Daktronics VS-5000 Series User manual

201 Daktronics Drive
Brookings, SD 57006-5128
www.daktronics.com/support
800.325.8766
GENERIC SERVICE
VARIABLE SPEED LIMIT SIGNS
VS-5000 SERIES
DISPLAY MANUAL
30 May 2018
DD3907919
Rev 0

Copyright © 2018
All rights reserved. While every precaution has been taken in the preparation of this manual, the publisher assumes no
responsibility for errors or omissions. No part of this book covered by the copyrights hereon may be reproduced or copied
in any form or by any means—graphic, electronic, or mechanical, including photocopying, taping, or information
storage and retrieval systems—without written permission of the publisher.
Daktronics trademarks are property of Daktronics, Inc. All other trademarks are property of their respective companies.

– i –
Table of Contents
1 Introduction.........................................1
How to Use This Manual ............................1
General Summary .....................................2
Operation ...................................................2
2 Component Description and Theory
of Operation........................................3
Sign Controller............................................3
LED Modules...............................................4
LED Diagnostics..........................................4
Power Supplies ...........................................4
Cooling .......................................................4
Light Sensors ...............................................4
3 Mechanical Installation .....................5
Lifting the Sign ............................................5
Mounting Methods ....................................5
4 Electrical Installation ..........................6
Getting Started ..........................................6
Conduit.......................................................6
Grounding ..................................................6
Power Installation.......................................7
Sign Communication ................................7
Default Speeds ..........................................7
Conduit Sealing ........................................7
First Time Turn On ......................................7
5 Maintenance and Troubleshooting ..8
Getting Started ..........................................8
Service and Diagnostics ...........................8
Sign Controller Replacement...................8
Accessing the Internal Components ......9
Replacing a Module .................................9
Replacing a Power Supply .......................9
Ventilation Systems (With Fans and
Filters) ........................................................10
Replacing a Ventilation Fan...................10
Routine/Preventative Maintenance ....11
Sign Cabinet Inspection .....................11
Sign Controller ......................................11
Structural Inspection ...........................11
Photo Sensor Assembly Inspection ....11
LED Cleaning.........................................11
Ventilation System Inspection.............11
Routine/Preventative Maintenance
Checklist ..................................................12
Troubleshooting of the Variable Speed
Limit Sign ...................................................12
6 Replacement Parts and Repair &
Exchange Programs .........................14
Daktronics Exchange and Repair and
Return Programs ......................................14
Exchange Program ..............................14
Before Contacting Daktronics.............14
Repair & Return Program........................15
Shipping Address..................................16
E-mail.....................................................16

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Introduction
1
1 Introduction
How to Use This Manual
This manual provides installation, maintenance, and troubleshooting information for
the Daktronics VS-5000 series Vanguard®Variable Speed Limit Signs (VSLS) and their
components.
For information regarding safety, installation, operation, or service of this system, please
refer to the telephone numbers listed on the cover page of this manual.
The manual is divided into the following sections:
• Introduction covers information needed to use this manual. Take time to read the
entire introduction as it explains concepts used throughout the manual.
• Component Description and Theory of Operation includes information about
components within Daktronics variable speed limit signs.
• Mechanical Installation explains mechanical installation information for the sign.
• Electrical Installation explains electrical installation information for the sign.
• Maintenance and Troubleshooting provides maintenance and troubleshooting
information for Daktronics variable speed limit signs and the sign controller.
• Repair and Exchange Programs provides instructions on how to use the Repair or
Exchange programs.
• Glossary denes terms and phrases used in this manual.
Daktronics identies manuals by the DD or ED number located on the cover page of
each manual. For example, this manual is referred to as DD3907919.
The serial number and model numbers can be found on the ID label, located on the sign.
This label looks similar to Figure 1. When calling Daktronics Customer Service, please have
this information available to ensure the request is serviced as quickly as possible.
Daktronics signs are built for long life and require little maintenance. However, from time
to time, certain sign components need replacing. Refer to the Daktronics Exchange and
Repair and Return Programs (p.14) if any component needs replacing, repairing, or
ordering.
Figure 1: Sign ID Label

