Daktronics Fuelight FL-4000 Series User manual

201 Daktronics Dr. PO Box 5128 Brookings SD 57006
Tel 888-DAK-SIGN (888-325-7446) Fax [phone]
www.daktronics.com
Fuelight™FL-4000 Series
Petroleum Price Displays
Installation & Operation Manual
DD1398943 Rev 5—22 July 2011

DD1398943
Product 1478
Rev 5 – 22 July 2011
Complete the chart with specific information about this display so the details are readily available
when calling for service or replacement parts.
daktronics
Copyright 2008-2011
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.
Fuelight™and Fuelink™are trademarks of Daktronics, Inc. Other trademarks used in this manual are the property of their respective
owners.
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Table of Contents i
Table of Contents
Section 1: Introduction................................................................................................................. 1
1.1 Display Overview ...................................................................................................................1
1.2 Safety Precautions...................................................................................................................2
Section 2: Mechanical Installation ..............................................................................................3
2.1 Support Structure Design ......................................................................................................3
2.2 Ventilation and Temperature Requirements.......................................................................3
2.3 Installing the Display..............................................................................................................4
Section 3: Power Installation.......................................................................................................5
3.1 Power Requirements ..............................................................................................................5
3.2 Grounding................................................................................................................................6
3.3 Power Installation ...................................................................................................................7
Section 4: Signal Installation....................................................................................................... 9
4.1 Signal Installation....................................................................................................................9
LED Driver........................................................................................................................9
Signal Wiring....................................................................................................................9
Driver Rotary Switch Line and Face Settings.............................................................10
Section 5: Control Options ........................................................................................................11
5.1 FLR-100 Control Kit ..............................................................................................................11
Editing the Display ........................................................................................................11
Increasing the Price........................................................................................................11
Decreasing the Price ......................................................................................................11
Rapid Increase/Decrease..............................................................................................11
5.2 FLR-500 Control Kit ..............................................................................................................12
Transmitter Use..............................................................................................................12
Petroleum Price Display Startup .................................................................................13
Petroleum Price Transmitter Operation .....................................................................13
Modifying Price Line Settings......................................................................................14
Dimming .........................................................................................................................15
5.3 FLR-1500 and FLD-2000 (Outdoor/Indoor) Control Kits ...............................................16
FLR-1500 Connection ....................................................................................................16
FLD-2000 Connection to the Display (Outdoor and Indoor) ...................................17
DM-100 Insert and Code...............................................................................................18
Petroleum Price Display Startup .................................................................................18

ii Table of Contents
DM-100 Controller Operation ......................................................................................19
Section 6: Maintenance and Troubleshooting .........................................................................23
6.1 Component Location and Access........................................................................................23
Visual Structural Inspection .........................................................................................23
6.2 Display Diagnostics ..............................................................................................................24
Driver Diagnostic LEDs ................................................................................................24
Power-up Self Test .........................................................................................................24
6.3 Troubleshooting ....................................................................................................................25
Section 7: Replacement Parts....................................................................................................27
7.1 About Replacement Parts.....................................................................................................27
Section 8: Daktronics Exchange and Repair & Return Programs..........................................29
8.1 Exchange Program ................................................................................................................29
Before Contacting Daktronics ......................................................................................29
8.2 Repair & Return Program ....................................................................................................30
Shipping Address ..........................................................................................................30
Glossary ....................................................................................................................................31
Appendix A: Reference Drawings..................................................................................................33
Appendix B: Daktronics Warranty and Limitation of Liability....................................................35

Introduction 1
Section 1: Introduction
1.1 Display Overview
The Fuelight™model number is described as follows:
FL-4000-HH-C-NA-DI
FL-4000
= Outdoor Fuelight™digit display
HH
= Digit height in inches
C
= Color: R=Red, A=Amber, G=Green
NA = Not Applicable
DI = Drop In
The FL-4000 series includes
standard petroleum price displays,
employing a variable tenths digit.
The Petroleum Price displays are
“drop-in” displays, designed for
installation in an existing or
custom sign. Fuelight™cabinets,
specially developed for outdoor
use, are constructed of heavy-
gauge aluminum and feature black
faceplates. Displays are set directly
into the surface of the sign.
Fuelight™displays use LEDs to illuminate their numeric digits. LEDs are high-intensity, low-
energy lighting units. All Fuelight™displays are configured with amber, green, or red LEDs.
Figure 1shows an example of a Fuelight™FL-4000 display.
Figure 1: FL-4000 Display

