Adaptive AlphaXpress 8731 Manual

Manual Part Number 1508610601 rev. A
AlphaXpress 8731
Front Access
Full-Matrix Display Signs
Installation and Maintenance Manual
March 2, 2009

2 AlphaXpress 8731 Sign Installation and Maintenance Manual (pn 1508610601 rev. A)
© Copyright 2009 Adaptive Micro Systems LLC. All rights reserved.
Adaptive Micro Systems
7840 North 86th Street
Milwaukee, WI 53224 USA
414-357-2020
414-357-2029 (fax)
http://www.adaptivedisplays.com
Adaptive is a registered trademark of Adaptive Micro Systems. All other brand and product names are trademarks
or registered trademarks of their respective companies.
Due to continuing product innovation, specifications in this manual are subject to change without notice.
Quick Start Guide
• Mount the sign, see “Mechanical Installation” on page 13.
• Connect 30amp AC service to input terminal blocks, see “Electrical installation” on page 15.
• Connect light sensor to controller #2, see “Light sensor wiring diagram” on page 17.
• Connect communications to the controller:
– See “Sign to ground controller network connection” on page 18 for three controller
configuration.
– or go to “Network connection directly to sign” on page 19 for two controller configuration.
• If required, set the controller’s IP address:
– See “To set the IP address for the new Controller #1 board” on page 38 for two
controller configurations.
– or go to, “To set the IP address for the new Ground Controller #3 board” on page 41 for
three controller configurations.

AlphaXpress 8731 Sign Installation and Maintenance Manual (pn 1508610601 rev. A) 3
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Related documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Equipment symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Warnings and cautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Controller memory battery backup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3V lithium backup battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
General system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
What is an LED? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
VMS control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
LED brightness control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Environmental control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Mechanical Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Setting the OPTIONAL tilting brackets (before mounting sign) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Lifting the sign . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
AC wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Beacon option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Light sensor wiring diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Sign to ground controller network connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Network connection directly to sign . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Outside views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Inside view. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
General Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Controller plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Controller plate for 27 x 126 signs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Ground controller panel (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Controller #1 and #2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Power panel and power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
LED driver board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

CONTENTS
4 AlphaXpress 8731 Sign Installation and Maintenance Manual (pn 1508610601 rev. A)
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Physical inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Exterior inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Interior inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Front lens cleaning (outside of sign) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Required materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Cleaning procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Part replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
List of field-replaceable parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Opening a sign. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . 36
Controller board replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Ground controller (Controller #3) board replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Power supply replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Diode replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
LED driver board replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Fan replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Light sensor replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
AlphaXpress 8731 models (single row models). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

AlphaXpress 8731 Sign Installation and Maintenance Manual (pn 1508610601 rev. A) 5
Introduction
Purpose
This manual is intended as a guide for installation, maintenance, and repairs considered field serviceable on all
Adaptive AlphaXpress 8731 signs.
This field service manual supplies technical information for service and technical personnel so that they can
maintain the equipment at the assembly but not the component level.
Revision history
Related documentation
Safety information
Equipment symbols
Warnings and cautions
Warnings and cautions are posted in appropriate locations throughout this manual.
Rev Date Description
A March 2, 2009 First release.
Document Number Title Description
TechMemo #00-0005 Preventing Electrostatic Discharge (ESD) Damage Describes the precautions to take to protect electronic
components from ESD damage.
Chassis ground

INTRODUCTION CONTROLLER MEMORY BATTERY BACKUP
6 AlphaXpress 8731 Sign Installation and Maintenance Manual (pn 1508610601 rev. A)
Controller memory battery backup
In the event of a power loss, a lithium battery provides power to the sign controller board(s).
Note: The backup battery provides only enough power to operate the sign’s controller memory, not the sign’s
LED displays.
3V lithium backup battery
One 3V lithium battery is located on the sign controller board(s).
Figure 1. A 3V lithium battery is located on the sign controller.
WARNING! Danger of explosion if battery is incorrectly replaced. Replace only with the same or
equivalent type recommended by the manufacturer. Dispose of used batteries according to the
manufacturer’s instructions.
3V lithium battery (Panasonic
CR2032 or equivalent)