Introduction
2
General Summary
The Daktronics variable speed limit signs consist of an aluminum cabinet containing LED
modules. Refer to Figure 2. The sign controller inside the sign operates the modules.
Operation
The central control software allows the DMS operator to check the status of the signs and
to control all messages.
A module is the building block of the Daktronics sign. By placing modules side by side
and on top of one another, a sign of any size can be designed and built. Individual
modules are easily removed from the sign if required. Figure 3 illustrates how Daktronics
numbers modules on a sign. Figure 4 breaks down the module numbering method.
Figure 2: VS-5220-2-18-W
Figure 3: Example Module
Numbering— Front View Figure 4: Module Numbering

Component Description and Theory of Operation
3
2 Component Description and Theory of Operation
Sign Controller
The sign controller is the component that receives communication from the computer
and then sends data to the modules. Figure 5 illustrates a sign controller.
Red diagnostic LEDs are located at various places on the controller. The following table
details some essential LEDs to monitor and the information each LED provides. The LED
name and number are noted in Figure 5.
DS3
DS2
Figure 5: Controller Component Layout
Figure Label LED Number Operation
Run DS4 Steady FLASH about once per second indicates controller is
working properly.
Send signal
(Signal TX) DS3 OFF is the normal state. FLASH when transmitting communication to the computer.
Receive signal
(Signal RX) DS2 OFF is the normal state. FLASH when receiving communication from the computer.

Component Description and Theory of Operation
4
LED Modules
The LED modules consist of a display panel and clusters of LEDs. Each module contains 64
clusters of LEDs, and each cluster is referred to as a pixel. The pixels create the digits seen
on the sign. The module receives data packets from the sign controller and then turns on
and off and sets the dimming level of the module’s pixels appropriately.
LED Diagnostics
A pixel test can be performed to test each pixel in the sign for proper operation. The Pixel
Test in the Vanguard®Central Controller software performs the check and monitors the
results. Refer to Vanguard®Software Help File [F1].
Power Supplies
The power supply mounts to the cabinet truss behind module A102. The power supply
provides the necessary voltage to the LED modules and sign controller.
Cooling
An exhaust fan and ltered air intake vent are mounted on the back of the sign for
cooling during warm weather. The fan turns on during warm weather to circulate the air
behind the LED modules. A thermostat inside the sign controls the fan.
Light Sensors
The light sensor consists of one (1) photocell at one location. The sensed lighting
conditions are converted to signals that transmit to the sign controller through the CAN
lines. The sign controller then adjusts the LED brightness levels appropriately.

Mechanical Installation
5
3 Mechanical Installation
Lifting the Sign
The top of the sign is equipped with eyebolts used to lift the unit. Take care to ensure the
rated load of the eyebolts is not exceeded.
Figure 6 illustrates possible lifting methods for the sign. The recommended lifting method is
shown on the left, with the lifting bar. If lifting the sign without the lifting bar (as shown on
the right) make sure to maintain at least a 45° lifting angle.
Use every lifting point provided. Do not attempt to permanently support the sign by the
eyebolts.
Mounting Methods
Securely mount each sign to a suitable mounting structure, provided by others. Have
each mounting structure inspected by a qualied structural engineer.
Daktronics is not responsible for the structural integrity of support structures and mounting
methods provided by others. Use mounting hardware appropriate to support the weight
of the sign.
Once the sign is installed:
1. Inspect the top and sides of the sign for any holes that may allow moisture to enter
the sign.
2. Plug and seal any openings that may allow water to enter the sign with silicone or
another waterproof sealant.
Figure 6: Lifting the Sign

