Visio-Arrow Board Not Working

Visio-Arrow Board Not Working
Legend
Silent Sentinel
Arrow Board
Not Working
Controller task
Manual Task
Select an Arrow
Decision
Š
Turn Selector Knob to display a Left Flashing Arrow.
Off-Page Reference
_
Check Battery Voltage
End
of
Process
_
End of Process
Š
Š
Check the battery voltage, using a DC voltmeter
Place Red lead on POS terminal of the left battery and
the Black lead on the NEG terminal of the battery on
the right.
Is battery
voltage above
11volts?
NO
+
+
YES
Reset Controller
Recharge the Batteries
Š
Š
Charge units with 2 batteries for 7 hours using a
45 amp charger.
Charge units with 4 batteries for 14 hours using a
45 amp charger.
End
of
Process
Š
Š
Š
NO
Is battery
voltage above
12 volts
Restart the Test From
the Beginning
Remove controller from divider plate.
Disconnect the battery and solar array power
connector from the controller. W ait one minute.
Reconnect battery and solar array connector.
NOTE: disconnecting the power to the controller
will reset the microprocessor.
Did
arrow panel
light?
YES
YES
Controller has been Reset
Š
Š
NO
Place unit back in service, if unit needs to be reset
again , send controller back to the factory to have the
reset circuit repaired.
Call Solar Technology Customer Service for a RMA
(Return Materials Authorization)
The unit's serial number will be required.
End
of
Process
Check for Voltage at Controller
Š
Š
Š
Check for Voltage across the ht ick red and black wires
going to the controller ( power wires ).
Check for Voltage at the thin red and black wires going
to the controller ( sense wires ) there should be more
then 11 volts.
Inspect all electr ical connections on the batteries.
Repair Wires
Š
Š
Š
Locate faulty connection.
Inspect all connectors on battery
terminals.
Repair or replace bad wire harness.
NO
Is
there power at
both power &
sense wires?
End
of
Process
1
Turn to page 2
YES
A
From page 1
A
More than 11 Volts
Present at
Controller
Are LEDs on
Controller lit
normally?
NO
YES
Repair Controller
Check Arrow Panel Connector
Š
Š
Š
Š
Send Controller back to the factory for repair.
Call Solar Technology Customer Service for a RMA
(Return Materials Authorization)
The unit's serial number will be required.
End
Inspect connector for corrosion or damaged pins
Check for power from pin # 8 to pin # 28 on Arrow
Panel Control Cable using a dc volt meter.
of
Process
4
WARNING
When testing for power
be careful not to touch leads to
each other or ground.
Controller Damage could occur.
5
12
27
36
20
28
44
52
59
37
45
53
63
19 18 17 16 15 14 13 12 11 10 9 8
7 6 5 4
1
11
19
60
Is
pulsating
voltage
present?
3 2 1
37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20
YES
Check Controller Connector
Š
Š
NO
Inspect connector on rear of controller for corrosion
or damaged pins
Check for power from pin # 8 topin # 28 using a dc
volt meter.
Turn to Page 3
B
Repair Controller
Turn to Page 4
C
YES
Is
pulsating
voltage
present?
NO
Š
Š
Send controller back to the factory for repair.
Call Solar Technology Customer Service for a RMA
(Return Materials Authorization)
End
The unit's serial number will be required.
of
Process
2
From Page 2
B
Power at
Arrow Panel Control
Cable
Reconnect Arrow Panel Control Cable
Š
1
3
5
16
17
6
7
21
12
14
18
2
19
8
22
9
23
25
20
Reconnect the arrow panel control cable to the
arrow panel.
Test LED Lamp
4
10
24
Š
Š
11
13
Remove the center lamp # 8
Test for power across wires with left arrow selected.
Note: Black is negative, blue is positive.
15
Is
there
flashing
power?
NO
YES
Check Wires for Continuity
Change LED Lamp
Š
Š
Test the wire using a continuity tester from pin # 8 to
the black wire of lamp # 8 andpin # 28 to blue wires of
lamp # 8.
Change the lamp with a known good LED Lamp.
Check the Remaining Lamps
Š
Check the remaining lamps in the same manner
Wiring diagram available in manual.
YES
Does lamp
light?
NO
Retest Cable Connector
Is there
continuity?
