North America Traffic PTL 2.4 Series User manual
PTL 2.4x
Portable Traic Signal Manual
REV 07 02.10.22
THE LEADER IN TRAFFIC CONTROL SYSTEMS
TM
I
Gen 3 controller software version: V39 08.08.19
LIMITED RIGHTS
Copyright © 2022 by North America Traffic Inc. All rights reserved, including the right to reproduce
this manual or portions thereof in any form whatsoever. Information contained in this manual is
considered “confidential” and is not available to the general public. It is a condition of the sale or rental
of any portable traffic control device that this information remains “confidential” at all times. For more
information, please contact North America Traffic.
DISCLAIMER
This manual is produced without any kind of warranty. Improvement and changes in this manual due to
typographical errors, inaccuracies in current information or improvements to programs and/or equipment
may be made at any time without notice. The user is responsible for verifying use of the latest version by
contacting North America Traffic.
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS
You can help improve this manual. If so, please let us know if you find any mistakes or if you know of a
way to improve the content of this manual. Mail your letter or recommendation directly to:
North America Traffic
7 Petersburg Circle
Port Colborne, Ontario, Canada L3K 5V5
Toll free: 1-877-352-4626 (USA and Canada)
Phone: 905-835-0800
Fax: 905-835-0453
info@northamericatraffic.com
C
I 1
1 S O 3
1.1 T 3
1.2 T 3
1.3 S W Z 3
1.4 E H 3
1.5 B H 4
1.6 O H 4
2 T D 5
3 C B 6
3.1 T 6
3.2 C I 8
4 P S/T 9
4.1 S 9
4.2 T 12
4.3 M L L P 15
4.4 O L 16
4.5 S H R 17
5 C N 18
5.1 C H 18
5.2 C S 19
5.3 SYSTEM P 19
5.4 I S N 20
6 M S 21
6.1 C T 21
6.2 W Z S 22
6.3 O 23
6.4 S O 25
6.5 H 25
7 S UW Z 27
7.1 L (B M)28
8 A M 34
8.1 N 34
8.2 NEMA D 35
8.3 E P 36
8.4 T D D W O 38
8.5 O A M 39
8.6 E S 40
9 C M 42
9.1 S C M G 3 43
9.2 O W G 1 44
9.3 O G 2 45
10 D M 46
10.1 F/D L 46
10.2 S S D 47
10.3 S I/E 47
11 O E 48
11.1 R R 48
11.2 V D 50
11.3 R M S (RMS) 50
11.4 E V P 51
11.5 I I 51
11.6 D A 52
12 C 53
12.1 R S 53
12.2 H 53
13 P S I 54
13.1 S 54
13.2 B 54
13.3 C 56
13.4 G U 56
14 G M 57
14.1 T M S 57
15 T 59
16 P L 63
3SECTION 1
1 S O
1.1 T
All personnel operating the North America Traffic PTL 2.4x must be fully trained.
1.2 T
Prior to transporting the PTL 2.4x (either individually and/or in tandem) complete the following checklist
to ensure safety while in tow:
• All lock down points are secure including:
◦Horizontal and diagonal mast arm lock pins
◦Tongue hitch pins
◦Ball hitch coupler lock pin
◦Rear light post locking bracket
• Make sure there are NO “loose” objects sitting on the unit (check solar panel, top of battery box,
fenders, bumpers, tongue, etc.)
• The batteries inside the battery box are secured correctly with the battery hold-downs and the battery
box lid has been locked
• The solar array is in the correct position for travel
• The jacks are fully retracted and locked into place
• The controller cabinet door has been shut and secured
• The hitch safety chains are secured
• The connection for the trailer lights has been secured and tested (check right/left turn signals, hazard
lights and brake lights for correct function)
Drive ahead about 10 feet and do a final walk around to ensure that all lock down points are secure;
safety chains are crossed under the tongue and latched securely; and no tools or parts are sitting on the
machine.
DANGER
!
failure to ensure that all of the above precautions have been taken can result in injury and/or
death.