Electrical Installation
6
4 Electrical Installation
Getting Started
Daktronics recommends that a separate circuit be run to the electronic display(s) to
isolate it and prevent any issues that could be caused by line voltage uctuations or
high frequency noise on the power line caused by other types of equipment. A separate
circuit also makes display maintenance and troubleshooting easier. Daktronics assumes
no liability for any issues caused by line voltage uctuations or other improper power
conditions if these recommendations are not followed.
Only qualied individuals should terminate power and signal cable within this Daktronics
display.
The Daktronics engineering staff must approve any changes made to the display. Before
altering the display, submit detailed drawings for the proposed modications to the
Daktronics engineering staff for evaluation and approval, or the warranty will be void.
Conduit
Daktronics does not include conduit. Possible power and signal entrances are
designated on the shop drawing. Separate conduit must be used to route the following:
• Power
• Signal
To prepare for power and signal entrance:
1. Remove the bottom three modules, using a 1/8" hex head wrench. Refer to
Accessing the Internal Components (p.9) for module removal steps.
2. Clear the area for drilling. Choose area free of wired components.
3. Make a separate pilot hole in the back or side of the enclosure for power and signal.
Ensure none of the internal components are damaged. Attach the conduit and route
power and signal cables. Use watertight connections where the conduit enters the
display cabinet.
Grounding
All components of a display system—including but not limited to displays, control
equipment, and connected peripheral equipment—must be electrically grounded.
Only qualied individuals may perform electrical work, including verication of ground
resistance. Daktronics is not responsible for improper grounding or damage incurred as a
result of improper grounding.
Grounding methods must meet the provisions of all applicable local and national codes.
Inspect and verify all grounding methods meet the provisions of all applicable local and
national codes.
Proper grounding is necessary for reliable equipment operation and general electrical
safety. Failure to properly ground the display system may void the warranty, disrupt
operation, damage equipment, and cause bodily harm or death.
Note: Before drilling, be aware of the location of internal components.

Electrical Installation
7
Power Installation
Connect a 15 Amp, 120 VAC, two-wire plus earth ground power source to the terminal
blocks within the sign. Terminate the Line and Neutral wires to the terminal block;
terminate Ground to the provided ground bar.
Sign Communication
If a point-to-point communication system is used for all the signs in the system (for
example, a laptop computer connected directly to the sign controller), set the sign
address to the same number in each sign, preferably address 1.
If a multi-drop network is used for communication with multiple signs in the system (for
example, a ber-optic drop and repeat network), the sign address must be set to a
unique address for each sign.
The rotary switches set the hardware address that the
software uses to identify the particular display. When
replacing a controller board, set the rotary switches
on the new controller to the same address as the
replaced controller. Each controller in a network needs
a unique address. Refer to Figure 7.
To set the rotary address switches, rotate them
counter-clockwise until the arrow points to the desired
number. The display’s power must be turned off and
then turned back on to activate the test mode or to
change an address.
Note: Setting both rotary switches to address 0 activates Test Mode. Turn the display’s
power off and back on to activate testing.
Default Speeds
The VSLS has default speeds loaded onto the sign controller. Both changeable and
permanent messages are loaded with speeds ranging from 5 to 180, in increments of
ve. To display these default messages, refer to the Vanguard®Software Help File [F1].
Conduit Sealing
Fill the ends of the conduit entering the signs with duct seal.
First Time Turn On
After the sign and all other VSLS site equipment are installed, the site must be tested
according to the eld test procedure for the sign site. This ensures all equipment is
installed properly and is operational. If a eld test procedure is not available, call
Daktronics Transportation Customer Service to obtain a copy.
Figure 7: Rotary Address Switch

Maintenance and Troubleshooting
8
5 Maintenance and Troubleshooting
Getting Started
• Disconnect power before performing any repair or maintenance work on the signs.
• Only qualied service personnel should access internal sign electronics.
• Daktronics engineering staff must approve any changes made to the signs. If making
modications to the signs, submit detailed drawings to the Daktronics engineering
staff for evaluation and approval or the warranty will be void.
Service and Diagnostics
The following sections address servicing of the following sign components:
• Modules
• Sign controller
• +9 V power supplies
• Ventilation fans and lters
• Beacons
• Thermostat
• Photo sensor
The tools required to service the sign include:
• Small Phillips screwdriver
• Small at screwdriver
• 1/8" hex head wrench
• Medium Phillips screwdriver
• Medium at screwdriver
• Nutdriver set
Sign Controller Replacement
Complete the following steps to replace a controller in the display. Required tools include
a 1/8" hex wrench and a 5/16" nut driver.
1. Turn off power to the display.
2. Remove the module directly in front of the controller. Refer to Figure 2 for the exact
location.
3. Disconnect the power plug from J5.
4. Remove all power and signal connections from the board. Label the cables as they
are removed to ensure proper replacement.
5. Remove the six nuts holding the board in place using a 5/16" nut driver.