INTRODUCTION SYSTEM OVERVIEW
AlphaXpress 8731 Sign Installation and Maintenance Manual (pn 1508610601 rev. A) 7
System overview
This section contains the LED Variable Message Sign (VMS) systems description and a general explanation of
how each system operates.
Introduction
The Adaptive LED family of Variable Message Signs is considered to be one of the highest visibility sign
systems available. Utilizing the latest generation of light emitting diode (LED) technology has allowed us to
construct a high-reliability, variable message sign display system.
The LED Variable Message Signs discussed in this manual are built with a combination of 9 x 18 pixel modular
cases, each with three 6 x 9 pixel display boards at 2.6-inch pitch configured in a full matrix. The signs are
designed to be used as outdoor highway information signs. The signs utilize a corrosion-resistant front-access
housing with control circuitry enclosed within. The only connections necessary are AC power and
Communications Input / Output between the sign housing and ground cabinet.
AlphaXpress 8731 models (three row models)
This manual applies to the following AlphaXpress models:
For AlphaXpress models other than three row configurations see the “Appendix” on page 51 for more details.
AlphaXpress 8731 Height*
(feet) Width*
(feet) Depth*
(feet) Lines Char/line Weight**
(lbs)
Typical
Power**
(watts)
Max
Power**
(watts)
Number of
30A***circuits
(required)
AX-8731-27X54-18A 7.5 13.5 1.2 3 11 1300 660 1700 1
AX-8731-27X72-18A 7.5 17.5 1.2 314 1800 880 2200 1
AX-8731-27X90-18A 7.5 21.5 1.2 3 18 2300 1100 2800 1
AX-8731-27X108-18A 7.5 25 1.2 321 3000 1350 3300 1
AX-8731-27X126-18A 7.5 29 1.2 3 25 3600 1550 3850 2
Pixel center-to-center spacing is 2.6” (66 mm) horizontally and vertically. Character count is based on a 7 x 4 single stroke font with single-column
spacing. A 7-pixel high character is 18” (460 mm) tall. Line count based on a 7 x 4 font with two-pixel row spacing.
*Approximate cabinet dimensions (feet).
**All weight and power specifications are approximations. Consult factory for more details.
***Circuits to be sized for 30–amp breaker(s) in the controller modular case.

INTRODUCTION SYSTEM OVERVIEW
8 AlphaXpress 8731 Sign Installation and Maintenance Manual (pn 1508610601 rev. A)
27 x 54 dimensions
Figure 2. AX-8731-27x54-18A
27 x 72 dimensions
Figure 3. AX-8731-27x72-18A
27 x 90 dimensions
Figure 4. AX-8731-27x90-18A
159.6” 14.25”
89.0”
34.25”
Powerpanel
cube
Powerpanel
cube
Controller
cube
206.4”
89.0”
14.25” 34.25”
Powerpanel
cube
Powerpanel
cube
Controller
cube
Powerpanel
cube
Powerpanel
cube
89.0”
253.2” 14.25” 34.25”
Powerpanel
cube
Powerpanel
cube
Controller
cube
Powerpanel
cube
Powerpanel
cube

INTRODUCTION SYSTEM OVERVIEW
AlphaXpress 8731 Sign Installation and Maintenance Manual (pn 1508610601 rev. A) 9
27 x 108 dimensions
Figure 5. AX-8731-27x108-18A
27 x 126 dimensions
Figure 6. AX-8731-27x126-18A
For views and dimensions other than three row configurations see the “Appendix” on page 51 for more details.
General system
The entire sign system may be broken down into four basic subsystems:
• VMS control system
• LED brightness control system
• Environmental control system
• Electrical system
In the following sections, we explain each of the above-mentioned systems in general terms for ease of
understanding. Referring to the drawings throughout this manual should help you to gain a general
understanding of the LED Variable Message Sign system.
What is an LED?
LED-based signs are one of the most versatile and visible display systems available. We use a cluster of small
LEDs to form a pixel. The pixels are arranged in various matrices to form alphanumeric characters. These
characters are then linked together to form an LED display line. The display line format used in AlphaXpress
8731 signs is full matrix, which allows for the display of any alphanumeric character, including punctuation
marks, as well as simple graphics characters.
89.0”
300.0” 14.25” 34.25”
Powerpanel
cube
Powerpanel
cube Controller
cube
Powerpanel
cube
Powerpanel
cube
89.0”
346.8” 14.25” 34.25”
Powerpanel
cube
Powerpanel
cube Controller
cube
Powerpanel
cube
Powerpanel
cube
Powerpanel
cube
Powerpanel
cube

