1.5” Series 1600 Outdoor
Incandescent Matrix Displays
Installation, Maintenance &
Troubleshooting Manual
ED-10586
Venus , Starburst and SunSpot are registered trademarks of Daktronics, Inc.
Cailube and Deoxit are trademarks of their respective companies.
ED-10586
Project#1176
Rev. 3 – 3 April 2001
Display Serial #____________________
Copyright 1998 – 2001 Daktronics, Inc.
All rights reserved. While every precaution
has been taken in the preparation of this
manual,
the
publisher
assumes
no
responsibility for errors or omissions. No part
of this book covered by the copyrights hereon
may be reproduced or copied in any form or
by any means - graphic, electronic, or
mechanical, including photocopying, taping,
or information storage and retrieval systems without written permission of the publisher.
Display Model #____________________
Date Installed _____________________
DAKTRONICS, INC.
P.O. Box 5128 331 32 nd Ave. Brookings, SD 57006
Phone (605) 697-4035 or (877) 605-1114 Fax 697-4444
www.daktronics.com e-mail helpdesk@daktronics.com
Table of Contents
Section 1 :
1.1
1.2
1.3
Introduction ............................................................................................... 1-1
How To Use This Manual ..........................................................................................1-1
Display Overview .......................................................................................................1-2
Definitions ..................................................................................................................1-2
Section 2 :
Mechanical Installation ............................................................................. 2-1
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
Display Definitions.....................................................................................................2-1
Support Column Selection..........................................................................................2-2
Eye Bolts.....................................................................................................................2-2
Sectional Display Mounting .......................................................................................2-2
Full Cabinet Display Mounting ..................................................................................2-4
Display Ventilation Requirements (For Enclosed Displays) .....................................2-4
Filter Specifications and Criteria................................................................................2-4
Filter Access ...............................................................................................................2-4
8 x 16 Module Removal and Installation....................................................................2-5
Properly Securing the Lens And Lens Assembly.......................................................2-5
Interconnection Between Displays .............................................................................2-5
Section 3 :
Electrical Installation ................................................................................ 3-1
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
4.
Grounding...................................................................................................................3-1
3.1.1 New Power Installation .................................................................................3-1
3.1.2 Existing Power Installation............................................................................3-2
Control Cable (Fiber Optic)........................................................................................3-2
Driver/ Module Numbering System ...........................................................................3-2
Signal Distribution......................................................................................................3-3
3.4.1 Data Distributor .............................................................................................3-3
3.4.2 Serial Line Controlled Display......................................................................3-3
Load Center Assignments (Full Matrix Displays)......................................................3-4
Module Connections...................................................................................................3-4
Power Line Voltage Considerations...........................................................................3-5
Display Voltage Monitoring.......................................................................................3-7
3.8.1 Line Voltage ..................................................................................................3-7
3.8.2 Lamp Voltage ................................................................................................3-8
Dimming .....................................................................................................................3-8
First Time Turn On.....................................................................................................3-8
Main Disconnect.........................................................................................................3-8
Maintenance & Troubleshooting...........................................................................4-1
4.1
Service Procedures: Front Access ............................................................................. 4-1
4.1.1 Removing a Module ...................................................................................... 4-1
4.1.2 Removing a Lampbank.................................................................................. 4-2
4.1.3 Replacing a Lampbank .................................................................................. 4-2
i
Table of Contents
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
4.15
4.16
4.17
4.18
4.19
4.20
4.21
4.22
4.23
4.24
4.1.4 Replacing the Module ....................................................................................4-3
Service Procedures: Rear Access...............................................................................4-3
4.2.1 Removing a Module (Rear Access) ...............................................................4-3
4.2.2 Removing/Replacing Lampbank (Rear Access) ............................................4-4
4.2.3 Replacing a Module (Rear Access)................................................................4-4
Lamp Testing and Replacement..................................................................................4-5
4.3.1 Lamp Life.......................................................................................................4-5
4.3.2 The Diagnostics Method of Lamp Testing and Replacement........................4-6
4.3.3 Optional Lampbank Driver Test Table ..........................................................4-7
4.3.4 Individual Lamp Replacement - Front Access...............................................4-8
4.3.5 Individual Lamp Replacement - Rear Access ................................................4-8
Lens Position and Sequence........................................................................................4-8
The 8x16 Lens Assembly Weather Stripping .............................................................4-9
Louver Replacement ...................................................................................................4-9
Lamp Driver Display Board........................................................................................4-9
Data Distributor ........................................................................................................4-10
Column Director .......................................................................................................4-11
Line Controller..........................................................................................................4-12
Serial Line Interface..................................................................................................4-13
Vertical Shift Board ..................................................................................................4-14
Transformer...............................................................................................................4-14
Fan Filters .................................................................................................................4-14
Filter Removal...........................................................................................................4-15
4.15.1 Filter Removal (Rear Access) ......................................................................4-16
4.15.2 Filter Removal (Front Access).....................................................................4-16
Fans ...........................................................................................................................4-17
