Trafcon 50074 Traffic Safety Light Control User Manual

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Users Manual

SmartFlash Arrowboard Controller

Installation & Operation Manual

81 Texaco Road

Mechanicsburg, PA 17050

717-691-8007

717-697-0813 FAX

www.trafcon.com

Revised: March, 2003

The Basics

There are two variations of the SmartFlash controller. Vehicle mounted units consist of two

parts, the remote control head, which includes a keypad mounted within a black enclosure

and is equipped with a mounting bracket. The second part, the controller, is a plain black

box, with mounting ears, and equipped with four receptacles. The controller also houses

most of the electronics.

Trailer mounted units consist of a controller unit with the keypad mounted within.

Main Features

Features common to both controllers include the following:

• Solid state circuitry

• Short circuit protected output circuitry

• Polarity protected circuitry

• Keypad operation with back lighting

• Ability to “hot-swap” controls and plugs

• Intensity and battery monitoring

• Automatic dimming

• Manual dimming (special option)

• Automatic raise/lower operation (optional)

• Support for electric and hydraulic actuators

• Low battery warning (LED display alternates between mode and “LB”)

• Audible confirmation of keyboard operation

• Text and graphic markings

Operating Instructions

Controller Layout

The “On and Off” Buttons

The ON and OFF buttons work as expected, when the Arrowboard is turned off the main

positive (common) feed to the Arrowboard is turned off and the current draw of the system is

about 10mA.

There is also a power LED that is on when the Arrowboard is turned on.

Lamp Sequence Control Buttons

The “Select Mode” button is used to scroll through the selectable sequences. Each

time this button is pressed the LED display on the controller or remote will scroll to

the next sequence. When in this mode the display will flash rapidly.

The “Enter” button is used to set the “new” sequence as the displayed sequence.

Once this button has been pressed the sequence on the Arrowboard will change to the

‘new’ sequence.

Other Buttons

“Toggle Display” button.

This button is used to change the “bulb brightness and battery level display” between its two

modes. Each time it is pressed it toggles to the other mode.

Bulb brightness and Battery level Display.

This display gives accurate readings of both bulb brightness and battery voltage levels.

MODE 1 Bulb Brightness.

This mode displays the level of brightness that the bulbs on the

Arrowboard are illuminated too. The scale is from 10% to

100% and is marked above the display.

MODE 2 Battery Voltage.

This mode displays the voltage level of the power source. The

scale is from 10 to 14 volts and is displayed underneath the

display.

The two readings are displayed independently; the operator can alternate between the two by

pressing the “Toggle display” button. The current mode of the display is shown by the

display indication LEDs; these are located to the right of the “Toggle Display” button.

Function Buttons (Optional)

• Auto/manual dimming control:

Holding both the “brightness down” and “brightness up” optional buttons down for

approximately five seconds results in a change from auto to manual dimming, or vice

versa. This procedure will not work when in “battery level” mode, or if the optional

buttons have not been configured.

Option Stickers

“Lamp Brightness UP” button:

Used to proceed upwards through the brightness options 1-10, and Auto.

“Lamp Brightness DOWN” button:

Used to proceed downwards through the brightness options 1-10, and Auto.

“Sign UP” button:

Used to move the Arrowboard into the up position.

“Sign Down” button: Used to move the Arrowboard into the down

position.

Display Features

The “Arrowboard Sequence Display” is the main display on the

controller.

The primary purpose of this display is to show a flashing sequence that is identical to that on

the arrowboard, this is the “real” sequence.

Once the “Select Mode” button has been pressed the flashing “real” sequence disappears and

a “new” sequence will appear on the display, this sequence flashes at twice the rate of the

“real” sequence.

Once a “new” sequence is shown on the display it will remain there until one of the following

occurs:

1) The “Select Mode” button is pressed again, in this case the “new”

sequence will scroll to the next “new” sequence

2) The “Enter” button is pressed, in this case the controller sends a change

sequence request to the “arrowboard driver” which then changes the

sequence, which is displayed on the arrowboard. At this point the “new”

sequence on the controller display will begin to flash slower and become

the “real” sequence.

