AESYS Standard Sign System User manual

Standard Sign System
Maintenance Manual
Publication Number ASMM2010 • Version 1.0 • April 2011

aesys
Standard Sign System
Maintenance Manual
ASMM2010
Page 2
Version 1.0 • April 2011
© 2011 Aesys, Inc. —All Rights Reserved.
The copyright laws of the United States and other countries specifically protect this material in its entirety.
It may not be reproduced, distributed, or altered in any way without the expressed written consent of
Aesys, Inc.
Under copyright laws, neither the documentation, nor any associated software may be copied, photo-
copied, reproduced, translated, or reduced to any electronic medium of machine readable form, in whole
or in part, without the written consent of Aesys, Inc.
Notice
Every effort was made to ensure that the information in this document was accurate at the time of
printing. However, all information is subject to change without notice.
Mandatory Customer Information Federal Communications Commission (FCC) Statement
NOTE: This equipment has been tested and found to comply with the limits for a Class A digital device,
pursuant to Part 15 (and Parts 25 and 90) of the FCC rules. These limits are designed to provide
reasonable protection against harmful interference when equipment is operated in a commercial
environment. This equipment generates, uses, and can radiate radio frequency energy; and, if not
installed and used in accordance with this and related manuals, may cause interference to radio
communications. Operation of this equipment in a residential area may cause harmful interference in
which case the user will be required to correct the interference at their expense.
Trademark Information
Aesys™ is a registered trademark of Aesys, Inc.
INFOLED™ is a pending trademark of Aesys, Inc. (U.S. Trademark Application Serial No. 77520984)
GET ON BOARD WITH AESYS™ is a pending trademark of Aesys, Inc. (U.S. Trademark Application
Serial No. 77582662)
Aesys Contact Information
To contact us, please refer to the information below:
Corporate Headquarters —U.S.A.
225 County Road
Tenafly, NJ 07670-1818
Telephone: [phone]
Facsimile: 201-871-3239
Corporate Headquarters —Canada
420 Main Street East, Suite 606
Milton, Ontario L9T 5G3
Telephone: [phone]
Facsimile: 647-722-3242
General Information and Sales Department
Sales email: [e-mail]
Service email: [e-mail]
Visit us on the Internet
www.aesysinc.com
Ordering Information
The ordering number for this publication is ASMM2010 • Version 1.0. To order this document, contact
Aesys U.S.A. or Aesys Canada.
IMPORTANT: If you are in possession of a printed or electronic version of this manual, be
aware that it may not be the current version. To ensure that you are using the most up-to-
date version of this manual, please contact Aesys, Inc.

aesys
Standard Sign System
Maintenance Manual
ASMM2010
Page 3
Version 1.0 • April 2011
Table of Contents
Chapter 1 —Preface and Overview .......................................................................................................... 9
....About This Maintenance Manual/Purpose.......................................................................................9
....Disclaimer ........................................................................................................................................9
....OSHA Compliance and Safety Guidelines.......................................................................................9
....Revision Information (English Version)..........................................................................................10
....Cautionary Symbols.......................................................................................................................10
Cautionary and Symbol Terminology ......................................................................................11
....Safety Summary and Cautions Concerning Servicing the Unit .....................................................11
Maintenance Related Guidelines ............................................................................................12
....Firmware and Manual Versions and Revisions .............................................................................12
Firmware Versions...................................................................................................................12
Current Firmware Releases.....................................................................................................12
Manual Versions......................................................................................................................13
Firmware and Manual Versions and Revisions.......................................................................13
....Change Management.....................................................................................................................13
....Aesys Terminology and Terms ......................................................................................................14
Chapter 2 —System Overview................................................................................................................15
....Introduction to the Standard Sign System .....................................................................................15
Chapter 3 —KC640 CCU Operation........................................................................................................16
....Introduction ....................................................................................................................................16
....KC640 Central Control Unit (CCU) Features.................................................................................17
....Start-Up/Power On Self Test (POST)............................................................................................18
....SmartMedia Card (SMC) Installation .............................................................................................19
....Selecting and Executing Destination/Message to Sign .................................................................20
....CCU Transmission/Communication Error (Status 2).....................................................................21
―Status 2‖ Error Troubleshooting Guide ..................................................................................21
....CCU LCD/Message Display...........................................................................................................22
....Dash/Run Number Sign Option .....................................................................................................22
....Selecting a Public Relations (P/R) Message .................................................................................22
....Deleting a Public Relations (P/R) Message...................................................................................23
Non-existent Code...................................................................................................................23
....Select Between Two Destinations (―DEST A‖ and ―DEST B)‖ .......................................................23
....Using the Scrolling Keys (<F7> and <F8>)....................................................................................24