Fan Controller ...........................................................................................................4-17
4.17.1 Fan Controller Signal ...................................................................................4-18
4.17.2 Fan Expander ...............................................................................................4-19
Lens Airflow .............................................................................................................4-19
Structural Inspection .................................................................................................4-20
Cleaning the Cables ..................................................................................................4-20
Modem/FCC Regulations..........................................................................................4-21
Troubleshooting ........................................................................................................4-21
Replacement Parts List..............................................................................................4-22
Unit Exchange/Replacement Procedure....................................................................4-23
Appendix A: Temperature/Photo Sensor ...................................................................... A-1
Appendix B: Supplementary Information...................................................................... B-1
Appendix C: Forms & Reports ....................................................................................... C-1
Appendix D: Project Specific Information..................................................................... D-1
ii
Table of Contents
List of Figures
Figure 1:
Figure 2:
Figure 3:
Figure 4:
Figure 5:
Figure 6:
Figure 7:
Figure 8:
Figure 9:
Figure 10:
Figure 11:
Figure 12:
Figure 13:
Figure 14:
Figure 15:
Figure 16:
Sample Display Configurations.................................................................................. 2-1
New Power Installation .............................................................................................. 3-1
Existing Power Installation......................................................................................... 3-2
Signal Connections to Card ........................................................................................ 3-3
Removing a Module ................................................................................................... 4-2
Inserting the Tool to Release the Lens Assembly Retaining Latch............................ 4-4
Starburst Display Lens Sequence ............................................................................... 4-8
Lamp Driver Display Board ....................................................................................... 4-9
Column Director ....................................................................................................... 4-11
Line Controller ......................................................................................................... 4-12
Filter Removal—Rear Access .................................................................................. 4-16
Loosening the Filter Cover Plate.............................................................................. 4-16
Removal of Filter...................................................................................................... 4-16
Fan Controller Card.................................................................................................. 4-18
Fan Control Expander Card...................................................................................... 4-19
Lens Airflow............................................................................................................. 4-20
List of Figures
iii
1.2
Display Overview
The Series 1600 displays utilize a proprietary lens system, making them the brightest,
sharpest color display systems available. They have been designed and manufactured for
performance, reliability, easy maintenance and long life.
There are two types of Series 1600 displays: Starburst color displays and SunSpot
monochrome displays. Both display types are identical except for the lenses they use, which
are addressed separately, as necessary, in this manual.
Refer to the appropriate controller manual for controller installation.
Daktronics displays are furnished with filters to clean the air before it passes through the
cooling fans. If the filters are removed or modified in any way, the changes must be
submitted to the Daktronics engineering staff for evaluation and approval or the warranty will
be null and void.
Two copies of the Installation Quality Checklist are located in Appendix C. Complete these
forms and mail one back to Daktronics Customer Service to receive a free set of replacement
air filters. This checklist is intended to assist with the display installation and assure its
dependable operation. Make sure each item listed on the checklist is acted upon. If product
quality concerns are noticed during the check-off, please note them on the back of the form or
call Daktronics Customer Service. Listed items may not necessarily be in the order in which
they should be performed.
Two copies of the Series 1600 Display Power Report are in Appendix C. Complete these
forms and return one copy to Daktronics Customer Service. Keep the other copy with the
maintenance manual for a permanent record.
There are ten copies of the Maintenance Checklist in Appendix C. Perform all the
maintenance procedures on this checklist. A list at the bottom of the form provides a personal
record of the dates. As each operational year is completed, file the completed form in a
personal maintenance record and begin a new form for the next year.
1.3
Definitions
8x16 Lens Reflector Assembly: The 8x16 lens reflector assembly consists of reflectors,
lenses and louvers. The entire assembly can easily be removed for maintenance.
Column Director: This circuit card directs the flow of data coming from the data distributor
to the proper line controller(s). It is part of the interface for 16.7 million color technology.
Controller: The controller is a computer that sends information to the display to show
various graphics.
Data Distributor: The data distributor consists of the receiver board and output cards. The
number of output cards can be anywhere from one to eight, depending on the size of the
display. The receiver board receives signal from the controller through the fiber optic cable
and distributes it to the output cards. The output cards send the signal to the display through
the column directors and line controllers. It is part of the interface for 16.7 million color
technology.
1-2
=
=
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Fan Control Circuit: The fan control circuits provide power to the fans and monitor the
fans for proper operation. If a fan failure is detected, the fan control circuit provides a signal
to the data distributor telling it to blank the display. This prevents the display from overheating. If the display is blanked from the controller for 1/2-hour, therefore not generating
any heat, the data distributor provides a signal to the fan control circuit telling it to turn the
fans off. This extends the life of the fans, filters and electronics.
Lampbank: A lampbank is a circuit board containing an array of lamps, 8 pixels high by 16
pixels wide with electronics to drive the lamps and turn them on and off.
Line Controller: This circuit card controls the drivers on the lamp bank and is part of the
interface for 16.7 million color technology.
Louver: Black aluminum louvers are positioned above each row of lamps to provide contrast
and help direct light.
Marquee Display: Marquee type displays have an estimated lamp life of 17,000 hours with
a line voltage of 120 volts at the 120 volt tap on the transformer.
Scoreboard Display: Scoreboard displays run off a higher voltage than the marquee
displays, giving them a lower lamp life of approximately 5,466 hours with a line voltage of
120 volts.
Module: A module consists of a lampbank, 8 pixels high by 16 pixels wide, with an 8x16
removable lens/reflector assembly attached to the front of the lampbank with latches.
Normally, one module is powered by one transformer.
Pixel: A single point of light produced by a single lamp. A group of pixels can be arranged
to form a letter, word or image.
Starburst: Refers to one of the two types of displays available (SunSpot is the other).
Starburst color displays use blue, red, green and white lenses. These lenses, combined with
the proper interface, can create 16.7 million shades of color on the display.
SunSpot: Refers to one of the two types of displays available (Starburst is the other).