If no buttons are pressed for a time period of 5 seconds the “new” sequence will disappear

and the “real” sequence will be displayed

The “Auto Dimming” LED:

This is located just above the “Bulb brightness and battery level” display. Its purpose is to

alert the operator when the Arrowboard is set in auto-dimming mode.

The “Sign Up” LED:

This is located above option button four. It is on when the Arrowboard is in the UP position.

20 Way D-3100 Plug

TOP

Smart Flash

MB Series Controller

10 Way D-3100 Plug (2) 4 Way D-5200 Plug

Smart Flash

MB Series Remote

10 Way D-3100 Plu

(2) 4 Way D-5200 Plug

Way D-3100

Smart Flash

C Series Controller

Controller D-3100 Plug Wiring

Circuit Wire Color Gauge

1 Red 16

2 Red 18

3 White 18

4 White/Red 22

5 Option

6 NC

7 Black 18

8 Green 18

9 White/Green 22

10 Option

Remote Cable 4 Way Plug Wiring

Circuit Wire Color Gauge

1 Red 18

2 Black 18

3 White 18

4 Green 18

NOTE: Use only shielded cable.

Top Plug

Pin Wire Color Gauge Function

Green/Yellow

White

Actuator – Positive

Black/Yellow

Black

Actuator - Negative

3 Red 14 Power – Positive

4 Orange 14 Common to Lamps

Bottom Plug

Pin Wire Color Gauge Function

1 Black 14 Ground - Negative

2 Black 14 Ground - Negative

3 Red 14 Power - Positive

4 Orange 14 Common to Lamps

Lamp Wiring Circuits

Circuit Wire Color Gauge Function Application

1 Brown 18 Lamp circuit All

2 Red 18 Lamp circuit All

3 Yellow 18 Lamp circuit 15,25

4 Green 18 Lamp circuit All

5 Blue 18 Lamp circuit 25

6 White 18 Lamp circuit All

7 Gray 18 Lamp circuit 25

8 Black 18 Lamp circuit All

9 Brown/White 18 Lamp circuit 25

10 Red/White 18 Lamp circuit 25

11 Yellow/White 18 Lamp circuit All

12 Green/White 18 Lamp circuit 25

13 Blue/White 18 Lamp circuit 15,25

14 White/Black 18 Lamp circuit All

15 Gray/White 18 Lamp circuit All

16 Black/White 18 Lamp circuit All

17 Red/Black 18 Mode lamp All except some miniboards

18 Tan 18 Mode lamp All except some miniboards

19 Purple 18 Mode lamp All except some miniboards

20 Pink 18 Low battery lamp Solar models

Orange 14 Gauge Lead, Common (+12VDC) to all Lamps.

Troubleshooting

Symptom Possible cause

No display – No backlight Dead battery

Plug(s) not connected

Defective controller

No display – Backlight works No mode selected

Plug(s) not connected

Defective controller

No dimming Defective photocell

Shorted photocell wires

Defective controller

Lamps stay dim Defective photocell

Broken photocell wire

Defective controller

Some lamps do not light Defective lamp(s)

Short at lamp

Broken wire(s)

Defective controller

Power tilt does not work Broken wire(s)

Defective actuator or control

Defective controller

MB Series – Smart Flash

Installation of Vehicle Mounted Controllers

1. Connect one 8 gauge red wire to the positive terminal of the battery. Do NOT use a

smaller wire gauge.

2. Connect the one 8 gauge black wire to the negative terminal of the battery or a

suitable ground connection. Do NOT use a smaller wire gauge.

3. If fusing is preferred it is recommended that a 35A fuse be installed on the red wire at the

battery.

4. Mount the remote control head in a convenient location within the vehicle cab.

5. Route the gray four-conductor cable from the sign panel to the remote control head and

connect.

Installation is now complete. See Operating Instructions section. Test all mode and

arrowboard functions thoroughly before use.

Installation for Wireless Option for Remote Control Head and

Arrowboard Panel

1. Locate suitable mounting location for the Smart Flash Remote with Internal RF

option. The manufacturer preferred mounting locations are on or above the dash of the

vehicle where there is access to a 12VDC power point. Mounting in locations other

than these may affect the performance of the internal wireless module.

2. Insert the power plug into a cigarette plug receptacle or a power point of your vehicle.

It is recommended that you leave the plug connected at all times. If you prefer to hard

wire the remote to a permanent power source, proceed with the following step

otherwise proceed to step 6.

3. Cut the power plug off directly behind the plug. Separate the two wires and strip the

ends. Terminate the ends with the appropriate terminals for the desired power

connection

4. Connect the positive wire to a point that is connected to the positive terminal of a

12volt DC battery.

Alternatively, connecting the positive wire to the ignition switch will only enable

arrowboard operation when the ignition is on. This configuration is not normally used.

5. Connect the negative wire to a point that is connected to the negative terminal of a

12volt DC battery.

6. Installation is now complete of the Smart Flash Remote with Internal RF option. If

your arrowboard panel has a factory-installed External RF module, proceed to step 10.

If your arrowboard panel does not have a factory-installed External RF module,

proceed to the next set of installation steps.

7. Locate a suitable mounting location for the External RF module on the arrowboard

back panel. Must be close enough to the 4-way receptacle to allow the 4-way plug

from the External RF module to connect. The antenna on the External RF module

should be pointing towards the top of the sign panel.

8. After mounting is complete, connect 4-way plug to External RF module and connect

the opposite end with the 4-way plug to the 4-way receptacle located on the

arrowboard.

9. This completes installation of the External RF module.

10. Turn power on at Remote Control Head and test all modes. If unit tests ok it is now

ready to be put in service.

AGENCY NOTICE

Changes or modifications not expressly approved by the manufacturer could void

the user’s authority to operate the equipment.

TC Series – Smart Flash Solar

Battery Maintenance

Batteries should be carefully inspected on a regular basis; the system can become discharged

for a number of reasons, for example:

• Operating conditions during the “winter” months of November through February, when

the power provided by the array is reduced.

• Improper maintenance, such as not cleaning the PV array.

• Electrolyte in the battery cells not maintained at the proper level.

• Loose or corroded battery terminal connections.

• Improper position of the system where the PV array is in the shadow of an object, or

tilted away from the sun.

• Prolonged cloudy weather where the system is operating.

Maintenance of batteries, especially the proper voltage level, in the above situations should

be performed as required. In some instances, it will be necessary to provide multiple

recharges from an external source or replace with fresh batteries.

Caution

It is important to maintain the proper level of electrolyte in the

batteries at all times. If the level is too high the electrolyte will

“boil” out of the top of the battery during charging and corrode the

terminal connections. If the level is too low the battery life will be

severely shortened.

Warning ! Charging batteries produce hydrogen, which can explode when

proper operating procedures are not followed. To prevent severe

personal injury, death, or substantial property damage when working

around batteries, be extremely careful. Always use approved eye

protection, face shield, rubber gloves, and insulated tools.

Electrolyte levels should be just below the bottom of the vent well, about ½ to ¾ inch above

the tops of the separators. The electrolyte level should not drop below the top of the plates.

See figure 1 for additional information.

Figure 1. Battery (showing inside elements)

After checking electrolyte, check that all vent caps are tightly in place.

Loose or corroded connections create high resistance that could cause battery bank

overcharging or undercharging and possibly damage the battery bank.

Cleaning the terminals, tightening the connections, and applying a thin coat of petroleum

jelly (Vaseline) will help to prevent corrosion.

Use the following table to determine the status of each battery in the system:

6-Volt Battery 12-Volt Battery Specific Gravity State of Charge

6.36 or more 12.72 or more 1.295 or more 100%

6.15 to 6.36 12.30 to 12.72 1.250 to 1.295 75% to 100%

6.00 to 6.15 12.00 to 12.30 1.200 to 1.250 50% to 75%

5.85 to 6.00 11.70 to 12.00 1.175 to 1.200 25% to 50%

5.70 to 5.85 11.40 to 11.70 1.120 to 1.175 0% to 25%

1. Check the voltage levels with a digital voltmeter and the specific gravity with an

approved hydrometer.

2. Before taking any readings, run system on the batteries for a few minutes.

This removes any minor surface charge on the battery plates. The surface charge will

affect the accuracy of your readings.

3. Service or replace any battery with a specific gravity that is ten percent higher or

lower than the average.

Storing and Handling Batteries:

The electrolyte in discharged batteries may freeze if the outside air temperature drops below

the freezing point of water: 32°F (0°). When a battery is discharged, the electrolyte solution

in the battery is mostly water. The electrolyte in a fully charged battery has a much higher

concentration of sulfuric acid and therefore freezes at a much lower temperature.

The Specific Gravity/Freeze Temperature chart provides information on specific gravity

verses freezing temperature for the batteries used in the system.

Specific Gravity Freeze Temperature

1.250 –62°F (–52°C)

1.200 –16°F (–27°C)

1.150 5°F (–15°C)

1.100 19°F (–7°C)

Care for batteries that are stored during winter months or slow periods is as follows:

1. Fill battery as required with distilled water.

2. Fully charge to a specific gravity of 1.272.

3. Place in a cool place between the temperatures of 32°F (0°C) and 80°F (38°C).

If one battery’s voltage differs from the rest of the bank by 5 percent, check its specific

gravity.

TC-1 Solar Trailer Battery Wiring Diagram

Positive

Charge

Point

Negative

Charge

Point

TC Series – Smart Flash Diesel

This manual was written to assist the mechanic or technician in troubleshooting the electrical

systems of the Trafcon TC Series diesel arrowboard.

In order to efficiently troubleshoot these systems, an explanation of each is included in

addition to the normal troubleshooting chart. The appropriate section should be read

thoroughly prior to an attempt to make repairs.

STARTING

The starting system consists of a toggle switch and a momentary contact starter switch.

When the toggle switch is moved to the “on” position, current flows to the electric fuel pump,

the alternator voltage regulator and one side of the starter switch. Pushing the starter switch

allows current to flow to the starter solenoid and engages the starter.

CHARGING

When the toggle switch is in the “on” position, current flows from the battery to the alternator

voltage regulator allowing the alternator to charge. The normal charge rate under “no load”

conditions is 13.8 – 14.2 volts. When troubleshooting a charging system it is important to

check the basics first. The batter connections should be checked, as well as the electrolyte

level in the battery. Low electrolyte in only one cell can indicate that the cell is bad. A

battery in which all the cells are dry can indicate an overcharging problem and a possible bad

battery. If the battery is suspect, check each cell using a hydrometer. Before attempting the

check the alternator, allow the engine to run for approximately 15 minutes. This will

eliminate false voltmeter readings due to a low battery. This step is absolutely necessary

after “jump starting” a unit.

If a calibrated voltmeter is not available, move the caution bar switch of the controller to the

“on” position and observe the unit’s voltage regulator. Remove the four screws that secure

the voltage regulator to the alternator and unplug the green wire from the brushholder

assembly. Momentarily connect a jumper wire from the brushholder terminal to the output

terminal of the alternator and observe the meter reading. A reading in the upper portion of

the green scale or higher indicates that the voltage regulator is defective. A reading that does

not change indicates a bad alternator.