2 Introduction
Fuelight™outdoor LED displays have
been designed for use with the FLR-100,
FLR-500, FLR-1500, and FLD-2000
communication kits.
In this manual, each individual side of
the sign structure will be referred to as a
“face.” Each face may consist of several
displays. Refer to Figure 2for an
example.
1.2 Safety Precautions
•Please read and understand
installation instructions before
installing.
•Do not drop control equipment or
allow it to get wet.
•Do not disassemble control
equipment or electronic components
of the display; failure to follow this safeguard will make the warranty null and void.
•Disconnect display power before servicing power supplies to avoid electrical shock.
•Make certain that the display is properly grounded with an earth ground electrode at the
display.
Figure 2: Face with Digit Displays

Mechanical Installation 3
Section 2: Mechanical Installation
Important Notes:
•Read and understand these instructions before installing the display.
•Properly ground the display with a ground rod at the display location.
•Disconnect power when servicing or not using the display.
•Do not modify the display structure or attach any panels or coverings.
2.1 Support Structure Design
FL-4000 displays are designed to be mounted into a larger sign structure. The sign must
prevent water from entering the back and sides of the display. Daktronics is not responsible
for operational failure due to water entering the sign.
Daktronics is not responsible for the support structure or for quality of the mounting
hardware used to attach the displays to the support structure. Structure and attachment must
conform to all applicable building codes.
Important Notes:
•It is the customer’s responsibility to ensure the installation will meet local standards.
•The mounting hardware must support all components.
•Be sure that any sprinkler systems near the display are pointed in a direction as to
not spray the front of the display.
2.2 Ventilation and Temperature Requirements
Fuelight™Petroleum Price digit displays are front ventilated. The display must NOT be fully
enclosed inside a support structure or sign or behind a sign face of plastic, glass, or other
material. The front of the display must be exposed to the air to allow for convection cooling.
Fuelight™Petroleum digit displays are designed to operate in ambient temperatures ranging
from -40oF to +120oF. However, the overall sign structure should be designed and ventilated
in a way to keep the interior of the sign cabinet at a temperature not to exceed 140oF.
Items to consider when designing a sign package to house LED price displays include:
•Solar gain from the black face of the price displays
•Solar gain from other sign cabinet surfaces
•Heat gain from electronics inside the displays
•Passive or active airflow with adequate intake and exhaust areas
Daktronics is not responsible for high-temperature failure due to inadequate ventilation.

4 Mechanical Installation
2.3 Installing the Display
Fuelight™Petroleum Price displays are
designed to be installed into pre-
fabricated sign cabinets. A rectangular
opening must be provided to
accommodate the display. Refer to the
appropriate Shop Drawing for
dimension requirements.
Displays can be hand lifted into the
support structure, refer to Figure 3for
an example.
Note: Daktronics assumes no liability
for display damage or injury resulting
from incorrect setup or incorrect lifting
methods.
Drill through the front flanges of the
cabinet to attach the display to the base
structure using appropriate hardware
for the site conditions. Actual site
demands will dictate variances and
appropriate mounting methods.
The structure design should only be done by a qualified individual. It is the customer’s
responsibility to ensure that the structure and the connectors are adequate. Daktronics is not
responsible for the installations or the structural integrity of support structures installed by
others.
Figure 3: Inserting Display into Custom Cabinet

Power Installation 5
Section 3: Power Installation
Important Notes:
•Only a qualified individual should terminate power and signal cable at the display.
•All proposed changes must be approved by Daktronics' engineering staff, or the warranty
will be void.
Shop Drawings show details on installation and access for electrical connections. Refer to the notes
on the appropriate Shop Drawing for electrical requirements of the display.
Daktronics Fuelight™displays’ front panels are hinged to allow access to the digits, cabling, and other
electronic components.
Note: Only qualified individuals should perform power routing and termination to the display. It is
the responsibility of the electrical contractor to ensure that all electrical work meets or exceeds local
and national codes. Improper installation could result in serious damage to the equipment and could
be hazardous to personnel.
3.1 Power Requirements
Do not connect displays to any voltage other than that listed on the Daktronics product label.
The dedicated 120 V circuit can be shared among all components of the sign structure
(including Fuelight™displays and fluorescent lighting), but not with other external electrical
devices (such as air compressors or island lighting). A dedicated circuit is defined as one hot,
one neutral and one ground wire. Maximum amperage will vary with the number and type
of digit displays connected. All local and national electrical codes must be followed during
electrical installation.
Note: It is critical that the display circuit be fused at 15 A and that all conductors used must
be designed to pass a 15 A current in normal operation. Failure to meet wiring and over-
current protection device requirements may violate local and national electrical codes and
will void the display warranty.
Conductors of circuits delivering power to a Daktronics display shall be sized in accordance
with local and national electrical codes so that the power distribution systems is capable of
delivering full load power to the display while maintaining a voltage within 5 percent of the
utility nominal voltage.