SunSpot displays use only one color lens, usually white. Depending on the interface, these
displays will be monochrome or capable of 64 shades of gray.
Serial Line Interface: The serial line interface is used in systems with controllers that
provide signal with a fiber optic cable. The serial line interface sends a signal to the vertical
shift board and is part of the interface for 16 color or monochrome displays.
Vertical Shift Board: The vertical shift board is mounted to the back of the left-most
lampbank (frontview) in a row. The vertical shift board receives the signal from the serial
line interface and controls all lampbanks in its respective row.
Introduction
1-3
In order to access the air filters from the rear of the display, 8 inches of clearance are required
between the bottom of the air inlet hoods and catwalk level. 8 inches is required to allow the
air filter to be removed and replaced without damage to the filter.
2.9
8 x 16 Module Removal and Installation
Refer to Sections 4.1 and 4.2 for directions on removing and installing modules during
section installation.
2.10
Properly Securing the Lens And Lens Assembly
Reference Drawing: Correct Lens Position, 1 1.2” ........................Drawing A-75204
Look down the rows of louvers from either end of the display and ensure that all lenses are
secured properly (refer to Section 4.4). Lenses that are not secured will be easily noticed as
the lens removal tab or the lens itself will not be in alignment with the other lenses or lens
removal tabs of that row. Also ensure that the rows of louvers are in proper alignment.
Be sure the seal between the lens assembly and the top of the display is waterproof. This seal
should be checked with the 0.032" feeler gauge provided. Insert the feeler gauge between the
module and the top of the display.
a) As the feeler gauge is slid along the top of the display, there should be considerable
resistance. This indicates that the weather-stripping (HS-1149) is providing a good, tight
seal against moisture.
b) If the feeler gauge moves freely or with very little resistance, the cause must be found.
•= It may be that the weather-stripping on either the module or the border is damaged
and must be replaced.
•= If the weather-stripping is not damaged, then the perimeter border must be adjusted
so that a good, tight seal is obtained between the weather-stripping of the module and
the perimeter border.
If the display was shipped in sections and bolted together on site, the weather-stripping
tightness between adjacent modules of each section should also be checked with the feeler
gauge. If the feeler gauge moves freely:
a) First check the weather-stripping on the 8x16 lens assemblies.
b) If the weather-stripping is okay, this would indicate that the sections were not bolted
together closely enough and are allowing a gap between the sections which will allow
moisture to enter the display. Refer to the installation procedure to ensure that all
installation instructions for bolting the sections together were followed.
2.11
Interconnection Between Displays
After mounting the display sections to a structure, the fan control circuits and modules may
require signal interconnect between the sections. Refer to project specific shop drawings and
system riser diagrams for locations of interconnect points.
Mechanical Installation
2-5
Section 4 :
Maintenance & Troubleshooting
IMPORTANT NOTES:
1. Power must be turned off before any repair or maintenance work is
done on the display!
2. Any access to internal display electronics must be made by qualified
service personnel.
3. Do not operate the display with the back sheets removed! The cabinet is positively
pressurized directing adequate airflow around the lamps and out through the lenses.
Display operation without the back sheets in place and fans running could cause damage
to the display and will void the warranty. Make certain the back sheets are fastened
securely into place.
4. Dirt and contaminants may enter the display if it is operated without the fan filters
in place or with dirty fan filters. These contaminants may cause premature failure of
the electronic components. Operating the display with dirty fan filters or without fan
filters will void the warranty.
5. The Daktronics product managers engineering staff must approve any changes
that may affect the weather tightness of the display. This is to include, but is not
limited to, border shrouding, back sheets, cooling fans, fan filter and filler panels. If ANY
modifications are made to the weather tightness of the display, detailed drawings MUST
be submitted to our engineering staff for evaluation and approval or the warranty will be
null and void.
6. Turning the power off when the display is not in use will extend the life of some
components.
The service required for the displays will be one of two parts: front access or rear access. Most
service procedures are easier using the front access method. However, due to the mounted position of
the display, available space and other variables, it may be necessary to perform some service
procedures from the rear.
4.1
Service Procedures: Front Access
4.1.1 Removing a Module
Reference Drawing: Lens Assy Removal, Front Access... Drawing A-99899
For many maintenance or repair procedures, the first step is to remove a module.
Each 8 by 16 lens assembly is secured to the frame by two spring-loaded latches, one
on each side. For access to these latches:
1. Remove the lens from row 4, column 1, and the lens from row 4, column 16 of
the lens assembly.
2. Place the front access tool, 0M-95442, into the latch access hole. The angled
edge of the tool should be down so it wedges the latch pin down as it is pushed
Maintenance &
Troubleshooting
4-1
further into the access hole.
1. When the front access tool is fully inserted, the module latches should be
released.
Figure 5: Removing a Module
4. With the latch released, pull the lens assembly slightly away (about a half-inch)
from the display. This will prevent it from re-latching.
5. Repeat this procedure with the remaining side.
6. With both sides unlatched, the assembly should pull away from the display far
enough so the signal and power harness can be disconnected from the lampbank.
When the signal and power harnesses are removed, the module can be removed
from the display.
Note: A 3/16” slotted screwdriver may be used in place of the access tool
(Daktronics part no. 0M-95442).
4.1.2 Removing a Lampbank
The lampbank is attached to the lens assembly with a metal clip at each corner. To
remove the lampbank:
1. Push the clips in with your thumb while gently pulling the lampbank out.
2. Repeat this step for the three remaining corners. Lampbanks should be serviced
in a static-free area to prevent static electricity from damaging components.
