Adaptive AlphaXpress 8731 Manual

Manual Part Number 1508610601 rev. A

AlphaXpress 8731

Front Access

Full-Matrix Display Signs

Installation and Maintenance Manual

March 2, 2009

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

Adaptive Micro Systems

7840 North 86th Street

Milwaukee, WI 53224 USA

414-357-2020

414-357-2029 (fax)

http://www.adaptivedisplays.com

Adaptive is a registered trademark of Adaptive Micro Systems. All other brand and product names are trademarks

or registered trademarks of their respective companies.

Due to continuing product innovation, specifications in this manual are subject to change without 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 connection directly to sign” on page 19 for two controller configuration.

• If required, set the controller’s IP address:

– See “To set the IP address for the new Controller #1 board” on page 38 for two

controller configurations.

– or go to, “To set the IP address for the new Ground Controller #3 board” on page 41 for

three controller configurations.

AlphaXpress 8731 Sign Installation and Maintenance Manual (pn 1508610601 rev. A) 3

Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Related documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Equipment symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Warnings and cautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Controller memory battery backup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3V lithium backup battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

General system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

What is an LED? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

VMS control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

LED brightness control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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 views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Inside view. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

General Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Controller plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Controller plate for 27 x 126 signs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Ground controller panel (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Controller #1 and #2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Power panel and power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

LED driver board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

CONTENTS

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

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Physical inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Exterior inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Interior inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Front lens cleaning (outside 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

AlphaXpress 8731 Sign Installation and Maintenance Manual (pn 1508610601 rev. A) 5

Introduction

Purpose

This manual is intended as a guide for installation, maintenance, and repairs considered field serviceable on all

Adaptive AlphaXpress 8731 signs.

This field service manual supplies technical information for service and technical 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 Electrostatic Discharge (ESD) Damage Describes the precautions to take to protect electronic

components from ESD damage.

Chassis ground

INTRODUCTION CONTROLLER MEMORY BATTERY BACKUP

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

Controller memory battery backup

In the event of a power loss, a lithium battery provides power to the sign controller board(s).

Note: The backup battery provides only enough 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 according to the

manufacturer’s instructions.

3V lithium battery (Panasonic

CR2032 or equivalent)

INTRODUCTION SYSTEM OVERVIEW

AlphaXpress 8731 Sign Installation and Maintenance Manual (pn 1508610601 rev. A) 7

System overview

This section contains the LED Variable Message Sign (VMS) systems description and a general explanation of

how each system operates.

Introduction

The Adaptive LED family of Variable Message Signs is considered to be one of the highest visibility sign

systems available. Utilizing the latest generation of light emitting diode (LED) technology has allowed us to

construct a high-reliability, variable message sign display system.

The LED Variable Message Signs discussed in this manual are built with a combination of 9 x 18 pixel modular

cases, each with three 6 x 9 pixel display boards at 2.6-inch pitch configured in a full matrix. The signs are

designed to be used as outdoor highway information signs. The signs utilize a corrosion-resistant front-access

housing with control circuitry enclosed within. The only connections necessary 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**

(watts)

Number of

30A***circuits

(required)

AX-8731-27X54-18A 7.5 13.5 1.2 3 11 1300 660 1700 1

AX-8731-27X72-18A 7.5 17.5 1.2 314 1800 880 2200 1

AX-8731-27X90-18A 7.5 21.5 1.2 3 18 2300 1100 2800 1

AX-8731-27X108-18A 7.5 25 1.2 321 3000 1350 3300 1

AX-8731-27X126-18A 7.5 29 1.2 3 25 3600 1550 3850 2

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 cabinet dimensions (feet).

**All weight and power specifications are approximations. Consult factory for more details.

***Circuits to be sized for 30–amp breaker(s) in the controller modular case.

INTRODUCTION SYSTEM OVERVIEW

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

27 x 54 dimensions

Figure 2. AX-8731-27x54-18A

27 x 72 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

INTRODUCTION SYSTEM OVERVIEW

AlphaXpress 8731 Sign Installation and Maintenance Manual (pn 1508610601 rev. A) 9

27 x 108 dimensions

Figure 5. AX-8731-27x108-18A

27 x 126 dimensions

Figure 6. AX-8731-27x126-18A

For views and dimensions other than three row configurations see the “Appendix” on page 51 for more details.

General system

The entire sign system may be broken down into four basic subsystems:

• VMS control system

• LED brightness control system

• Environmental control system

• Electrical system

In the following sections, we explain each of the above-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 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 line. The display line format used in AlphaXpress

8731 signs is full matrix, which allows for the display of any alphanumeric character, including punctuation

marks, as well as simple graphics characters.

89.0”

300.0” 14.25” 34.25”

Powerpanel

cube

Powerpanel

cube Controller

cube

Powerpanel

cube

Powerpanel

cube

89.0”

346.8” 14.25” 34.25”

Powerpanel

cube

Powerpanel

cube Controller

cube

Powerpanel

cube

Powerpanel

cube

Powerpanel

cube

Powerpanel

cube

INTRODUCTION SYSTEM OVERVIEW

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

VMS control system

The VMS control system used in the Variable Message Sign consists of the following components:

• IDI 1320 controller

• IDI 1321 controller

• LED display board/driver board

General operation

The controllers interface with the “Host” computer system, and communicate with the Host through a CAT5

Ethernet cable (customer-ordered) or an RS232 Input/Output (I/O) port (standard). 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 standard on AlphaXpress 8731 signs;

the option is available, however, at the customer’s request.

Placement of controllers

The controllers are located in the lower right modular case of all AlphaXpress 8731 sign configurations.

Figure 7. Controller plate on model AX-8731-27x54-18A.

Controller plate

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