INTRODUCTION SYSTEM OVERVIEW
10 AlphaXpress 8731 Sign Installation and Maintenance Manual (pn 1508610601 rev. A)
VMS control system
The VMS control system used in the Variable Message Sign consists of the following components:
• IDI 1320 controller
• IDI 1321 controller
• LED display board/driver board
General operation
The controllers interface with the “Host” computer system, and communicate with the Host through a CAT5
Ethernet cable (customer-ordered) or an RS232 Input/Output (I/O) port (standard). Using this network
connection or I/O port, the Host issues commands to, and requests status information from, the LED VMS
equipment. The controllers monitor and control the entire LED VMS system. Communication by the controllers
to and from the Host and the VMS is accomplished using industry standard 10/100 Ethernet or RS232
communications circuitry and NTCIP protocol. Ethernet does not come standard on AlphaXpress 8731 signs;
the option is available, however, at the customer’s request.
Placement of controllers
The controllers are located in the lower right modular case of all AlphaXpress 8731 sign configurations.
Figure 7. Controller plate on model AX-8731-27x54-18A.
Controller plate

INTRODUCTION SYSTEM OVERVIEW
AlphaXpress 8731 Sign Installation and Maintenance Manual (pn 1508610601 rev. A) 11
LED brightness control system
The VMS is equipped with a brightness control system for the LEDs. The brightness control system ensures
that the display is readable in all lighting conditions.
The photocells are enclosed in the light sensor globe to protect them from the environment. Three photocells
continually monitor the ambient light conditions. The photocell assembly is constructed in such a manner that
adverse weather conditions (such as heavy snow) should have no effect on its performance. The main
components of the brightness control system are the following:
• IDI 1320 controller
• Light sensor globe
General operation
The photocells are enclosed in a globe to protect them from the environment. The photocells continuously
monitor the ambient light conditions and send the information directly to the controller. The controller assembly
determines exactly how much ambient light is present through the light-sensing photocells and sends the
proper command to the display module for it to adjust duty cycle of the LED current drive, thus dimming or
brightening the LED modules according to the ambient light. (If the on time of the duty cycle is 50%, then the
brightness will be at 50%; if the on time of the duty cycle is 75%, then the brightness will be at 75%, and so on.)
The photocell assembly is constructed in such a manner that adverse weather conditions should have no
effect on its performance.
Light sensor globe mounting
Because the function of the photocells depends on ambient lighting, the light sensor globe should be mounted
in a location where it will receive maximum light exposure throughout the day. When choosing a mounting
location for the light sensor globe, make sure the globe can receive ambient light on all sides of the globe.
Environmental control system
To protect the sign components from overheating, two fans are mounted in each of the sign’s modular cases.
The operation of each fan is controlled independently by a thermostat dedicated to each fan. The fans turn on
when the internal temperature of the sign reaches 122ºF (50ºC), and turn off when the internal temperature is
below 90ºF (32ºC).
Electrical system
The electrical supply system is responsible for supplying the necessary power to operate the LED sign system.
The sign housing AC and DC electrical system consists of the following components:
• GFCI outlet
• DC power supply
Electrical distribution (AC)
The AC input to the sign system consists of 120VAC 30A single-phase service wired to the input AC terminal
block located on the controller plate. See “AlphaXpress 8731 models (three row models)” on page 7 or the
“Appendix” on page 51 for the number of circuits required for your sign. AC is internally wired to the DC power
supplies.

INTRODUCTION SYSTEM OVERVIEW
12 AlphaXpress 8731 Sign Installation and Maintenance Manual (pn 1508610601 rev. A)
Electrical distribution (DC)
Attached to the back panels in the sign housings are the power supply boxes containing one +12VDC
switching power supplies. The electronic power supplies convert the 120VAC to the required DC voltage to
power all of the electronics in the sign. DC power to the electronics is redundant and has a primary and
secondary source of DC power. Therefore, failure of a power supply will not impact sign performance. The
controller monitors the status of the power supplies.
See the “Appendix” on page 51 for power panel locations on sign configurations other than three row models.
Figure 8. Model AX-8731-27x54-18A
All power supply panels are located in the second (center) row on three row AlphaXpress 8731 sign
configurations. Refer to Figure 2 – Figure 6 for power supply panel locations.
WARNING! Hazardous voltage. Multiple power sources may be present. Risk of electrical shock.
Disconnect all power sources before servicing.
Sign model number Number of power supply panels
AX-8731-27X54-18A 2
AX-8731-27X72-18A 4
AX-8731-27X90-18A 4
AX-8731-27X108-18A 4
AX-8731-27X126-18A 6
Power supplies
Breakers
Input AC
terminal
block
See the“Electrical installation”on page 15
for detailed information on AC wiring.