1.3 S W Z
It is the end user’s responsibility to ensure that advanced warning signs and barricades are used in
accordance with the local road authority guidelines.
1.4 E H
Before working on the electrical system, always disconnect the 24 VDC batteries (main power supply) and
the solar panel to avoid injury.
4SECTION 1
1.5 B H
Safety Precautions
Always use eye protection, a face guard and rubber gloves when working with batteries. Have an eye
wash kit available at all times or tap water to flush acid out of eyes. Always have water and baking soda
available to wash off and neutralize acid when it comes in contact with skin. If acid is taken internally,
drink large amounts of water and seek medical attention immediately.
Gas Explosion or Fire
Batteries release an explosive hydrogen gas while being charged. Keep cigarettes, sparks, flames, and any
other ignition sources away at all times.
Acid Burns
Battery acid can cause burns if it comes in contact with exposed skin and can cause blindness when in
contact with your eye(s). Always wear protective goggles and gloves when working with batteries.
Electrical Burns
An electrical short between the positive and negative terminals of the battery can cause severe burns and
death, even though the voltage is low.
1.6 O H
Prior to setting up the machine, ensure there is sufficient clearance to raise and lower the light post safely.
5SECTION 2
Actuation – Traffic actuation allows traffic flow to
control green times within specified timing param-
eters. A microwave traffic sensor, video detection
or other actuation device, is attached to the ma-
chine which detects approaching traffic. When a
vehicle is detected, the sensor sends a command
to the controller putting that phase in queue (refer
to Sensor Locking for further options). Only one
signal in a phase needs to detect a vehicle in order
for that phase to be placed in queue.
Phase – a movement of traffic that consists of a
green, yellow and red clearance interval.
Cycle – the total time to complete one operation
of all phases.
Queue – is an ordered series of upcoming phases
that are created when vehicles are detected by a
vehicle detector. Each phase in queue will become
active in sequence once the preceding phase is
complete.
Turn Phases:
Protected – assigns the right-of-way to drivers
turning left and allows turns to be made only
on a green arrow display.
Permissive – operation requires left-turning
drivers to yield to oncoming (or conflicting) ve-
hicle and pedestrian traffic before completing
the turn. A permissive left turn is served con-
currently with the adjacent through movement.
Protected-Permissive – operation represents
a combination of the permissive and protected
modes. Left-turning drivers have the right-of-
way during the protected left-turn phase. They
can continue left turn movements “permis-
sively” when the opposing through movement
receives its circular green indication.
Signal Housings:
High-High – one traffic light is positioned
5.2m (17ft) above the roadway and the sec-
ondary traffic light is 5.2m (17ft) above the
shoulder of the road.
High-Low – one traffic light is positioned 5.2m
(17ft) above the roadway and the secondary
traffic light is 2.7m (9ft) above the shoulder of
the road.
2 T D
6SECTION 3
3 C B
3.1 T
1. LED Signal Lamps and Housing
• 12” diameter, LED lamp module with high-flux lensing and complies with ITE standards.
• ITE certified polycarbonate housing with an aluminum backboard.
• Standard ball cap visors extend over each LED lamp by 10” (tunnel visors available).
• Back Lamp: 4” amber LED lamp mounted on the signal head provides phase status to workers in the
construction zone. Behavior is displayed as:
◦Flashing = Phase status is GREEN
◦Solid = Phase status is AMBER or RED
2. Horizontal Mast Arm
• The galvanized/painted, steel telespar arm that contains the signal head(s) that are positioned over
the roadway when fully deployed.
3. Communication Link (Radio Transceiver)
• A Radio Transceiver is installed in each PTL 2.4x Unit in order for the units to communicate.
• The Radio Transceiver is a 1-Watt system designed to communicate up to 1 mile (with line of sight).
◦The Unit operates on the approved frequency range as per the MUTCD/FCC Part 90.17 – (910
MHz - 917 MHz spread spectrum, frequency hopping) – No FCC licensing required.
12
4
3
5
6
8
7
7SECTION 3
• High gain omni-directional antenna (standard on every trailer).