YES
Bad connection between Arrow Panel control cable
connector and the arrow panel harness connector.
Š
Clean and inspect all pins.
End
of
Process
NO
Change Arrow Panel Harness
Call Customer Service
Broken wir es inside arrow panel
Š
Change the arrow panel wire harness
Š
End
of
Process
Call Solar Technology Customer Service
department for additional assistance.
End
of
Process
3
From Page 2
C
Power at
Controller but not at Arrow
Panel Control Cable
Test Arrow Panel Control Cable
Š
Check wires of Arrow Panel Control Cable for
continuity.
Note: You will need a Continuity tester a paper clip and
a magnifing glass.
4
1
5
11
19
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37
12
27
36
20
28
44
52
59
37
45
53
63
Are there
any open wires?
NO
60
YES
Reconnect Cable to Controller
Replace Arrow Panel Control Cable
Š
Š
Š
Reconnect the Arrow Panel Control Cable to the
Controller
Test Arrow Panel connector for power using a dc volt
meter.
4
1
5
11
19
12
27
36
20
28
44
52
59
37
45
WARNING
When testing for po wer
be careful not to touch lea ds
to each other or ground.
Controller Damage co uld
occur.
Install known good Control Cable
End
of
Process
Is
pulsating
voltage
present?
NO
53
63
60
YES
Reconnect Cable to Arrow Panel
Repair Controller and Cables
Š
Š
Reconnect cable to Arrow Panel and if Arrow Panel does
not light start test from the beginning.
Š
End
of
Process
4
Send the Battery harness,Controller and the Arrow
Panel control harness back to the factory for repair.
Call Solar Tech Customer Service for a RMA number
End
You will need the serial number of the unit.
of
Process
Checking Arrow Board
Charging Circuit
Approximate Amps for Solar panel
on a sunny day with sun directly
overhead.
4.4 amps
75 Watt Solar panel
3.6 amps
50 Watt Solar panel
2.0 amps
30 Watt Solar panel
The following test assumes that the batteries need to
be charged and there is enough sun to produce full
voltage from the solar array. All battery terminal
connections havebeen checked and verified good.
Legend
Controller task
Manual Task
Turn Arrow Panel Off
The Arrow Selector Knob should be in the OFF
position to test the Charging Circuit.
NOTE: The Charging Circuit is always ON.
Note: These readings are typicall
under ideal conditions, bright sunny
day with the sun directly overhead.
Actual reading will probably be
lower.
Decision
Off-Page Reference
End
of
Process
Locate Unit in Direct Sun
Š
End of Process
Locate unit outside in adequate sunlight.
Note: You will not be able to check the charging circuit
under shop lights.
Measure Solar Array Charging Amps
Š
Š
Remove Controller from the divider plate.
Attach a DC digital clamp meter to the white wire from
the Solar Array.
Measure Amp reading.
Š
Compare Amp Reading to Chart
Š
Compare your Amp reading to the chart above.
NO
Is Amp
reading appropriate
for the size solar array on
the unit?
Yes
Measure Solar Array Amp Output (Dead Short Test)
Check Charging Current
Š
Š
Š
Š
Disconnect the Power Connector from the Controller.
Connect your DC clamp meter to the white wire from
the Solar Array.
Using a needle nose pliers short out the white and
black wires from the Solar Array.
Note: Do not leave wires shorted out longer then 15
seconds.
Š
Measure the current from the Controller to the Battery
Bank.
Connect your DC clamp meter to the thick red wire that
comes from the Controller to the Battery Bank.
Note: Arrow Selector Knob should be in the off position
for this test
Turn to Page 2
Turn to Page 3
A
B
1
From Page 1
A
Amp Reading from Dead Short Test.
Is Amp
reading appropriate for
the size solar array on
the unit?
NO
YES
Check Solar Panel Output Voltage
Repair Controller
Š
Š
Check voltage across Solar ArrayPower Cable using a
DC voltmeter.
Š
Š
Double check battery terminal connections for loose
wires and corrosion.
Send the Controller back to the factory for repair.
Call Solar Technology Customer Service for a RMA
(Return Materials Authorization)
The unit's serial number will be required.
End
of
Process
Check Solar Array Wire Connections
Is there
approxim ately 20
volts?
Š
Š
NO
Open the junction box on the bottom of the solar panel.