AlphaXpress 8731 Sign Installation and Maintenance Manual (pn 1508610601 rev. A) 13
Installation
Mechanical Installation
Setting the OPTIONAL tilting brackets (before mounting sign)
Figure 9. Tilt assembly illustrations and degree settings for the optional tilting brackets.
WARNING! When installing the tilt assembly, make sure the correct hole(s) for the degree of forward
or backward tilt are used. If the tilt assembly is improperly installed, the brackets could malfunction
and the sign could fall potentially resulting in death.
TLITDRAWKCAB
HGUORHTGED1-
GED5-
A
M
N
P
R
S
ROFTNIOPTOVIP
TLITGED5-URHTGED1-
:ETON
ROFWOLEBMAEBGNITLITEES
SNOITACOLELOHTOVIP
A
B
C
D
EF
G
H
J
K
L
:ETON
ROFWOLEBMAEBGNITLITEES
SNOITACOLELOHTOVIP
TLITDRAWROF
HGUORHTGED1
GED01
ROFTNIOPTOVIP
GED01URHTGED0
TLITDRAWROF
TLITON
A
A
WEIVTNORFMAEBGNITLIT
HTIWESUROF
K,H,F,D,B
HTIWESUROF
L,J,G,E,C,A
HTIWESUROF
R,N,A
HTIWESUROF
S,P,M
Degree
of Tilt Hole
Loc Degree
of Tilt Hole
Loc
0A8J
1B9K
2C10L
3D-1M
4E-2N
5F-3P
6G-4T
7H-5S
Torque to 45 FT LBS per bolt
Note: Tilting brackets are optional equipment, not all signs are shipped with them.

INSTALLATION MECHANICAL INSTALLATION
14 AlphaXpress 8731 Sign Installation and Maintenance Manual (pn 1508610601 rev. A)
Lifting the sign
Figure 10.Sign lifting guidelines.
WARNING! Crush hazard! Do not lift sign with more than a 15 degree tilt.
Always use lifting bar to lift sign. Otherwise eyebolts may fail and sign may fall, causing
serious injury or death.
RECOMMENDED
Lifting bar
Front view
Use both eyebolts
to lift the sign.
NOT RECOMMENDED
Front view
Not less
than 60°
Use both eyebolts
to lift the sign.

INSTALLATION ELECTRICAL INSTALLATION
AlphaXpress 8731 Sign Installation and Maintenance Manual (pn 1508610601 rev. A) 15
Electrical installation
AC wiring
AC wiring for 27 x 126
Figure 11.When installing the 27x126 sign, a two-service power entry is required.
AC wiring for all other sizes
Figure 12.Terminal block on controller plate for all signs except 27x126.
WARNING! Hazardous voltage. Contact with high voltage may cause death or serious injury. Always
disconnect power to unit prior to servicing.
Controller plate
Line 1
120VAC / 30Amp Service
Line 2
120VAC / 30Amp Service
Ground
Neutral
Note: Terminal block
accepts a maximum of
8AWG wire.
Controller plate
Line
120VAC / 30Amp Service
Ground
Neutral
Note: Terminal block
accepts a maximum of
8AWG wire.

INSTALLATION ELECTRICAL INSTALLATION
16 AlphaXpress 8731 Sign Installation and Maintenance Manual (pn 1508610601 rev. A)
Beacon option
Figure 13.Rear view of sign showing where to connect the beacon option.
Beacon option assembly
WARNING! Hazardous voltage. Contact with high voltage may cause death or serious injury. Always
disconnect power to unit prior to servicing.
Part PN Description Field Installed Part PN Description Field Installed
1508230201 SIGNAL CLOSURE
KIT Yes 61910044 SERRATED LOCK
RING Yes
64000029 1.5-INCH HEX
NIPPLE Yes 64000030 1.5-INCH
NOTCHED
COUPLING Yes
63320022 NEOPRENE
GASKET Yes 64000028 6-INCH
THREADED
NIPPLE No
634008901 12-INCH BEACON
HOUSING WITH
LED Yes 64000031 HUB PLATE No
Beacon Option Components
See below table for details.
Beacon Option
When used, one is
wired on each side.
Mounted on frame.
Black
White
Attach green wire to
chassis of beacon
These components
mount from the inside
of the beacon housing.
Use included wirenuts to wire black
and white wires to the beacon leads.