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Standard Sign System
Maintenance Manual
ASMM2010
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....Blanking/Disabling the Sign ...........................................................................................................24
....Second Level Key Mode................................................................................................................24
Sign Brightness Adjustment Feature (<F1>)...........................................................................25
Enabling/Disabling the Internal Sign (<F2>)............................................................................26
Change Page Duration of P/R Message (<F3>) .....................................................................26
Line + Terminus Mode (<F4>).................................................................................................27
Ignition/Engine Off —Disabling the Display Feature (<F5>) ..................................................27
Dash Sign Enabled and Disabled Feature (<F6>) ..................................................................28
Protocol (Decimal/Hexadecimal) Setup Feature (<F7>) .........................................................28
Access Code Password Option (<F8>)...................................................................................28
....Reset Default Settings ...................................................................................................................29
....Alarm Reset/Disable ......................................................................................................................29
....Emergency Button Error.................................................................................................................29
....Emergency/Panic Alarm Feature...................................................................................................30
....Manual Input Messages (MIM) ......................................................................................................31
Manual Input Message (MIM) Procedure................................................................................31
Special MIM Feature Key Functions .......................................................................................31
....CCU Technical Information Supplement........................................................................................31
Viewing Other Destination Message Timeout.........................................................................31
Access Code/Password Recovery ..........................................................................................31
Downloading Data (Destination/Message Listing)...................................................................32
Uploading Firmware ................................................................................................................32
CCU Basic Operation-related Information...............................................................................32
Additional Software Considerations ........................................................................................33
CCU Hardware-related Information.........................................................................................34
Technical Characteristics ........................................................................................................35
Chapter 4 —Display Panels (Signs) .......................................................................................................36
....Introduction ....................................................................................................................................36
....Sign Components...........................................................................................................................38
Sign CPU Circuit Board...........................................................................................................39
Microprocessor..................................................................................................................39
EPROM Memory...............................................................................................................39
DIP SWITCH.....................................................................................................................40
PLD (Programmable Logic Device) ..................................................................................42
Internal Power Supply.......................................................................................................42

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Standard Sign System
Maintenance Manual
ASMM2010
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Version 1.0 • April 2011
Interface Circuits to the CCU ............................................................................................42
CCU Filters........................................................................................................................42
Power Supply Circuit Board.....................................................................................................42
Transient Suppressor ..............................................................................................................44
Color Management Circuit Board (0305).................................................................................45
LED Circuit Boards..................................................................................................................45
....Sign Access ...................................................................................................................................47
Chapter 5 —Software Considerations ...................................................................................................48
....Overview ........................................................................................................................................48
Software for the KC640 CCU ..................................................................................................48
Software for the Signs (Via Processor Circuit Board) .............................................................48
Chapter 6 —Troubleshooting and Repair..............................................................................................49
....Introduction ....................................................................................................................................49
Chapter 7 —Spare Parts/ Electrical Information...................................................................................52
....Sign Parts Catalog Overview.........................................................................................................52
....Electrical/Cable Harness Information Overview ............................................................................52
....Sign Mounting Brackets Identification............................................................................................52
....Printed Circuit Boards....................................................................................................................52
....Destination Sign Parts Catalog Listings.........................................................................................53
List of Figures
Figure 1 —Manual Version Information .....................................................................................................13
Figure 2 —Standard Sign System General System Diagram....................................................................15
Figure 3 —KC640 Central Control Unit......................................................................................................16
Figure 4 —KC640 Central Control Unit, Selected Features I ....................................................................17
Figure 5 —Start-Up and Boot Program Code............................................................................................18
Figure 6 —Aesys Logo Briefly Appears.....................................................................................................18
Figure 7 —Firmware Revision Number......................................................................................................18
Figure 8 —KC640 SmartMedia Card and slot connector ..........................................................................19
Figure 9 —KC640 Central Control Unit, Selected Features II...................................................................20
Figure 10 —Transmission Message ..........................................................................................................20
Figure 11 —Error on the Letters A and C ..................................................................................................21
Figure 12 —Error with the Letter B............................................................................................................21

