light sensors O J5 PROGRAMMING PORT P S2 RESET CONTROLLER RESET SWITCH Used to reset the controller for a soft start Q P3 RS232 PORT RS232 COMM PORT 2 used to interface laptop computer to Controller 1 R P2...

Page 23: ...0003LFSP or 30300002SP See Diode module replacement on page 37 B V 12VDC DC output C V 12VDC D DC output voltage adjust Adjustment range Output should be set to 12VDC 0 1V E Input power indicator Green AC voltage supplied to power supply F Signal connector Used for remote control remote sense and power good signal G AC in ground AC input 90 264VAC 47 63Hz H AC N AC in neutral I AC L AC in neutral ...

Page 24: ...O 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 Connects to Controller 1 via a ribbon cable D P5 Programming port for the LED driver board processor E P2 LED DRIVER BOARD ADDRESS This address is set using an address plug pn 150...

Page 25: ...ctronics for foreign debris and general cleanliness Check the interior of the sign for general cleanliness Make sure the sign s drain holes are not plugged Front lens cleaning Required materials Cleaning brush with very long and soft bristles Mild nonabrasive liquid detergent liquid glass cleaner Note Do not use solvents Use of solvents will damage the lens UV stabilizer Soft cloth or soft paper t...

Page 26: ...4 fans see Internal view 1 07 inch pitch sign on page 17 or Internal view 1 35 inch pitch sign on page 18 for locations 3 If an air filter needs cleaning wash it using warm water and dish cleaning liquid Rinse the air filter in clean water and dry it with a clean cloth 4 Return the clean air filter to the sign 5 Reattach the air filter cover 6 Close the sign WARNING Hazardous voltage Contact with ...

Page 27: ...Power supply page 35 Diode module page 37 Relay 1 2 3 page 39 LED driver board page 41 Fan page 42 Heater page 43 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...

Page 28: ... face frame Figure 15 Door latch locations on 1 07 inch and 1 35 inch signs 3 Lift the front face frame up until the frame s prop rods lock in place Figure 16 Front face frame and prop rod 4 Lift the LED panels up and fasten each to the underside of the front face frame using the quick release pin Figure 17 Fastening LED panels WARNING Hazardous voltage Contact with high voltage may cause serious ...

Page 29: ...o release the prop rod and then lower the it down until the door is closed 3 Push the door closed until it latches on the bottom of the front of the sign To open a 1 75 inch pitch sign There is a label on the sign with instructions for opening the sign 1 Remove power from the sign 2 Unhook the latches securing the front face frame Figure 19 Door latch locations on the 1 75 inch pitch sign 3 Pull t...

Page 30: ...andle clockwise approximately 40 times until the door lift arms have fully extended Stop turning the winch as soon as you feel resistance Figure 21 Turning the winch handle 5 Turn handle in a counter clockwise direction until door support arms are engaged Figure 22 Lift arms and door support arms on the 1 75 inch pitch sign Clockwise CS Lift Arm Door Support Arm ...

Page 31: ...e sure the lift arms are moving and cables are not slack Figure 24 Cranking the door closed 3 Turn the handle counter clockwise approximately 40 times until the door is closed 4 Push the door closed until it latches on the bottom of the front of the sign and rehook the four latches securing the front face frame Figure 25 Push the door completely closed Lift Arm Door Support Arm Clockwise CS Lift A...

Page 32: ... be replaced 4 Set the DIP switches and jumpers on the replacement board to match the DIP switches and jumpers on the board being replaced Figure 26 Controller jumper locations and dip switch settings WARNING Hazardous voltage Contact with high voltage may cause serious injury or death Always disconnect power to unit prior to servicing Jumpers Jumpers Controller 2 DIP switches 2 ON All others OFF ...

Page 33: ...s and jumpers 7 Fasten the new controller board to the sign 8 Verify that the DIP switches and jumpers match the settings on the failed controller board 9 Reconnect all cables to the new controller board 10 If Controller 1 Ethernet controller was replaced follow the steps in Set the IP address for new Controller 1 board on page 34 11 If Controller 2 was replaced installation is now complete close ...

Page 34: ...Note If the controller is operational LED 1 is normally flashing use Get to see if the sign s IP address can be retrieved Figure 28 Settings in the IP Set Utility 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 Close the sign and apply power Get retrieves IP information from the sign Set assigns...

Page 35: ...oosening the six screws and sliding the cover off 4 Remove all wires from the power supply to be replaced DC connections V orange colored wire V violet colored wire Signal harness AC connections Hot black wire Neutral white wire Ground green wire Figure 29 Power supply wiring Note Power panel view may be reversed 180 degrees from the position above WARNING Hazardous voltage Contact with high volta...

Page 36: ...er supply from the sign Figure 30 Screw locations on the power supply 6 Fasten the new power supply to the sign 7 Reconnect all the wires to the new power supply 8 Apply power and verify that the new power supply operates correctly by measuring 12VDC on DC terminal blocks Note Make sure both power supplies are on when performing this test 9 Reattach power panel cover ...

Page 37: ...e Figure 31 Nuts securing the diode module to the power plate 6 Apply thermal joint compound pn 67004105 to the bottom of the replacement diode module 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 WARNING Hazardous voltage Contact with high voltage may...

Page 38: ...pn 1507610501 rev A 8 Reconnect wiring to the diode module and tighten the screws Figure 32 Diode module connections W10 Connects Here W6 Connects Here W8 Connects Here TB3 W10 Connects Here W6 Connects Here W8 Connects Here TB3 Diode module part number 30300003LFSP Diode module part number 30300002SP ...

Page 39: ...1 Open the sign See Opening a sign on page 28 2 Turn the sign breaker to the OFF position 3 Locate the relay to be replaced Relay part number 48000009SP Figure 33 Relay locations WARNING Hazardous voltage Contact with high voltage may cause serious injury or death Always disconnect power to unit prior to servicing Relay 2 Relay 1 Relay 3 not shown ...

Page 40: ...he wires from the relay Note If there is a cover over the relay to be replaced remove it 5 Remove the screws holding the relay to the sign 6 Attach the new relay to the sign 7 Reconnect the wires to the new relay and reattach the relay cover if applicable See the wiring diagrams provided with the sign 8 Close the sign and apply power to the sign 4 3 2 1 INPUT OUTPUT Relay shown with same orientati...

Page 41: ... Figure 34 Example of a 1 07 inch 1 35 inch pitch sign The larger 1 75 inch pitch signs have lift arms and winch handles 5 From the front of the LED panel remove the four screws that hold the LED driver board to the LED mounting panel 6 Attach the new LED driver board to the LED mounting panel 7 Raise the LED mounting panel up and fasten the panel to the front face frame 8 Reconnect the cables to ...

Page 42: ... slide the fan panel out of the panel slot Figure 36 Screws securing the fan panel housing 6 Holding the front fan guard secure against the fan panel remove the two 6 32 nuts circled from the top of the fan guard and remove the fan Figure 37 Location of the 6 32 nuts on the fan guard WARNING Hazardous voltage Contact with high voltage may cause serious injury or death Always disconnect power to un...

Page 43: ...ntroller plate must be heated to 120ºF 50ºC to initiate fan operation Notice Move the heat gun around to avoid burning the wiring Verify the fan is blowing in the correct direction intake fan pointing toward inside of sign exhaust fan pointing toward outside of sign Have the central controller of sign run a fan test to verify fan status Heater replacement To replace a heater 1 Open the sign See Op...

Page 44: ...Introduction 44 Front Access Full Matrix LED Sign Maintenance Manual pn 1507610501 rev A THIS PAGE INTENTIONALLY BLANK ...

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