Inspect all wire connections, make certain wires are
tight on the terminals and screws are tight on
terminals.
YES
Repair or Replace Solar Panel
Š
Š
Check Solar Array and Power Cable
Check Solar Panel for physical damage
If there is no obvious damage send Solar Panel back
to the factory for repair.
Call Solar Technology Customer Service for a RMA
(Return Materials Authorization)
End
The unit's serial number will be required.
of
Š
Š
Check for voltage at Solar Panel power terminals.
Check for voltage across the whiteand black wires of
the Solar Panel power term inals using a DC volt
meter.
Process
NO
Is there
approxim ately 20
volts?
YES
Repair or Replace Solar Array Power Cable
Š
Š
Check Power Cable for physical damage
Check wires for continuity. If there is an open wire
replace the Solar Array Power Cable.
End
of
Process
2
From Page 1
B
Check Charging Current.
Is Amp
reading similar
to the solar array
reading?
NO
YES
Repair Controller
Charging Circuit OK
Š
Š
Š
Š
Send the Controller back to the factory for repair.
Call Solar Technology Customer Service for a RMA
(Return Materials Authorization)
The unit's serial number will be required.
End
Charging Circuit checks out OK
Call Solar Technology Customer Service if additional
assistance is needed.
End
of
Process
of
Process
3
Battery Charge Table
Approximate Time required to
charge a battery bank from shut
down mode.
75 Amp. Charger
2 Batteries
4 Hours
4 Batteries
8 Hours
45 Amp. Charger
2 Batteries
7 Hours
4 Batteries
14 Hours
Check for Bad Battery
Legend
Controller task
Charge Battery Bank Fully.
Š
Charge Batteries fully for accurate testing.
Note: Refer to Battery Charge table for charging times.
Manual Task
Decision
30 Amp. Charger
2 Batteries
10 Hours
4 Batteries
20 Hours
10 Amp. Charger
2 Batteries
30 Hours
4 Batteries
60 Hours
Off-Page Reference
Test Batteries with a Hydrometer.
Š
Check the Specific Gravity level of every cell of each
battery.
Note: Hydrometers can be purchased at a local auto
supply store.
Is
specific gravity reading
even on all cells of each
battery?
NO
End of Process
YES
Is
specific gravity reading
above 1225?
Replace Battery
Š
End
of
Process
Replace any battery that has one cell with a lower
specific gravity reading than the other cells of the
same battery.
YES
End
of
Process
NO
Replace All Batteries not Holding a Charge
Batteries not holding a charge.
Š
Replace any Battery with a Specific Gravity Reading
under 1225.
Turn to Page 2
A
1
From Page 1
A
Specific Gravity Reading above 1225.
Load Test Batteries.
Š
Š
Disconnect jumper wires from Batteries.
Load test Batteries individually.
Note: Tester should be set to 6 volts (if required)
Did battery pass
the load test?
NO
YES
Replace Bad Battery.
Batteries Check OK.
Š
Š
Š
Replace any battery that did not pass the load test
with a 6 volt GC-2 type deep cycle battery.
Š
End
of
Process
2
End
of
Process
Place unit back in service.
Inspect Charging Circuit if you suspect you have a
problem.
Refer to the Arrow Board Charging Circuit Flow Chart.
Arrow Panel
Single Lamp Not Working
Legend
Controller task
5
Manual Task
Normal Operation.
Decision
17
6
18
7
5
Inspect Lamp Wire Terminals.
9
23
6
18
7
21
10
14
11
13
15
2
19
8
22
4
24
16
17
12
20
25
1
End of Process
Š
Š
8
14
3
2
19
22
21
12
It is normal for lamp number 6 to be out while
displaying the left arrow.
It is normal for lamp number 10 to be out while
displaying the Right arrow
Off-Page Reference
End
of
Process
16
1
3
20
9
23
25
4
10
24
11
13
15
Remove lamp shroud.
Inspect wire terminals.
Are
any wires broken
or corroded?
NO
YES
Test LED Lamp.
Replace Wire Terminals.
Š
Š
Š
Turn controller to pattern with malfunctioning lamp
Replace the lamp with a lamp from a different position
that is known to work.
Replace the wire terminals makecertain the wire is not
corroded.
End
of
Process
Replace LED lamp
Did the new
lamp work?