4.1.3 Replacing a Lampbank
4-2
When lampbanks are reattached to the lens assemblies, be sure the lamp sockets are
seated tightly against the reflectors. The 8x16 lampbank mounting angles are notched
to allow the lampbank to be secured to the lens/reflector assembly by the tabs on the
side brackets. All four tabs, one in each corner, must be snapped securely onto the
lampbank. If the lampbank is not secured properly to the lens assembly, the lamp
filament will not be at the focal point of the reflector and parts of that lens assembly
will appear dim. If focal point adjustment is required, steps are provided in the
Maintenance &
Troubleshooting
lampbank mounting angle to allow for variations in materials.
4.1.4 Replacing the Module
Reference Drawings: Correct Lens Position, 1 1/2”......... Drawing A-75204
To reinstall a lens assembly in the display:
1. Reconnect power and signal connections to the lampbank.
2. Tilt the module about 30 degrees and place the bottom corners of the side
brackets to the inside of the frame verticals.
3. Push the lens assembly firmly back into place until the latches snap into place and
the lens assembly is secured to the display. It may be necessary to use a solid
object, such as a short length of two-by-four, to properly seat the assembly.
•=
Place the two-by-four across the louvers so the pressure on them is evenly
distributed and strike the board with the heel of your hand. This should drive
the assembly in place.
4. Pull firmly on the assembly to ensure that it is fully in place and secured to the
display. The lens assemblies must fit together tightly enough so the weather
stripping forms a seal and prevents water from leaking between the lens
assemblies and into the display. The seal between the assemblies should be
checked with a 0.032” feeler gauge. Refer to Section 2.10.
5. Snap the lenses back into the face plate of the lens assembly. If a lens is not
replaced properly, it is easily noticed. The lens removal tab or the lens itself will
not be in alignment with the other lenses or lens tabs. Refer to Drawing A75204.
6. Ensure that the rows of louvers on the lens assembly are in proper alignment.
4.2
Service Procedures: Rear Access
When removing an 8 by 16 lens assembly from the rear of the display, follow the safety
lanyard procedure. The use of a safety lanyard will prevent the module from falling and
causing damage or injury. Post a safety lanyard procedure list on each end of each level of
the catwalk. A copy of this procedure can be found in Appendix B.
4.2.1 Removing a Module (Rear Access)
Use a battery powered screwdriver with a 5/16 ” hex bit to remove the back sheets
from the area to be serviced.
1. Disconnect the power wires to the fans.
2. Disconnect all power and signal harness connections from the lampbank.
3. Place a safety lanyard snap into any one of the three holes in one of the side
brackets of the lens assembly.
4. Loop the safety lanyard around the conduit and secure the remaining snap into
one of the three holes in the bracket on the other side of the lens assembly.
Maintenance &
Troubleshooting
4-3
1. Insert the tool ( 0M-95441) into the
area just below the lampbank
positioning tab of the side bracket at
a slight angle (refer to Figure 6).
The tool will work best if positioned
with the notched side up.
2. Slowly turn the tool downward so it
pushes down on the lens assembly
retaining latch.
3. Gently push the corner of the lens
assembly out of the display, just far
enough (about a half-inch) to prevent
the latches from springing back into
place.
Figure 6: Inserting the Tool to Release the Lens Assembly
4.
Repeat the same step for the
Retaining Latch.
remaining side of the module.
5. With both latches released, grasp the lens assembly with both hands and push the
entire module forward and out through the front of the display.
6. Turn the lens assembly until it can be pulled back through the opening in the
display and removed.
Note: In some cases, components mounted to the display cabinet will not allow a
module to be pulled through the opening created by removing the module. In this
case, the lens assembly above or below that section must be removed first and the
module can be removed through that opening.
11. Remove the safety lanyard from the side brackets and gently lay the lens
assembly, lens side down, on a static free surface.
4.2.2 Removing/Replacing Lampbank (Rear Access)
The lampbank is attached to the lens assembly with metal tabs at each corner.
1. Push in on these tabs with your thumb while gently pulling the lampbank out until
it clears the tab.
2. Repeat Step 1 for the three remaining corners.
When servicing the display from the rear, the above steps may be possible without
removing the lens assembly from the display. However, if there are components
mounted to the frame that do not allow removal of the lampbank, it will be necessary
to remove the complete module from the cabinet in order to allow access to the
lampbank.
For directions on re-attaching lampbanks to the lens assembly, refer to Section 4.1.3.
4.2.3 Replacing a Module (Rear Access)
Modules should be fitted into the matrix from the front of your display. However,
there may be situations where you only have rear access. To replace the module from
the rear, it should first be connected to the display with a safety lanyard (refer to
Appendix B).
4-4
Maintenance &
Troubleshooting
1. With the safety lanyard in place, the lens assembly must be passed through the
opening, rotated right side up and then pulled back into place.
2. When pulling the lens assembly into place, it should be tilted about 30 degrees so
the bottom goes in first.
3. Pull the lens assembly firmly back into place until the latches, one on each side of
the frame verticals snap into place.
There are some areas on the display where components prevent the lens assembly
from passing through the opening in the display. In this case, a second lens assembly
above or below the first one must be removed, creating an opening large enough for
the lens assembly to pass through.
Lens assemblies must fit together tight so the weather stripping forms a good seal and
prevents water from leaking between the lens assemblies and into the display. The
seal between the assemblies should be checked with a 0.032” feeler gauge. Refer to
Section 2.10.