4. Diagonal Mast Arm Support
• the square, aluminum arm that connects the Horizontal Mast Arm to the Main Light Post.
5. Main Light Post
• the round, aluminum post. When deployed, this post sits in the vertical position.
6. Solar Array
• The solar panels supplied with every PTL 2.4x unit provides 400 Watts of power and are housed in
an anodized aluminum frame.
• The solar energy is sent to the solar panel controller which then transfers the power to the battery
bank.
• The energy generated by the solar panel assists in extending the autonomy of the unit – not to
charge the batteries to their maximum capacity; a full charge is achieved by using the 40 Amp smart
charger.
7. Power Supply
• Power is supplied by either twelve (12) or sixteen (16) – 6 Volt deep cycle batteries, in series-parallel
to generate 24 VDC.
• Batteries are charged using the 40 Amp smart charger (external plug provided near cabinet door
providing easy access for connection to a 120 VAC source).
• Batteries receive some assisted energy supplied by the solar array – for more information see: item
6. Solar Array above.
Note: For more detailed information pertaining to batteries, charger, and solar array, refer to SECTION 13
POWER SYSTEM INFORMATION.
8. Trailer Section Components
• The Trailer Section for the PTL 2.4x includes the following features:
◦#10 Dexter torsion bar suspension axle
◦ST205/75R15 tires
◦Electric brakes
◦Removable tongue with two (2) locking pins
◦Four flat-mount screw jacks to level and stabilize
◦All electrical and lighting requirements for highway driving
◦2” Hitch Ball Coupler on tongue; 2” Ball Hitch mounted on rear frame for tandem towing
• The frame structure and all supports are welded and inspected by certified welders, implemented
under ISO 9001:2015 guidelines.
• Approved for use on highways.
8SECTION 3
3.2 C I
1. Controller – controls all functions of the PTL 2.4x.
2. Transfer Flasher Relay (TFR) – transfers control
of the local signal indications in the event of a
fault.
3. Wiring Conduit – protected channel through
which wires are routed.
4. Terminal Block – all electrical inputs and outputs
are applied here.
5. Toggle Switches – main power on/off and lift
system control switches.
6. Battery Charger – used to charge the batteries
when unit is plugged into a 120 VAC power
source.
7. Solar Controller/Regulator – stabilizes and
transmits the energy collected by the solar panel
to the battery bank.
8. Fuse Block – fuses for all electrical functions.
9. Isolated Power Distribution Studs – the
distribution point to which power from the
batteries, solar array and battery charger is
connected to the signal control system and
peripheral hardware.
2
1
3
4
3
6
8
9
3
7
5
9SECTION 4
4 P S/T
CAUTION
!
ALWAYS check for overhead power lines or ulity
lines in the immediate area to avoid contact with the
light post and actuated mast arm. Move the machine
to another locaon if necessary;
ALWAYS raise the light post first, before extending
out the horizontal mast arm. Failure to do so may
place undue stress on the lisystems mechanics.
Use Traffic Control Persons to control traffic flow when
deploying and raising the light posts.
4.1 S
1. Put the PTL 2.4x in position on the side of the
road.
2. Level and stabilize each unit with the four
stabilizing jacks.
a. Remove cotter pin from locking pin.
b. While holding the base of the screw jack,
remove locking pin.
c. Place base of screw jack on the ground.
d. Line up the nearest holes on the screw jack
and put the locking pin through.
e. Secure locking pin with cotter pin.
f. Turn crank until screw jack is firmly on the
ground.
g. Repeat for each screw jack.
h. Once completed, do a walk around and
check to make sure none have lifted off the
ground, and that the trailer is level.
3. Disconnect PTL 2.4x tongue from the hitch of
the towing vehicle.
4. Remove the wheels for added security using a
standard tire iron (optional).
5. Remove the tongue from the front of the unit
for added security (optional).
Note: The tongue weighs about 90 lbs, so 2 people
may be needed.
a. Unplug the running light cable from trailer.
b. Remove locking pins from the tongue.
c. Firmly pull tongue forward until it is removed
from the trailer.
d. Place tongue in safe location to prevent
damage.