6 Power Installation
3.2 Grounding
Displays MUST be grounded according to
the provisions outlined in any applicable
local and national electrical codes and
according to the specifications in this
manual. Daktronics requires a resistance to
ground of 10 ohms or less.
The display system must be connected to an
earth-ground electrode installed at the
display, as shown in Figure 4. Proper
grounding is necessary for reliable
equipment operation and protects the
equipment from damaging electrical
disturbances and lightning. Refer to
Drawing B-329675 for more information on
grounding.
The display must be properly grounded, or
the warranty will be void.
Important points about grounding:
•Follow local and national codes: The material of an earth-ground electrode differs
from region to region and from conditions present at the site. Consult any local and
national electrical codes that may apply.
•Do NOT use the support structure as an earth-ground electrode: The support
structure is generally embedded in concrete. If embedded in earth, the steel is either
primed, or it corrodes, making it a poor ground.
•Provide one grounding electrode for each sign structure:The grounding electrode is
typically at least one grounding rod for each sign structure. Other grounding
electrodes as described in any applicable local and national electrical codes may be
used.
•Confirm that resistance to ground is 10 ohms or less: This is required by Daktronics
for proper display performance. If the resistance to ground is higher than 10 ohms, it
will be necessary to install additional grounding electrodes to reduce the resistance.
The grounding electrode must be connected to the ground wire inside the display.
Figure 4: Correct Grounding

Power Installation 7
3.3 Power Installation
Daktronics Fuelight™displays are installed using the provided ground and neutral
conductors. For this type of installation, the power circuit must contain an isolated earth-
ground conductor. Do not connect neutral to ground at the disconnect or at the display, this
would violate electrical codes and void the warranty. Use a disconnect so that all
ungrounded conductors can be disconnected.
To connect power to the display:
1. Connect power to the power harness (“pigtail”) inside the display; refer to Figure 5
for an example.
The power harness has a 5-pin plug at one end and three wires: black, white, and
green/yellow. The plug is connected to the mating plug on the transformer and
allows for easy disconnection of the power harness.
2. Use wire nuts to connect power wires to the power harness.
Figure 5: Power Harness

Signal Installation 9
Section 4: Signal Installation
4.1 Signal Installation
LED Driver
In the display, the LED driver performs the task of switching digits on and off. One driver at
each display installation is designated as the host driver (the driver with the antenna/signal
connection). This driver receives its signal directly from a control unit via the Signal In
connector (J12, J13, or J14). J12 is used with the FLR-500 and FLR-1500 control kits. J13 is used
with the FLD-2000 control kit on host drivers and for signal to client drivers. J14 is used with
the FLR-100 control kit.
Signal Wiring
Signal termination varies depending upon the type of
control kit included with the display. Signal from the
control transmitter/controller communicates with the
host driver. Signal then travels from J11 (output) on the
host driver to J13 (input) on the driver of the next face or
line.
1. Route cable to J12 (for FLR-500 or FLR-1500), J13
(for FLD-2000), or J14 (for FLR-100) on the host
driver within the host display, refer to Figure 6
for details.
2. Route the RJ14 cable from J11 OUT on the host driver to the next client display,
connecting at J13 IN.
3. Follow step 2 for all displays in the network.
Driver Connectors
J1
Power Out to Digit 1
J2
Power Out to Digit 2
J3
Power Out to Digit 3
J4
Power Out to Digit 4
J5
AC Power Input
J11 Signal Output (to client driver in next line of the
face)
J12 Host Driver Signal Input (for FLR-500 and FLR-
1500)
J13 Host Driver Signal Input (for FLD-2000) and
Client Driver Signal Input (from driver of
another line)
J14
Host Driver Signal Input (for FLR-100)
Figure 6: Driver

10 Signal Installation
Refer to the quick guide provided with the display for more information on signal
installation.
Quick Guide
Document Number
Quick Guide: FLD-2000 Control Kit Installation
DD1399090
Quick Guide: FLR-100 Control Kit Installation
DD1400918
Quick Guide: FLR-500 Control Kit Installation
DD1399078
Quick Guide: FLR-1500 Control Kit Installation
DD1399086
Driver Rotary Switch Line and Face Settings
The first driver at each display installation is designated as a host driver –
the driver with the antenna/signal connection. The host driver sends the
line information out to the client drivers.
Every driver must have a unique line and face setting (or “address”) that
identifies the face and line of the display.
The line and face numbers are set by turning the rotary switches located
on the driver at S1 and S2, refer to Figure 7 for locations. Set the line
number using S1 and the face number using S2.
All displays with the same line number will show the same price. For
example, two displays, one with a driver set to Line 1, Face 1 and one with
a driver set to Line 1 Face 2, will display the same price. Refer to Figure 7
for an example.
Figure 7: Rotary
Switches