INSTALLATION ELECTRICAL INSTALLATION
AlphaXpress 8731 Sign Installation and Maintenance Manual (pn 1508610601 rev. A) 17
Light sensor wiring diagram
Note: The light sensor power is protected by a 3AG, 1.5A SLO-BLO fuse.
Figure 14.Light sensor wiring.
LED3 LED4
LED2LED1
2
+
7 854 631
N
O
+
S2
LED3 LED4
LED2LED1
2
+
7 854 631
N
O
+
S2
JP1
JP3
JP2
JP4
JP5
JP6
JP7
JP9
JP8
JP10
JP11
JP1
JP3
JP2
JP4
JP5
JP6
JP7
JP9
JP8
JP10
JP11
CNTRL#2 CNTRL#1
*
*
P1
J1
*
P4
PORT 3
PORT 0
J2
D/OUTPUT
J3
J4
D/INPUT
P1
PORT 0
*
J5 A/INPUT
*
J6 PORT 1
*
P3
*
*
P1
J1
*
P4
PORT 3
PORT 0
J2
D/OUTPUT
J3
J4
D/INPUT
P1
PORT 0
*
J5 A/INPUT
*
J6 PORT 1
*
P3
MAIN
SEE NOTE 2 SEE NOTE 2
SEE NOTE 2
FIRMWARE
PAR T #
REV
CONTROLLER PART#
CONTROLLER PART#
FIRMWARE
PAR T #
MAIN
REV
GND - BLK
PWR - RED
Wire power per
label on plate
Light sensor power (cable marked “power”)
Wire and plug the
light sensor and
power supply panel
communication
cables (cable marked
“comm”) into J6 on
Controller #2.

INSTALLATION ELECTRICAL INSTALLATION
18 AlphaXpress 8731 Sign Installation and Maintenance Manual (pn 1508610601 rev. A)
Sign to ground controller network connection
Figure 15.Ground controller communications wiring.
Network wiring conduit
Install two runs of network wire (pn 71240402)
from the ground controller to the sign.
Connect one run to the RS422 terminal block on
the ground controller and to the RS422 terminal
block on the sign’s controller plate (see below).
(Theotherwirerun isaspareincasethefirstrun
ever fails.)
RED - ORANGE/WHITE
BLACK - WHITE/ORANGE
SHIELD
GREEN - BLUE/WHITE
WHITE - WHITE/BLUE
RED
BLACK
SHIELD
GREEN
WHITE
RED
BLACK
SHIELD
GREEN
WHITE
Run network wiring conduit into this area.
If any drilling is required, vacuum any
metal filings from the sign. Otherwise, the
sign fans could blow these pieces around
and possibly damage electronic
components.
RED - ORANGE/WHITE
BLACK - WHITE/ORANGE
SHIELD
GREEN - BLUE/WHITE
WHITE - WHITE/BLUE
S2
*
*
*
1
910
***
2
Ground controller
(housed in weatherproof
structure near the sign)
Controller plate

INSTALLATION ELECTRICAL INSTALLATION
AlphaXpress 8731 Sign Installation and Maintenance Manual (pn 1508610601 rev. A) 19
Network connection directly to sign
Figure 16.Communication wiring directly to sign.
Run network wiring conduit into this area.
If any drilling is required, vacuum any metal filings from
the sign. Otherwise, the sign fans could blow these
pieces around and possibly damage electronic
components.
For Ethernet connectivity:
1. Connect Ethernet cable to the Ethernet surge
suppressor on the controller plate. See (Item H)
“Controller plate”on page 24or “Controllerplate
for 27 x 126 signs” on page 25.
2. Set the IP address. See “To set the IP
address for the new Controller #1 board” on
page 38 for details.
For RS232 connectivity, connect DB9
cabletoP3portonController1.See(ItemR)
“Controller #1 and #2” on page 27.
Use the sign’s 3/4" conduit
hole for connecting the
communication(networking)
option to the sign. See
“Outside views” on page 22
for conduit use.
Item H
Item R on Controller #1
Network wiring conduit
Controller plate

20 AlphaXpress 8731 Sign Installation and Maintenance Manual (pn 1508610601 rev. A)
INSTALLATION
THIS PAGE INTENTIONALLY BLANK
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