Maintenance and Troubleshooting
9
6. Take note of the rotary address on the sign controller and ensure the address on the
replacement board is the same. Refer to Figure 7.
7. To install the new controller, replace the six nuts holding it to the display back.
Reconnect power and signal cables. Turn on power, observing the boot-up
sequence, and then note that the LED in the lower-right corner shows power.
Accessing the Internal Components
Remove the appropriate module to access the interior sign components, referring to
Figure 2. Latches at the bottom and/or top of each module secure it to the sign cabinet.
To remove a module:
1. Using a 1/8" hex head wrench, loosen the two latches securing the module.
2. Carefully remove the module from the sign. The interior sign components are now
accessible.
Replacing a Module
Remove the desired module for service; refer to Accessing the Internal Components
(p.9). If a module requires replacement:
1. Disconnect power to the sign.
2. Remove the module to service, referring to Accessing the Internal Components
(p.9).
3. Press the locking tabs of the white 4-pin power connector to release it. Release the
ribbon cable for signal.
4. Remove the signal connector from the back of the module
To install the new or repaired module:
1. Plug the 4-pin power connector into the back of the module.
2. Position the new module and secure it using a 1/8" hex head wrench. Be sure the
module is secure.
3. Turn on power to the sign.
4. Test the modules.
Replacing a Power Supply
To replace or adjust the voltage of the sign’s power supply, perform the following steps:
1. Locate the failed power supply. To locate the failed power supply, refer to Figure 2.
2. Remove and disconnect the module in front of the power supply.
3. Reconnect the signal cable to the back of the module.
4. Remove the bottom mounting screw from the failed power supply being adjusted or
replaced. Then rotate the bottom of the power supply toward you.
5. If replacing a power supply, continue on to Step 6; if only adjusting the voltage on
the power supply, skip to Step 8.
Note: This is a “keyed” connector; it only ts together one way. Do not force the
connection.

Maintenance and Troubleshooting
10
6. Before removing all wires from the power supply, label each wire as to where they
attach. After removing the wires, remove the top mounting screw from the failed
power supply.
7. Replace the failed power supply with the new power supply by performing these
steps in reverse.
8. Locate the voltage adjustment screw.
9. Make sure the voltmeter is set to DC voltage, and then connect the negative (black)
meter lead to V- (negative) on the power supply. Connect the positive (red) meter
lead to V+ (positive) on the power supply.
10. Using the voltage adjustment screw, set the power supply to 9.5 (+/- 0.01) V DC.
11. If the power supply is set correctly, remove the meter leads from the power supply.
Then rotate the power supply back to its original position and replace the bottom
mounting screw.
Ventilation Systems (With Fans and Filters)
Each time a ventilation fan assembly is opened, perform the following:
• Check the fan blades for dirt and debris. Clean the fan blades to maintain the fan’s
efciency and to ensure proper cooling. If the fan blades have a large accumulation
of dirt and debris, change the lters more often.
• Spin the fan blades with a pen or pencil to ensure the bearings are free and the fan is
balanced.
• Push the black button near GFCI outlet to check if the fans activate.
To check the operation of the fans:
• Check the lters every year. Clean the lters with water and a mild detergent, such as
dish soap.
• Compressed air can be used to clean the lter provided the nozzle is held at least
6" away from the lter, the pressure is no greater than 60 psi, and the air is blown
through the lter opposite the airow direction as indicated by the arrow stamped on
the lter frame.
If the fan does not turn or does not operate smoothly, replace it.
Replacing a Ventilation Fan
The ventilation fan is mounted behind the LED modules. If a fan fails, follow the
instructions below to remove and replace it:
1. Turn off power to the sign.
2. Disconnect the fan’s power cord.
3. Remove the hardware securing the fan guard and fan to the fan bracket and
remove the fan.
4. Attach the new fan to the bracket and secure it using existing hardware.
Note: Take note of the airow orientation when attaching the new fan. Air should
be owing out of the sign.
5. Reconnect power to the fan and to the sign.
6. Test the fan momentarily to be sure it runs properly.