Control Options 11
Section 5: Control Options
The FLR-100, FLR-500, FLR-1500, and FLD-2000 (indoor or outdoor) control kits can be used to
change petroleum prices displayed on the LED Fuelight™Petroleum Price displays. The instructions
provided in this section discuss the functions the operator uses to control the Petroleum Price display
with each control type.
5.1 FLR-100 Control Kit
The FLR-100 control kit can control four unique prices on multiple faces using an RC-50
transmitter and has a maximum range of 100 feet. The instructions provided in this section
discuss the functions the operator uses to control the displays.
Editing the Display
To edit the price on the display, press and hold any button for five seconds. When the display
is in Edit mode, the decimal LEDs blink.
On the transmitter, each pair of buttons corresponds to a price line on the display. Each line
is numbered to indicate the line it corresponds to.
Increasing the Price
To increase the price, press [+] for the
corresponding line.
Note: Make sure the display is in Edit
mode.
Decreasing the Price
To decrease the price, press [-] for the
corresponding line.
Note: Make sure the display is in Edit
mode.
Rapid Increase/Decrease
To rapidly increase or decrease a price,
press and hold the button for the
corresponding line.
Note: If no button is pressed for more
than 10 seconds, the display exits the
Edit mode. The prices are saved, and
the display returns to its normal state.
Figure 8: Transmitter

12 Control Options
5.2 FLR-500 Control Kit
The FLR-500 control kit includes a radio transmitting
device, a radio receiving device, and all hardware and
instructions.
The FLR-500 control kit programs petroleum prices
displayed on the LED Fuelight™Petroleum Price display
and has a maximum range of 500 feet.
Note: Although multiple wireless handheld transmitters
may be connected to a single wireless base station server,
the rate display application allows for only one handheld
device to be connected at a time.
Transmitter Use
The RC-100 transmitter can be configured to program
petroleum price displays. Refer to the control quick guide,
which came with the control kit, for information on the
correct setup of the FLR-500 Control Kit.
The RC-100 transmitter is charged by a wall pack
transformer. Plug the wall pack transformer into a 120
VAC power pack, and connect it to the transmitter. Once
charged, the RC-100’s operation time will vary depending upon how often it is used.
Figure 9: Transmitter

Control Options 13
Petroleum Price Display Startup
To operate the Fuelight™Petroleum Price displays, the transmitter must first be programmed
to the four digit “Rate Display” function. For programming, the display must be connected to
power and Press the <SET FUNCTION> key on startup and use the following table as a
guide to startup procedure.
LCD Screen Action
PRESS ENTER TO
SELECT A NEW
CODE
Press <ALT>, and then <NEW CODE> to select
a new price display function. Press <CLEAR> to
resume a new function. Use the <
↑↓
>arrow
keys to select the new price function; then press
<ENTER/EDIT>.
SELECT FUNCTION
RATE DISPLAY ↓↑
Press the arrow up or down keys <
↑↓
>until the
gas price option is shown. Press the
<ENTER/EDIT>key to accept.
The handheld transmitter should now be ready for use. The transmitter will “remember” the
last function setting, so this step should only need to be done with a new transmitter or one
that is configured for different displays.
Petroleum Price Transmitter Operation
The transmitter LCD display will default to showing the current display settings on power
up. The following text will be shown on the LCD.
LCD Screen Action
LINE PRICE
1 ↓$000.0
<EDIT> TO MODIFY
1 ↓$000.0
The display will toggle between these two
screens.
“000.0” represents the dollars and cents value
shown on a given line.
Press the up or down arrow keys <
↑↓
>to scroll
through the current setting for any of the lines
on the display.
Press the <ENTER/EDIT> key to modify any of
the line settings.

14 Control Options
Modifying Price Line Settings
The petroleum price can be modified either by pressing the <EDIT>key during operation or
using the <MENU>key. Refer to the following key to identify the item to be edited.
L = Current line number to be edited
000.0 = Current dollars and cents value to edit
LCD Screen Action
EDIT LINE L
$000.0 ↓
Press any of the number keys to edit the price
value for this line.
Press <ENTER/EDIT>to accept the new value
or press <CLEAR> to abort the changes.
Note: The flashing asterisk on the LCD shows
the current data being edited.
Press the down arrow key <
↓
>to modify the next
line, or press the <
↑↓
>keys to move to the next
or previous item on the list.