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Standard Sign System
Maintenance Manual
ASMM2010
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Version 1.0 • April 2011
Figure 13 —Sample Code Number and Destination Message..................................................................22
Figure 14 —Public Relations (P/R) Code Number on the LCD .................................................................22
Figure 15 —Non-existent Code Message..................................................................................................23
Figure 16 —Select Destination ―A‖ ............................................................................................................23
Figure 17 —Select Destination ―B‖ ............................................................................................................23
Figure 18 —Disable Displays Prompt........................................................................................................24
Figure 19 —Disabled Display Confirmation...............................................................................................24
Figure 20 —Second Level Access Code Screen.......................................................................................24
Figure 21 —Second Level Key Mode Screen............................................................................................25
Figure 22 —Display Selection Screen .......................................................................................................25
Figure 23 —Sign Selection Screen............................................................................................................25
Figure 24 —Enabling the Internal Sign......................................................................................................26
Figure 25 —Public Relations (P/R) Message Page Duration Screen........................................................26
Figure 26 —Public Relations (P/R) Message Page Duration Set-up Completed......................................27
Figure 27 —Line + Terminus Mode (<F4>) Main Screen..........................................................................27
Figure 28 —Disabling Displays Screen .....................................................................................................27
Figure 29 —Dash Sign Enabled and Disabled Feature Main Screen .......................................................28
Figure 30 —Protocol (Decimal/Hexadecimal) Setup Feature Main Screen ..............................................28
Figure 31 —Access Code Password Option Initial Screen........................................................................28
Figure 32 —Access Code Password Change Password Screen ..............................................................29
Figure 33 —Access Code Password Option Change Confirmation Screen..............................................29
Figure 34 —Emergency Button Error Display............................................................................................30
Figure 35 —Emergency/Panic Alarm Connector.......................................................................................30
Figure 36 —KC640 CPU Board (Part Number 0404B, Front View) ..........................................................34
Figure 37 —KC640 CPU Board (Part Number 0404B, Rear View)...........................................................34
Figure 38 —Opaque Sign Louvers ............................................................................................................36
Figure 39 —Sign Bracket Mounting Holes.................................................................................................37
Figure 40 —Standard Sign System General System Diagram..................................................................37
Figure 41 —Mounting Nuts........................................................................................................................38
Figure 42 —Sign CPU Circuit Board..........................................................................................................39
Figure 43 —DIP Switch (Detail).................................................................................................................40
Figure 44 —Power Supply Circuit Board (Viewed from Front)..................................................................43
Figure 45 —Transient Suppressor Circuit Board (Viewed from Right Side)..............................................44
Figure 46 —Color Management Circuit Board...........................................................................................45
Figure 47 —LED Circuit Boards (Interior View).........................................................................................45

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Standard Sign System
Maintenance Manual
ASMM2010
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Version 1.0 • April 2011
Figure 48 —Accessing HG 320.200X24/1 YW Slim 2-type Front Sign Components................................47
Figure 49 —Accessing Slim-type Sign Components.................................................................................47
Figure 50 —Sign Electrical/Cable Harness Interconnection Block Diagram .............................................54
Figure 51 —Electrical Schematic Electrical Connections, Full View .........................................................55
Figure 52 —Electrical Schematic Electrical Connections, Detail ―A‖ .........................................................56
Figure 53 —Electrical Schematic Electrical Connections, Detail ―B‖ .........................................................57
Figure 54 —Electrical Schematic Electrical Connections, Detail ―C‖.........................................................58
Figure 55 —Electrical Schematic Electrical Connections, Detail ―D‖.........................................................59
Figure 56 —General Connection Diagram, Full View................................................................................60
Figure 57 —General Connection Diagram, Detail ―A‖ ...............................................................................61
Figure 58 —General Connection Diagram, Detail ―B‖ ...............................................................................62
Figure 59 —General Connection Diagram, Detail ―C‖ ...............................................................................63
Figure 60 —General Connection Diagram, Detail ―D‖ ...............................................................................64
Figure 61 —General Connection Diagram, Detail ―E‖ ...............................................................................65
Figure 62 —General Connection Diagram, Detail ―F‖................................................................................66
Figure 63 —Standard Junction Box, Full View ..........................................................................................67
Figure 64 —Standard Junction Box, Detail ―A‖ ..........................................................................................68
Figure 65 —Standard Junction Box, Detail ―B‖ ..........................................................................................69
Figure 66 —Standard Junction Box, Detail ―C‖..........................................................................................70
Figure 67 —Standard Junction Box, Detail ―D‖..........................................................................................71
Figure 68 —Main Power Cable..................................................................................................................72
Figure 69 —F02 Front Sign Extension Cable............................................................................................73
Figure 70 —Front Sign...............................................................................................................................74
Figure 71 —S02 Side Sign and Rear Sign Extension Cable.....................................................................75
Figure 72 —Side Sign................................................................................................................................76
Figure 73 —Rear Sign ...............................................................................................................................77
Figure 74 —C01 KC640 Data and Power Cable .......................................................................................78
Figure 75 —Alarm Cable Hook-up Wire ....................................................................................................79
Figure 76 —Adaptor DB9 Male/Female.....................................................................................................80
List of Tables
Table A —Manual Revision Information (English Version)........................................................................10
Table B —Manual and Equipment Safety Symbols...................................................................................10
Table C —Description of Cautionary Terms..............................................................................................11