Maintenance and Troubleshooting
11
Routine/Preventative Maintenance
The service intervals listed in this section are recommendations. These service intervals
can be adjusted if necessary due to special considerations. Contact Daktronics
Customer Service for recommendations based upon specic conditions.
Sign Cabinet Inspection
At least once every year:
• Check for evidence of water intrusion in the sign, (i.e., water stain marks).
• Check for any leaks that may have developed. Seal them with a silicone sealant or
another suitable sealer.
• Inspect all module gaskets for tears, missing pieces, etc. Replace as necessary.
• Check the drain holes in the bottom of the cabinet to ensure they are unobstructed.
Sign Controller
At least once every year:
• Ensure all connectors are secure and the cables are not damaged in any way.
• Check the operation of the sign controller.
Structural Inspection
At least once every year:
• Inspect the mounting structure thoroughly for signs of corrosion, loose bolts, and
overall stability.
• Check the connections of the earth-ground wires, if accessible.
Photo Sensor Assembly Inspection
At least once every year:
• Inspect the light sensor assembly for foreign material that could obstruct airow
around the photo sensors.
• Clear away any foreign material.
LED Cleaning
If needed, clean the LEDs with a damp cloth or a soft brush. Do not spray cleaner directly
onto the LEDs. The frequency the LEDs need cleaning depends on site conditions.
Ventilation System Inspection
At least once every year check that all the fans run.
To do this, note the setting on the cooling thermostat and then turn it clockwise until the
fans turn on. Make sure all fans are running. Press the black button to test the thermostat.
After opening the intake fan assembly, check the fan blades for dirt and debris. If the fan
blades have a large accumulation of dirt and debris, change the lters more often. Keep
the fan blades clean to maintain fan efciency and ensure proper cooling. Next, spin
the fan blades with a pen or pencil to ensure the bearings are free and the fan is still in
balance.
Check and clean lter as necessary.

Maintenance and Troubleshooting
12
Routine/Preventative Maintenance Checklist
Refer to the instructions in each step above. One copy of the following table can be
lled out for each sign.
Sign Location:
Maintenance Item
Monthly
Remote
Diagnostics
1 yr. As Needed Dates Performed and
Initials
Connections are Secure X
Sign Enclosure Inspection X
Structural Inspection X
Photo Sensor Inspection X
Face Panel Cleaning X
LED Cleaning X
Venilation System Inspection X
Internal Hardware Tight X
LED & Electronic Test X
Troubleshooting of the Variable Speed Limit Sign
Contact your local service representative or Daktronics Customer Service at the number
listed on the cover of this manual for further troubleshooting assistance.
Problem Observed Possible Cause Solution
No LEDs will light and the
sign controller will not
communicate with the central
controller.
No power. Check that the sign has power.
Sign controller or modem is
bad.
Refer to Sign Controller
Replacement (p.8).
No LEDs will light, but
the central controller is
communicating with the sign
controller.
No power at the sign.
Check that the circuit breakers
and power supply in the
trafc cabinet are on and not
tripped.
Sign controller is bad or not
connected to the sign.
Refer to Sign Controller
Replacement (p.8).
One module is “dead”—no
LEDs will light.
4-pin connector unplugged at
module. Plug in connector.
Terminal is bad or not fully
seated in 4-pin plug at module,
or wire is bad.
Inspect all wires and terminals
for 4-pin plug. Repair as
needed.
One module is garbled, too
bright, too dim, erratic, etc.
Terminal is bad or not fully
seated in ribbon cable plug at
module, or wire is bad.
Inspect all wires and terminals
for ribbon cable plug. Repair
as needed.

Maintenance and Troubleshooting
13
One pixel will not light.
Terminal is bad or not fully
seated in plug at module, or
wire is bad.
Repair as needed.
The module is bad. Replace failed module.
One pixel will not turn off. The module is bad. Replace failed module.
Ventilation fan is not running.
Temperature inside the sign
is lower than the thermostat
setting.
This is not a problem.
The thermostat or its wiring is
bad. Repair as needed.
Fan is bad. Replace fan.
Ventilation fan is running
continuously.
Temperature inside the sign
exceeds the thermostat
setting.
This is not a problem.
The thermostat is stuck on or
the wiring is shorted.
Replace the thermostat or
repair wiring.
LED brightness is wrong—entire
sign is too bright or too dim.
Light sensor assembly is
obstructed.
Clear obstruction.
One or more wires or terminals
in the light/temp control
cable are misplaced, open or
shorted to other wires or the
frame in sign, sign controller, or
control cable from sign to sign
controller.
Repair as needed.
Operator error—light sensor is
not enabled or levels are set
incorrectly.
Correct settings.
Light sensor PCB is bad. Replace light sensor.
Sign controller is bad. Refer to Sign Controller
Replacement (p.8).