4.3
Lamp Testing And Replacement
This display is designed for easy lamp replacement with either front or rear access. Nonfunctioning lamps should always be replaced prior to scheduled events or as soon as possible
for best viewing.
A 3.58 watt lamp is positioned behind each lens. Use the Diagnostics program on the Venus
7000 controller to locate bad lamps. Use the lamp test form located in Appendix C, to mark
the location of bad lamps. Refer to Section 4.23 for the part numbers of replacement lamps
and lenses.
•=
•=
•=
Daktronics-approved 3.58 watt lamps have an estimated life of 17,000 hours if operated at
11.0 volts. Always use Daktronics approved lamps. Lamps purchased from Daktronics
are built to tighter specifications than similar lamps built in standard production. The
recommended lamps give the sufficient intensity and beam spread to match the display
design. Lamps not built to Daktronics specifications will not perform as well, will not
give the intended results and will adversely affect the beauty of the display.
Lamp testing should be done by a qualified individual who is capable of operating the
controller equipment.
Display power must be OFF for lamp replacement.
4.3.1 Lamp Life
The life rating of a lamp is the average value in hours within which 50% of a test
quantity is expected not to fail and within 70% of the rated life, 90% of a test
quantity is expected not to fail.
Lamp life will be increased if the average intensity of the lamp is less than maximum.
Predicted lamp life is for lamps operating in a laboratory with continuous operation
in a stable temperature and mechanical environment. Actual lamp life will differ
from predicted life due to switched operation, varying temperature, mechanical
vibrations due to wind, traffic and display service and actual hours of operation.
Typically, lamp failures for the 17,000 hour 11.0 volt lamp in the 1-1/2" displays can
Maintenance &
Troubleshooting
4-5
4.8
Data Distributor
The data distributor (DD) is made up of two components, the receiver board and the output
cards. The DD is responsible for receiving the incoming signal from the Venus 7000 and
distributing it to the appropriate column director through the output cards.
Each DD receiver is capable of controlling 8 output cards, giving a total of 16 useable
outputs.
LED functions for the 10 position block are as follows:
DS10
DS11
DS12
DS13
DS14
DS15
DS16
DS17
DS18
DS19
Not used
Processor Initialization Complete
EPLD Configuration Complete
Test Mode
Taxi Command Received (Will Flash with Data Received)
Sign is blank
Sign Forced Blank (Signal Loss or Fan Failure)
On = Fans on, Blinking = Fan failure, Off = Fans off
Heartbeat; indicates processor running
Not used
The test pattern jumpers on the DD receiver for 16 million incandescent are as follows:
1. Test 1 in the ON position will display an ALL ON/ALL OFF test pattern.
2. Test 1 and 2 in the ON position will display the driver test pattern.
The output cards have two signal outputs per board. Each of these signal outputs have four
output jacks for use in multi-sided sign configurations such as a four-sided basketball
scoreboard.
The output cards are separated and secured with four stand-off’s, one in each corner. Each
card must be removed from the receiver board one at a time before the receiver board can be
removed from the display.
LED functions for output boards are as follows:
•= Output 1—J2, J3, J6 and J7 (Labeled Data1 on the output board)
•= Output 2—J4, J5, and J9 (Labeled Data2 on the output board)
Output cards are assigned an address through a rotary switch located on the board. The
addresses for multiple boards must be set in a sequential order starting at 0. For example, 0,
1, 2, 3 for a 4 board configuration. 1, 2, 3, 4 would be incorrect.
A fan control circuit is also present on the DD receiver for controlling a maximum of 8 fan
controllers without the use of a fan expander. All fan controllers must be in a “Good Section”
status for the display to operate properly. Without all fan controllers present, the display will
blank after approximately two minutes. Think of the fan control circuit as a multi-input and a
gate. Each of these LED’s corresponds to a fan controller. LED On means the section is
good; LED Off means the section has failed.
LED designations without a fan control expander board are as follows:
4-10
Maintenance &
Troubleshooting
•=
•=
•=
•=
•=
•=
•=
•=
DS1 SFan Controller 1
DS2 SFan Controller 2
DS3 SFan Controller 3
DS4 SFan Controller 4
DS5 SFan Controller 5
DS6 SFan Controller 6
DS7 SFan Controller 7
DS8 SFan Controller 8
If a fan Control Expander Board is used with the Data Distributor, the LED indicators on the DD
become indicators for the Fan Expander inputs, not the Fan Controllers.
LED designations with a Fan Control Expander Board are as follows:
•= DS 1 & 2SFan Control Expander Input A
•= DS 3 &4SControl Expander Input B
•= DS 5 & 6SFan Control Expander Input C
•= DS 7&8SFan Control Expander Input D
4.9
Column Director
Figure 9: Column Director
The column director (CD) is a printed
circuit board that directs the flow of
data from a data distributor to the line
controllers. One column director
receives data and passes it on to a
maximum of four line controllers, for
a 32-row by 64-column section of the
display (the maximum size; the
section could be smaller). Column
directors are connected to each other
in a horizontal chain, from left to
right, for each output of the data
distributor. The input jack on the
column director is labeled “CD IN”.
The output jacks are labeled “LC
OUT” and “CD OUT” respectively.
Refer to Figure 9.
The column director distributes signal form the DD to portions of the sign. CDs are capable
of controlling a maximum of 32 pixels high x 64 pixels wide or a maximum of 4 line
controllers.
Maintenance &
Troubleshooting
4-11
CDs have 3 jacks for signal distribution. They are as follows:
CD In
Incoming signal from either the DD or a previous CD
LC Out
Line controller information for the section that the CD is controlling
CD Out Outgoing signal to next CD
The CD sources power from the line controller signal cable. There is a power LED present
on the CD for power indication.
4.10
Line Controller
The line controller (LC) stores the data for a
display area of 8 rows by 64 columns and
uses that data to send drive signals to the
modules. These signals include the level of
intensity for each pixel as well as the overall
intensity level (display dimming). It also
passes data on to the next line controller
using network cable. The input jack on the
line controller is labeled “LC IN”. The
output jack is labeled “LC OUT”. The line
controller has a power indicator (green) and
a red indicator. Both will be on steady if the
line controller is operating properly. Refer
to Figure 10.
The line controller distributes the signal
received from the column director to a series Figure 10: Line Controller
of lampbanks. LC’s are capable of
controlling a maximum of 8 pixels high by 64 pixels wide or a maximum of 4 lampbanks.
Never daisy chain more than 4 line controllers together. Four is the maximum!
Note: All lampbanks controlled by an LC must be on the same power phase.
LC’s have 3 jacks for signal distribution. They are as follows:
I1, Data Out
I3, Out
I4, In
Outgoing signal to the lampbank
Outgoing signal to the next LC
Incoming signal from either the CD or a previous LC
The LC receives power from the lampbank it is attached to through the ribbon cable. The LC
has 2 LED’s present on it, power and program. Power should be on whenever the lampbank
is energized. The program LED must be on for proper operation. If it is not, the LC’s Altera
device has not been programmed. At this point you can re-power the lampbank to try and reprogram the Altera or replace the LC. Altera programming is only done at the power-up.
Note: Do not unplug the ribbon cable from the LC with the power still on to the lampbank. It
is possible to destroy the input IC of the lampbank by doing so.
4-12
Maintenance &
Troubleshooting
4.16
Fans
Fans are provided to control the heat buildup generated by the electronic components. One
cooling fan will provide ventilation for eight to twelve 8 by 16 display modules (depending on
display configuration).
Fans should be checked after the display has been in operation for 1500 hours and every 1500
hours after that to ensure that the display is being cooled properly. Fans should be checked
more often if the display is located in a dusty or harsh weather environment (i.e. along a
gravel road with dust laden air).
1500 hours is equivalent to 83 days if the display is operated for 18 hours a day and the power
to the display is turned off when not in use to ensure that the fans are not operating when the
display is not running. 1500 hours is equivalent to 62 days if the display is on running nonstop, 24 hours a day.
The fan operation can be easily checked on rear access displays.
1. Once the filters have been removed (refer to Section 4.15), turn the power back on.
2. Look up inside the rain shield and note if the fans are turning properly.
CAUTION: The fan blades are exposed during this step. Turn the power off when
finished checking the fans.
Each time a module is removed, take a minute to inspect the fans.
1. Check the fan blades for dirt and debris. If the fan blades have a large accumulation
of dirt and debris, this indicates that the filters need to be changed more often. Fan
blades must be kept clean to maintain fan efficiency and ensure proper cooling.
2. Spin the fan blades with a pen or pencil to ensure that the bearings are free and the
fan is still in balance.
After 10% of the fans have been replaced, it is recommended to replace all cooling fans to
reduce associated maintenance costs which may incur with increased heat buildup from fan
failure.
4.17
Fan Controller
Reference Drawing: Fan Controller Enclosure .......................... Drawing A-106894
Some displays have the ability to control fan power and to sense the proper operation of the
fans. These displays have fans with built-in RPM sensors. Fan sensing and control is done
using a fan control box in conjunction with the data distributor. The fan control box consists
primarily of a printed circuit board for sensing and control, a relay for switching power to the
fans and connectors for each fan. Refer to Drawing A-106894. A fan control box delivers
power to a maximum of eight (8) fans. The fan controller monitors the operation of the fans
using the RPM sensors, (RPM’s decrease when a fan fails) and reports a good or bad status
back to the data distributor. The fan controller will sense this and report a bad status back to
the data distributor, which will blank the display to prevent overheating. The fan controller
has eight indicators to show which fan is bad.
Maintenance &
Troubleshooting
4-17
If a display has more than eight fans and/or is built in sections, up to eight fan control boxes
can be chained together. Each reports a good or bad status to the data distributor, which has
indicators to show the status of all fan controllers. If less than eight fan controllers are
needed, the last one in the chain has a terminator plug which fools the data distributor into
thinking there are eight fan controllers reporting a good status.
The fan controller can also turn the fan power off. When the data distributor senses the
display has been blank for more than 1/2 hour, it sends a signal to the fan controllers to turn
power off to the fans (with the relay). This prolongs the life of the fans and filters. The fan
controller can also have a thermostat connected to it to sense overheating, which will cause it
to report a bad status.
4.17.1 Fan Controller Signal
Refer to Figure 14 for an
illustration of the Fan Controller
Card.
Fan controllers accept signals from
a maximum of 8 fans and 1
thermostat. All of these
components must be present in
order for a “Good Section” status
to be returned to the DD. All
components are checked at the
power up of the fan controller and
throughout operation. Fan
presence is only checked at power
up.
Figure 14: Fan Controller Card
Fan controllers have 3 jacks for signal detection. They are as follows:
J2
In (J3)
Out (J4)
External cable connections for controlled fans
Cable connection from DD, Fan expander or previous fan controller
Cable connection to next fan controller or fan termination plug
A fan termination plug must be inserted into the Out jack of the final fan controller to
complete the fan circuit. Without the fan termination plug, the display will blank
after approximately 2 minutes as if a fan were not present.
Plug Location
DS 1
DS 2
DS 3
DS 4
4-18
Job
Power
Section Good
Fan Power
Fan 1 Status
On
Off
Blinking
Section good
Fan power on
Fan good
Section failure
Fan power off
Fan not present
Fan failure
Maintenance &
Troubleshooting
DS 5
DS 6
DS 7
DS 8
DS 9
DS 10
DS 11
DS 12
Fan 2 Status
Fan 3 Status
Fan 4 Status
Fan 5 Status
Fan 6 Status
Fan 7 Status
Fan 8 Status
Thermostat input
Fan good
Fan good
Fan good
Fan good
Fan good
Fan good
Fan good
Thermostat input
good
Fan not present
Fan not present
Fan not present
Fan not present
Fan not present
Fan not present
Fan not present
Thermostat input
failure
Fan failure
Fan failure
Fan failure
Fan failure
Fan failure
Fan failure
Fan failure
4.17.2 Fan Expander
Figure15: Fan Control Expander Card
Refer to Figure 15 for an illustration of the fan control expander card.
The fan expander is used in conjunction with the fan control circuit of the DD for
accepting input from a maximum of 32 fan controllers.
All 32 of the indicator LED’s on the fan expander must be on for proper operation. If
less than 4 series of fan controllers are connected to the fan expander, a termination
plug must be inserted into any empty plugs.
4.18
Lens Airflow
Periodically check airflow through the lenses to ensure that there are no obstructions in the
lens exhaust holes. Airflow is necessary to cool the lenses and lamps adequately (refer to
Figure 16).
The interior of the module should be kept clean to prevent a buildup of dust on the lenses.
Use an air hose and a vacuum cleaner to keep the display clean.
Maintenance &
Troubleshooting
4-19
Inspect the cabinet seal
periodically to make certain it
is sealing properly. If leaks are
detected, repair or replace the
pile weather stripping seal in
the area where the leak
occurred.
A method for checking both
the airflow through the lenses
and the cabinet seal is as
follows:
1. Direct smoke toward the
fan inlet and observe the
exits of the smoke.
2. Check all around the
Figure 16: Lens Airflow
cabinet and the lenses.
If smoke does not exit a
particular group of lenses, remove the lenses to clean out any debris. Replace the lenses
and re-test.
4.19
Structural Inspection
Visual inspection should be done annually to check the paint and look for possible corrosion,
especially at footings, structural tie points and ground rods. Fasteners should be checked and
tightened or replaced as required.
At least once a year, check the inside of the display for signs of water intrusion, i.e. - water stain
marks. Water can enter a display where weather stripping has come loose or deteriorated.
Fasteners may have come loose allowing gaps in the panels or where moisture may be entering
around hardware which is in the top of the display. Check electronic components closely for
signs of corrosion.
4.20
Cleaning the Cables
If it becomes necessary to remove or replace a signal cable, clean the plugs and the circuit
board jacks with Deoxit (Daktronics part no. CH-1015). Inspect and clean the jacks and
plugs thoroughly to ensure the absence of any foreign matter as the presence of dirt or water
many cause signal interconnect problems.
After the parts are cleaned, push the plug into the jar of Cailube (Daktronics part no. CH1019), ensuring that the paste wets the plug to a depth of at least 1/8" on all four sides. Also
check to make sure that all of the pin holes of the plug are filled with paste and that sufficient
paste is present on the end of the plug to form a V. There should be sufficient paste present
on the end of the plug so that when the plug is inserted into the jack of the circuit board, the
paste is pushed out around the jack and forms a weather-proof seal.
Deoxit is the electrical contact cleaner in an aerosol can and Cailube is the electrical contact
lubricant and protector paste in a 1oz. jar. Both can be found in the Tool Kit Accessories
package. Daktronics part number CH-1021 is an 8 oz. jar of the electrical lubricant and
4-20
Maintenance &
Troubleshooting
Entire module does not work.
•=
•=
•=
•=
Section of display does not work.
A group of 4 modules does not work.
•=
•=
•=
Entire display does not work.
•=
•=
•=
4.23
Check signal connection (ribbon cable).
Check power connections.
Check in-line transformer fuse.
Replace lampbank.
Check appropriate main fuse or breaker.
Check termination panel or load center.
Replace line controller.
Check 120 VAC input power to sign.
Check data distributor, especially fan control
indicators.
Check all signal connections.=
Replacement Parts List
Part Description
8x16 Lens Reflector Assembly; Starburst
8x16 Lens Reflector Assembly; SunSpot
Line Controller Card
Column Controller Card
Fan Controller Card
Data Distributor Output Card
Electrical Contact Lubricant & Protector (paste) 8oz jar
Fan Control Expander Card
Fan, 120 Volt, 1060 CFM w/ Capacitor
Fan Filter, 15.62” by 19.62”
Fuse, Power Harness, MDL-7, 1/4” by 1 ¼”, Slow-Blo
Lamp; T-3 1/4, Wedge Base, Xenon Filled
Lampbank; 816-10 w/xenon lamps
Lampbank; 816-10 w/xenon lamps, mono/16 color
Data Distributor Input Card
Serial Line Interface
Vertical Shift Register
Lens; Blue - StadiaView
Lens; Green - StadiaView
Lens; Red - StadiaView
Lens; Starburst White - StadiaView
Lens; Monochrome White - StadiaView
Louver, Top, 10 Degree, 1 x 16
Louver with Weather Barrier, 10 Degree, 1 x 16
Portable Test Fixture, 1 O Module with 120 V Trans.