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Standard Sign System
Maintenance Manual
ASMM2010
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Version 1.0 • April 2011
Table D —Firmware Release Information for the KC640 Central Control Unit (CCU)..............................12
Table E —Public Relations (P/R) Message Page Duration Values and Durations ...................................26
Table F —Sign CPU Circuit Board DIP Switch Settings for Address Settings ..........................................41
Table G —Hardware-related Troubleshooting...........................................................................................49
Table H —KC640 CCU Troubleshooting ...................................................................................................50
Table I —Sign Troubleshooting .................................................................................................................51
Table J —Destination Sign Identification Sorted by Model Group.............................................................53
Table K —Guide to Electrical Information Illustrations and Parts List .......................................................54
Table L —Standard Parts List....................................................................................................................81

ASMM2010
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Version 1.0 • April 2011
Chapter 1 —
Preface and Overview
About This Maintenance Manual/Purpose
This maintenance manual contains information about the Aesys, Inc. Standard Sign System, which is
manufactured by Aesys, Italy. The intended audiences for this manual include end user Maintenance
Personnel, Aesys Field Support Personnel, Authorized Aesys Technicians, Product Evaluators and
certified third-party personnel. It is particularly intended for personnel who are responsible for day-to-day
operation and maintenance of the system and for unit system installation. In addition and as is
appropriate, this manual may be used in customer training.
Information in this maintenance manual includes the following:
Functional description of the product
General maintenance information
Troubleshooting guide
Electrical information including schematics, and
Software-related information.
Disclaimer
IMPORTANT:
This manual contains information about the Standard Sign System manufactured by
Aesys, Inc. No representations or warranties are made as to the accuracy or completeness
of the information and procedures contained herein. No representations or warranties are
made as to the completeness and compliance of any installations, which are performed
using this manual.
OSHA Compliance and Safety Guidelines
OSHA (the Occupational Safety & Health Administration of the United States Department of Labor) has
established specific standards for Personal Protective Equipment (PPE). The standards are detailed in
the document entitled General Requirements 1910.132, (Standards - 29 CFR) and should be reviewed by
all personnel prior to working on Aesys, Inc. equipment and systems. Refer to http://www.osha.gov/ for
information about steps that must be taken to protect the eyes, face, ears, hands, and other body parts
from potential harm. It is the responsibility of the technician or other service personnel to adhere to all
OSHA guidelines as they concern PPE devices and their proper use.

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Standard Sign System
Maintenance Manual
ASMM2010
Page 10
Version 1.0 • April 2011
Revision Information (English Version)
If it becomes necessary to revise this manual, Aesys will give the reasons for the revision in this section.
Table A —Manual Revision Information (English Version)
Revision
Description
Revised
Date
Revised
By
Approved
By
1.0
Initial release based on Aesys Publication Number
ASMM2009, Version 4.1.
04/01/2011
CW
SD, CM
Cautionary Symbols
Table B describes the various symbols that may be included in this manual and mounted on the
equipment.
Table B —Manual and Equipment Safety Symbols
Symbols
Definitions
WARNING/CAUTION: Risk of electric shock.
WARNING/CAUTION: Refer to safety-related sections of this and any related
manuals.