Replacement Parts and Repair & Exchange Programs
14
6 Replacement Parts and Repair & Exchange
Programs
The following labeling formats might be found on various Daktronics drawings:
• “TB_ _” denotes a termination block for power or signal cable.
• “F_ _” denotes a fuse.
• “J_ _” denotes a power or signal jack.
• “P_ _” denotes a power or signal plug for the opposite jack.
Daktronics part numbers are commonly found on drawings. Those part numbers can be
used when requesting replacement parts from Daktronics Customer Service. Take note of
the following part number formats.
• “0P-_ _ _ _-_ _ _ _” denotes an individual circuit board.
• “0A-_ _ _ _-_ _ _ _” denotes an assembly. An assembly can be a single circuit
board or a collection of components that function together, usually mounted on
a single plate or in a single enclosure.
Most circuit boards and components within this sign carry a
label that lists the part number of the unit. If a circuit board
or assembly is not listed in the replacement parts list, use
the label to order a replacement. A typical label is shown in
Figure 8. The part number is in bold.
Daktronics Exchange and Repair and
Return Programs
To serve customers’ repair and maintenance needs, Daktronics offers both an Exchange
Program and a Repair & Return Program.
Exchange Program
Daktronics unique Exchange Program is a quick service for replacing key parts in need
of repair. If a part requires repair or replacement, Daktronics sends the customer a
replacement, and the customer sends the defective part to Daktronics. This decreases
display downtime.
Before Contacting Daktronics
Identify these important part numbers:
Display Serial Number:
Display Model Number:
Contract Number:
Date Installed:
Location of Sign (Mile Marker Number):
Daktronics Customer ID Number:
Figure 8: Typical Label

Replacement Parts and Repair & Exchange Programs
15
parts that have been damaged due to acts of nature or causes other than normal
wear and tear.
Repair & Return Program
For items not subject to exchange, Daktronics offers a Repair & Return Program. To send
a part for repair, follow these steps:
1. Call or fax Daktronics Customer Service:
Refer to the appropriate market number in the chart listed on the previous page.
Fax: [phone]
2. Receive a case number before shipping.
To receive a case number, contact a services coordinator via phone, email, or by
creating a MySupport account on the Daktronics website. This expedites repair of the
part.
3. Package and pad the item carefully to prevent damage during shipment.
Electronic components, such as printed circuit boards, should be placed in an
antistatic bag before boxing. Daktronics does not recommend using packing
peanuts when shipping.
4. Enclose:
• your name
• address
• phone number
• the case number
• a clear description of symptoms
To participate in the Exchange Program, follow these steps.
1. Call Daktronics Customer Service:
2. When the new exchange part is received, mail the old part to Daktronics.
If the replacement part xes the problem, send in the problem part which is being
replaced.
a. Package the old part in the same shipping materials in which the replacement
part arrived.
b. Fill out and attach the enclosed UPS shipping document.
c. Ship the part to Daktronics.
3. A charge will be made for the replacement part immediately, unless a qualifying
service agreement is in place. In most circumstances, the replacement part will be
invoiced at the time it is shipped.
4. If the replacement part does not solve the problem, return the part within 30 working
days or the full purchase price will be charged.
If, after the exchange is made the equipment is still defective, please contact
Customer Service immediately. Daktronics expects immediate return of an exchange
part if it does not solve the problem. The company also reserves the right to refuse
Market Description Customer Service Number
Department of Transportation, mass transits,
airports, parking facilities 800-833-3157

Replacement Parts and Repair & Exchange Programs
16
Shipping Address
Daktronics Customer Service
Case #____________
331 32nd Ave
Brookings, SD 57006
E-mail
[email protected]