Š
Š
Š
Š
Š
YES
LED lamp is not working.
Send lamp back tothe factory for repair.
Call Solar Technology Customer Service for a RMA
(Return Materials Authorization)
End
The unit's serial number will be required.
of
Process
NO
Inspect Arrow Panel Control Cable Connection.
Š
Are there
any broken or
corroded pins?
Inspect connector for broken or corroded pins.
NOTE: Lamps share a common positive with 4 other
lamps. Lamp is switched using the negative side.
NO
YES
Repair Connection.
Inspect Arrow Panel Wire Harness
Š
Š
Š
Clean corrosion from pins using contact cleaner.
Replace Arrow Panel wire harness
Check for continuity of arrow panel wiring.
Note: Refer to pages 4& 5 for pin numbers.
End
of
Process
Turn to Page 2
A
1
From page 1
A
Check Arrow Panel Wire for Continuity.
Š
Refer to page 4 and 5 for pin numbers associated with
the wires to the lamp that is not working. For this
example we will use lamp number 8. The blue wire
(pos) goes to pin number28. The black wire (neg)
goes to lamp number 8.
1
5
4
11
12
20
28
19
27
36
37
45
44
52
59
53
60
63
Is there
continuity at both
wires?
YES
NO
Check for Power at Arrow Panel Control Cable.
Repair or Replace Arrow Panel Wire Harness.
Š
Š
Š
Test for power across the appropriate pins using a volt
meter. In this case pin # 8 isneg. and pin # 28 is pos.
Note: lamps share a common positive with 4 other
lamps. Lamp is switched by the negative side.
Locate open wire and repair or
Replace arrow panel wire harness
End
of
Process
4
1
5
11
19
Turn to page 3
12
27
36
20
28
44
52
59
37
45
53
63
60
B
WARNING
When testing for power
be careful not to touch leads to
each other or ground.
Controller Damage could occur.
2
From page 2
B
Is there
pulsating
power?
NO
YES
Check for Power at Controller.
Bad Connection at Arrow Panel Control Cable.
Š
Š
Š
Š
Remove the Controller from the divider plate.
Remove the Arrow Panel Control Cable.
Test for power across the appropriate pins using a volt
meter. In this case pin # 8 isneg. and pin # 28 is pos.
Š
Š
Check for a bad connection between the Arrow Panel
Control Cable and the Arrow Panel Connector.
Look for any corroded pins
Look for terminals that are not ully
f inserted into the
Arrow Panel Contr ol Cable (female terminal).
End
of
Process
WARNING
When testing for p ower
be careful not to touch le ads
to each other or ground.
Controller Damage c ould
occur.
19 18 17 16 15 14 13 12 11 10 9 8
7 6 5 4
3 2 1
37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20
Is there
pulsating
power?
NO
YES
Repair Arrow Board Controller.
Replace Arrow Panel Control Cable.
Š
Š
Open wire in Arrow Panel Control Cable
Š
Repair or Replace the Arrow Panel Control Cable.
Send Controller backto the factory for repair.
Call Customer Service for a RMA number. The units
serial number will be required.
End
of
Process
End
of
Process
3
Connector Pin Designations
Pin #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
Wire Color
Function
Brown
Red
Orange
Yellow
Green
Blue
Violet
Grey
White
White/Red/Red
White/Brown
White/Red
White/Orange
White/Yellow
White/Green
White/Blue
White/Violet
White/Grey
Red/Yellow
White/Black
White/Black/Brown
White/Black/Red
White/Black/Orange
White/Black/Yellow
White/Black/Green
White/Black/Blue
White/Black/Violet
White/Black/Grey
Red/Green
Red/Black
Tan
Pink
White/Red/Brown
White/Red/Black
White/Red/Green
White/Red/Blue
White/Red/Violet
Lamp # 1
Lamp # 2
Lamp # 3
Lamp # 4
Lamp # 5
Lamp # 6
Lamp # 7
Lamp # 8
Lamp # 9
Lamp # 10
Lamp # 11
Lamp # 12
Lamp # 13
Lamp # 14
Lamp # 15
Lamp # 16
Lamp # 17
Lamp # 18
Lamp # 19
Lamp # 20
Lamp # 21
Lamp # 22
Lamp # 23
Lamp # 24
Lamp # 25
Common Positive Lamps 1,3,5,12,14
Common Positive Lamps 2,4,11,13,15
Common Positive Lamps 6,7,8,9,10
Photocell Positive 5 Volts
Common Positive Lamps 16,17,18,19,20
Common Positive Lamps 21,22,23,24,25
Common Positive Rear panel lamps
Photocell Signal
as viewed
Rear panel left
from front of
Rear panel center
arrow panel
Rear panel right
Low Battery Indicator
}
4
Lamp Position Numbers
17
3
21
12
14
20
19
18
7
6
5
2
16
1
9
8
23
22
25
5
4
11
10
13
24
15
Legend
Controller task
Arrow Panel Lamps Appear Dim
Manual Task
Decision
Check Arrow Board Aiming.