CAUTION
!
CAUTION
!
10SECTION 4
6. Unlock the mast arm from the mast arm
support and move it into position.
a. Remove cotter pin from locking pin.
b. Remove locking pin.
c. Swing the mast arm towards the front of the
machine.
d. Line up holes on mast arm with holes on
mast arm support.
e. Put locking pin in hole.
f. Put cotter pin in locking pin.
7. Unlock the mast arm support from the signal
post and move into position.
a. Remove cotter pin.
b. Remove locking pin.
c. Swing mast arm support towards the rear of
the signal.
d. Continue swinging the mast arm until it stops
at the signal post.
8. Raise the main light post.
Note: Ensure there is no overhead wires or
obstructions when raising the main light post.
11SECTION 4
a. Ensure the lock bar is open.
b. Open the control cabinet.
c. On the switch plate, use the LIGHT POST
toggle switch to raise the light post.
d. Once the signal has been raised and is
between the vertical supports, place the lock
bar in place and lock with the pad lock
provided.
e. Once the main light post is deployed and
locked in the vertical position, use the
HORIZONTAL ARM toggle switch to extend
the 17 foot signal housing over the roadway
by an additional 44 inches.
9. Position the solar panels.
a. Using a 9/16” wrench, loosen the nuts found
on each side of the solar panel support.
b. Tilt the solar panels to a 45° angle.
0°
15°
30°
45°
60°
5°
10°
20°
25°
35°
40°
50°
55°
c. Tighten the nuts on both sides of the solar
panel support to secure the panels at a 45°
angle.
d. Loosen the solar panel horizontal lock bolt
using a 3/4” wrench.
e. Rotate the solar panel array until it is facing
south and re-tighten the bolt.
12SECTION 4
4.2 T
CAUTION
!
ALWAYS check for overhead power lines or ulity
lines in the immediate area to avoid contact with the
light post and horizontal mast arm.
CAUTION
!
ALWAYS retract the horizontal arm first, before
lowering the light post. Failure to do so may place
undue stress on the lisystems mechanics.
Use Traffic Control Persons to control traffic flow when
lowering the light post system.
1. Position the solar panels in towing mode.
a. Loosen the solar panel horizontal lock bolt
using a 3/4” wrench.
b. Rotate the solar panel array until it is square
with the trailer.
c. Using a 9/16” wrench, loosen the nuts found
on each side of the solar panel support.
d. Tilt the solar panels until it is at 0°
(horizontal).
e. Tighten the nuts on both sides of the solar
panel support to secure the panels at a 0°
angle.
0°
15°
30°
45°
60°
5°
10°
20°
25°
35°
40°
50°
55°
2. Lower the signal post.
a. Unlock the pad lock and open the signal post
lock bar.
b. Open the control cabinet. Using the
HORIZONTAL ARM toggle switch, retract the
signal housing on the horizontal mast arm.
c. Lower the main light post using the LIGHT
POST toggle switch until it rests on the
horizontal support.
3. Move mast arm support into towing position.
a. Using the signal head, swing the mast arm
support around towards the signal post.
b. Once it is over the trailer, step up onto the
trailer.
CAUTION
!
13SECTION 4
c. Push up on the mast arm support to place in
between the supports and line up holes for
locking pin.
d. Put locking pin into holes.
e. Put cotter pin into locking pin.
4. Move mast arm into towing position.
a. Remove the cotter pin from the locking pin.
b. Remove the locking pin.
c. Swing mast arm toward the mast arm
support.
d. Push up on the mast arm to place in between
the supports.
e. Put locking pin in holes.
f. Put cotter pin in locking pin.
5. Place tongue on machine.
a. Position tongue in front of machine.
b. Firmly slide tongue into trailer until the front
and rear holes are lined up.
c. Insert the two locking pins.
14SECTION 4
d. Secure the locking pins with cotter pins.
e. Plug in the trailer running light plug.
6. Raise screw jacks.
a. