Trafcon 50074 Traffic Safety Light Control User Manual

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Document ID	341957
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Date Submitted	2003-07-22 00:00:00
Date Available	2003-07-22 00:00:00
Creation Date	2003-06-27 10:48:12
Producing Software	Acrobat Distiller 5.0.5 (Windows)
Document Lastmod	2003-06-27 10:48:50
Document Title	Users Manual
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Document Author:	Steve Blackett

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
sequence will scroll to the next “new” sequence
“new”
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.
Smart Flash
MB Series Controller
TOP
20 Way D-3100 Plug
10 Way D-3100 Plug
(2) 4 Way D-5200 Plug
Smart Flash
MB Series Remote
Smart Flash
TC Series Controller
0 Way D-3100
10 Way D-3100 Plug
(2) 4 Way D-5200 Plug
7
Controller D-3100 Plug Wiring
Circuit
10
Wire Color
Red
Red
White
White/Red
Option
NC
Black
Green
White/Green
Option
Gauge
16
18
18
22
18
18
22
Remote Cable 4 Way Plug Wiring
Circuit
Wire Color
Red
Black
White
Green
Gauge
18
18
18
18
NOTE: Use only shielded cable.
Top Plug
Pin
Wire Color
Green/Yellow
or
White
Black/Yellow
or
Black
Red
Orange
Gauge
16
Function
Actuator – Positive
16
16
Actuator - Negative
16
14
14
Power – Positive
Common to Lamps
Bottom Plug
Pin
Wire Color
Black
Black
Red
Orange
Gauge
14
14
14
14
Function
Ground - Negative
Ground - Negative
Power - Positive
Common to Lamps
10
Lamp Wiring Circuits
Circuit
10
11
12
13
14
15
16
17
18
19
20
Wire Color
Brown
Red
Yellow
Green
Blue
White
Gray
Black
Brown/White
Red/White
Yellow/White
Green/White
Blue/White
White/Black
Gray/White
Black/White
Red/Black
Tan
Purple
Pink
Gauge
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
Function
Lamp circuit
Lamp circuit
Lamp circuit
Lamp circuit
Lamp circuit
Lamp circuit
Lamp circuit
Lamp circuit
Lamp circuit
Lamp circuit
Lamp circuit
Lamp circuit
Lamp circuit
Lamp circuit
Lamp circuit
Lamp circuit
Mode lamp
Mode lamp
Mode lamp
Low battery lamp
Application
All
All
15,25
All
25
All
25
All
25
25
All
25
15,25
All
All
All
All except some miniboards
All except some miniboards
All except some miniboards
Solar models
Orange 14 Gauge Lead, Common (+12VDC) to all Lamps.
11
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
12
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.
13
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.
14
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)
15
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
6.36 or more
6.15 to 6.36
6.00 to 6.15
5.85 to 6.00
5.70 to 5.85
12-Volt Battery
12.72 or more
12.30 to 12.72
12.00 to 12.30
11.70 to 12.00
11.40 to 11.70
Specific Gravity
1.295 or more
1.250 to 1.295
1.200 to 1.250
1.175 to 1.200
1.120 to 1.175
State of Charge
100%
75% to 100%
50% to 75%
25% to 50%
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
1.250
1.200
1.150
1.100
Freeze Temperature
–62°F (–52°C)
–16°F (–27°C)
5°F (–15°C)
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.
16
TC-1 Solar Trailer Battery Wiring Diagram
Positive
Charge
Point
Negative
Charge
Point
17
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.
18
19
30024
30031
30026
30028
90264
10443
90322
10183
90176
90241
10137
10266
10183
90245
10489
10018
10426
10440
DIESEL
20
10193
10043
90249
90242
10044
10197
10310
90317
50438
10216
50435
21
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
Limited 1 year warranty on these Trafcon products. Trafcon warrants each new unit against factory
defects in material and workmanship for a 1 year period from the original date of purchase.
EXCEPTIONS: Batteries- 60 months (pro-rated).
THIS WARRANTY DOES NOT COVER THE FOLLOWING: Tires, Finish, Incandescent lamps.
3. FLASHING ARROW BOARDS-VEHICLE MOUNTED (MB & TM)
LIMITED 1 YEAR WARRANTY
Limited 1 year warranty on these Trafcon products. Trafcon warrants each new unit against factory
defects in material and workmanship for a 1 year period from the original date of purchase.
22
THIS WARRANTY DOES NOT COVER THE FOLLOWING: Finish, Incandescent lamps.
4. ARROW DYNAMIC SIGNS-TRAILER MOUNTED (TC-ADS)
LIMITED 1 YEAR WARRANTY
Limited 1 year warranty on these Trafcon products. Trafcon warrants each new unit against factory
defects in material and workmanship for a 1 year period from the original date of purchase.
EXCEPTIONS: Solar modules- 36 months, Batteries- 18 months.
THIS WARRANTY DOES NOT COVER THE FOLLOWING: Tires, Finish.
5. ARROW DYNAMIC SIGNS- VEHICLE MOUNTED (MB-ADS)
LIMITED 1 YEAR WARRANTY
Limited 1 year warranty on these Trafcon products. Trafcon warrants each new unit against factory
defects in material and workmanship for a 1 year period from the original date of purchase.
THIS WARRANTY DOES NOT COVER THE FOLLOWING; Finish.
6. SPEED DISPLAY SIGNS- STATIONARY, VEHICLE & TRAILER MOUNTED (SST)
LIMITED 1 YEAR WARRANTY
Limited 1 year warranty on these Trafcon products. Trafcon warrants each new unit against factory
defects in material and workmanship for a 1 year period from the original date of purchase.
EXCEPTIONS: Solar modules- 36 months, Batteries- 18 months.
THIS WARRANTY DOES NOT COVER THE FOLLOWING: Tires, Finish.
7. WORK ZONE RADIOS- STATIONARY, VEHICLE & TRAILER MOUNTED (WIZARD)
LIMITED 1 YEAR WARRANTY
Limited 1 year warranty on these Trafcon products. Trafcon warrants each new unit against factory
defects in material and workmanship for a 1 year period from the original date of purchase.
EXCEPTIONS: Solar modules-36 months, Batteries- 18 months.
THIS WARRANTY DOES NOT COVER THE FOLLOWING: Tires, Finish.
7. PORTABLE EQUIPMENT PLATFORMS (PEP)
LIMITED 1 YEAR WARRANTY
Limited 1 year warranty on these Trafcon products. Trafcon warrants each new unit against factory
defects in material and workmanship for a 1 year period from the original date of purchase.
EXCEPTIONS: Solar modules- 36 months, Batteries- 18 months.
THIS WARRANTY DOES NOT COVER THE FOLLOWING: Tires, Finish.
RIGHTS RESERVED
Trafcon reserves the right to make changes in design, materials and specifications or to make product
changes as deemed necessary without prior notice. Obligations or liabilities will not be assumed with
respect to similar products previously advertised or produced.
PRINTING ERRORS
Every effort has been made to avoid printing errors in our printed literature and on our website. Should there
have been any specification or application errors, we must disclaim responsibility.
OMISSIONS
Any product(s) or component(s) not specifically covered or excluded herein, will be covered for a 1 year period
from date of purchase or by the Original Equipment Manufacturer’s warranty, whichever is greater.
23

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