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 = = fåíêçÇìÅíáçå= 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.