Š
Off-Page Reference
End
of
Process
Aim Arrow Board at traffic using the Sighting Tubes.
Note: Vehicle should be visible in Sighting Tubes.
End of Process
Clean Photocell.
.
Š
Clean inside of Photocell using a wet Q-tip or corner of
a rag
Note: Photocell must be kept clean
Did
lamps get
brighter?
NO
YES
Check Photocell.
Keep Photocell Clean.
Š
Š
Place a flashlight over the Photocell.
Make cleaning the Photocell part of a routine
maintenance program.
End
of
Process
Clean Lamps
16
1
3
5
17
6
21
12
14
18
7
2
19
8
22
23
25
20
9
4
10
24
Did
lamps get
brighter?
YES
Š
Š
Clean the lens of the lamps using a soft cotton cloth.
Call Solar Technology Customer Service for further
assistance if lamps are still not bright enough.
End
of
Process
11
13
NO
15
By-Pass Photocell.
Š
Š
Š
Did
lamps get
brighter?
Remove lamp #15 to expose the wires to the
Photocell.
Disconnect the Photocell wire connector.
Jump the two terminals of the Photocell wire harness.
NO
YES
Replace Photocell.
15
Š
Turn to Page 2
Replace the Photocell with a
known good Photocell.
End
of
Process
1
A
From Page 1
A
Lamps do not get Brighter After
Shorting Out Terminals.
Check Control Cable Connections.
Š
Disconnect Arrow Panel Control Cable from Arrow
Panel look for any damaged or corroded pins
Are any pins
damaged or
corroded?
NO
YES
Check Photocell Wire Harness.
Clean Corrosion from Pins.
Š
Š
Test Arrow Panel wire harness photocell wire circuit for
continuity.
Check continuity from pin # 29 to the blue wire.
Check continuity from pin # 33 to the black wire.
Š
Š
Š
Clean corrosion from pins using a spray type
electronics cleaner.
Apply dielectric grease to connector to prevent further
corrosion
End
of
Process
1
5
Broken or Damaged Pins.
4
11
12
20
28
Š
19
27
36
Š
Š
44
52
37
45
59
53
60
Š
63
The pins in this connector cannot be serviced in the
field.
Replace the Arrow Panel wire harness.
Send the Arrow Panel harness backto the factory for
repair.
Call Solar Technology Customer Service for a RMA
Return Materials Authorization)
The unit's serial number will be required.
End
of
Process
Is there
continuity on both
wires?
NO
YES
Turn to Page 3
Replace Arrow Panel Harness.
Š
Š
Š
Š
B
2
Open wire in harness.
Remove Arrow Panel from unit.
Remove the rear skin of the Arrow Panel.
Replace the Arrow Panel W ire Harness.
End
of
Process
From Page 2
B
Arrow Panel Wire Harness
Continuity.
Check Arrow Board Control Cable.
Š
Š
Š
Remove connector from the controller.
Check for continuity from pin # 29 to pin # 29
Check for continuity from pin # 33 to pin # 33
4
1
5
11
12
19
1
2 3
4 5
6
7 8 9 10 11 12 13 14 15 16 17 18 19
27
36
20
28
44
52
59
37
45
53
63
60
20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37
Is there
continuity on both
wires?
NO
YES
Replace Arrow Board Control Cable.
Repair Controller.
Š
Š
Š
Replace Control Cable with a known good cable.
End
of
Process
Send Controller back to the factory for repair
Call Solar Technology Customer Service for a RMA
Return Materials Authorization)
End
The unit's serial number will be required.
of
Process
3
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