Reflector; 1 x 8
Safety Lanyard
Socket; T-3 1/4 Wedge
Transformer, 120 Volt
Weather Stripping, Pile, Lens Assembly
4-22
Daktronics Part No.
0A-1176-0001
0A-1176-0002
0P-1145-0044
0P-1145-0032
0P-1176-0003
0P-1145-0029
CH-1021
0P-1176-0010
0A-1176-0012
A-1176-0009
F-1031
DS-1241
0P-1176-0001
0P-1176-0002
0P-1145-0069
0P-1176-0008
0P-1176-0009
DS-1232
DS-1234
DS-1233
DS-1231
DS-1235
0M-91308
0M-91309
0A-1176-0007
MP-1048
0A-1176-0010
X-1209
T-1107
HS-1149
Maintenance &
Troubleshooting
Weather Stripping, Tape, Louver
Weather Stripping, Open Cell, Filter Gasket
Tool Kit Accessories (includes the following)
Lamp Voltage Tester
Lamp Extractor
Electrical Contact Cleaner (spray can)
Electrical Contact Lubricant and Protector (paste) 1oz jar
Rear Access Module Remover Tool
Front Access Module Remover Tool
0.032 Feeler Gauge, Weather Stripping
Fuse, Serial Line Interface, MDL-2 1/2, 2 1/2 A
4.24
HS-1051
HS-1039
0A-1176-0008
0P-1089-0010
TH-1032
CH-1015
CH-1019
0M-95441
0M-95442
0M-69133
F-1002
Daktronics Exchange/Repair & Return Programs
To serve customers’ repair and maintenance needs, Daktronics offers both an exchange and a repair
and return program. The exchange program reduces down time by providing timely replacement of
key components. This service is provided to qualified customers who follow the program guidelines
explained below. It is our pleasure to provide this service to ensure you get the most from your
Daktronics products. Please call our Help Desk (1-877 / 605-1114) if you have any questions
regarding the exchange program or any other Daktronics service.
When you call the Daktronics Help Desk, a trained service technician will work with you to solve the
equipment problem. You will work together to diagnose the problem and determine which exchange
replacement part to ship. If, after you make the exchange, the equipment still causes problems, please
contact our Help Desk immediately.
If the replacement part fixes the problem, package the defective part in the same packaging the
replacement part arrived in, fill out and attach the enclosed UPS shipping document and RETURN
THE PART TO DAKTRONICS. (You may use the same box and packing the exchange part was
sent in.) This will speed up the transaction and alleviate confusion when the failed component arrives
at Daktronics. (Daktronics expects immediate return of the exchange part if it does not solve the
problem.) For most equipment, you will be invoiced for the replacement part at the time it is shipped.
This invoice is due when you receive it.
Daktronics reserves the right to refuse equipment that has been damaged due to acts of nature or
causes other than normal wear and tear.
If the defective equipment is not shipped to Daktronics within 30 working days from the invoice date,
it is assumed you are purchasing the replacement part and you will be invoiced for it. This second
invoice represents the difference between the exchange price and the purchase price of the equipment.
This amount is due when you receive the second invoice. If you return the exchange equipment after
30 working days from invoice date, you will be credited for the amount on the second invoice minus a
restocking fee.
]To avoid a restocking charge, please return the defective equipment within 30 days from the
invoice date.
Daktronics also offers a Repair and Return program for items not subject to exchange.
Maintenance &
Troubleshooting
4-23
10” 1600 Series Safety Lanyard Procedure
When removing a module from the rear of the display, the safety lanyard procedure should be followed to avoid
personal injury or damage to a module. Refer to the appropriate figures and use the following steps to remove a
module from the rear of the display:
/Disconnect any power and signal harness from the lampbank.
Removal of Module
1. Place a safety lanyard snap into any one of the three holes in one of the side brackets of the lens/reflector
assembly. Note arrow in Figure 1.
2. Loop the safety lanyard around the conduit and secure the remaining snap into one of the three holes in the
remaining side bracket as pointed out in Figure 2.
3. Insert tool (0M-95441) into area just below the lampbank positioning tab of the side bracket at a slight angle
as in Figure 1.The tool will work best if it is positioned with notch side up.
4. While slowly twisting the tool downward to release the module retaining latch, gently push the corner of the
module out of the display.
5. Repeat Steps 3 and 4 for remaining side of module.
6. Grasp the module with both hands and push the entire module forward out in front of the display.
7. Turn the module which allows it to be pulled back through the opening of the display and removed.
8. Remove the safety lanyard from the side brackets and gently lay the module lens side down on a static free
surface.
Re-Installation of Module
1. Loop the safety lanyard around the support conduit and secure the safety lanyard snaps in the center holes of
the side brackets.
2. Push the module through the opening of the display and place into position.
3. Pull back on the safety lanyard near the areas where the snaps are attached to the side brackets until the
latches securing the module snap into place.
4. Gently push out on the module corners to test and insure that the latches are indeed secured to the frame
5. Remove the safety lanyard.
Figure 1: Releasing Module Retainer
Figure 2: Securing and Looping Lanyard
ED-10529 REV. 1
© Copyright 12Feb98 Daktronics, Inc.