FUEL PUMP

The electric fuel pump is energized when the toggle switch is in the “on” position. When

operating normally a steady “clicking” sound can be heard. If the fuel pump does not “click,”

check for the presence of voltage with a test light. Also, check the fuse next to the toggle

switch. This fuse completes a ground circuit to the volt/hourmeter panel. The purpose of this

fuse is to protect the wiring harness in the sign panel from damage if the common lead should

come in contact with ground and also provides protection for the gauges.

DIESEL

30031

30024 30026

30028

90264

10443

10183

90241

90322

90176

10137

10266

10183

10489

10440

10426

10018

90245

50435

10216

50438

10044

90317

10310

10197

90249

10043

90242

10193

TRAFCON INDUSTRIES, INC.

MANUFACTURER’S WARRANTY

LIMITED WARRANTY POLICY

Trafcon Industries, Inc. (Trafcon) hereby warrants to the original purchaser (customer), sold directly or through

an authorized dealer, the product(s) listed for the time period(s) listed, from the date of purchase. Trafcon

warrants the product(s) against defects in material and workmanship provided the products are installed and

maintained properly, and operated under normal conditions. This warranty does not apply to product(s) that

have been improperly applied, installed or maintained. The customer will be responsible for removing any

defective item(s) from the product and returning the item(s), or the entire product, transportation costs prepaid,

to Trafcon 81 Texaco Rd, Mechanicsburg, PA 17050. The customer will be responsible for reinstallation of

item(s) upon return. All returns must have a Return Material Authorization (RMA) number prior to shipping.

RMA numbers can be obtained by contacting Trafcon at 717-691-8007, or on the Internet at www.Trafcon.com.

Proof of purchase will be required to obtain the RMA. Trafcon will, at its option, repair or replace defective

product(s) or component part(s). Such item(s) will be returned by Trafcon, transportation costs paid (normal

ground delivery), within the United States. Repaired or replaced product(s) or component part(s) will carry the

remainder of their respective original warranty term(s).

Exclusions from this warranty are: unauthorized sale outside the United States, the finish, tires, incandescent

lamps, any condition(s) caused by abnormal use or service, negligent operation, act of God, and product specific

limitations, if any, listed below.

THE LOSS OF USE OF THE PRODUCT, LOSS OF TIME, INCONVENIENCE, COMMERCIAL LOSS OR

CONSEQUENTIAL DAMAGES ARE NOT COVERED. TRAFCON RESERVES THE RIGHT TO CHANGE

THE DESIGN OF ANY PRODUCT WITHOUT ASSUMING ANY OBLIGATION TO MODIFY ANY

PRODUCT PREVIOUSLY MANUFACTURED.

This warranty gives you specific legal rights and you may have other rights, which may vary from state to state.

THERE ARE NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING ANY IMPLIED

WARRANTIES OF MERCHANTABILITY AND FITNESS, WHICH EXTEND BEYOND THIS

WARRANTY PERIOD. THERE ARE NO WARRANTIES THAT EXTEND BEYOND THE FACE HEREOF.

SELLER DISCLAIMS IMPLIED WARRENTY OF MERCHANTABILITY.

THE WARRANTY SHALL NOT APPLY TO ANY TRAFCON PRODUCT WHICH HAS BEEN

MODIFIED, IMPROPERLY INSTALLED, IMPROPERLY MAINTAINED OR IMPROPERLY USED.

The product(s) and time period(s) under this warranty are as follows:

1. FLASHING ARROW BOARDS, TRAILER MOUNTED, SOLAR (TC1)

LIMITED 3 YEAR WARRANTY

Limited 3 year warranty on these Trafcon products. Trafcon warrants each new unit against factory defects

in material and workmanship for a 3 year period from the original date of purchase.

EXCEPTIONS: Batteries- 18 months.

THIS WARRENTY DOES NOT COVER THE FOLLOWING: Tires, Finish.

2. FLASHING ARROW BOARDS, TRAILER MOUNTED, DIESEL (TC3)

LIMITED 1 YEAR WARRANTY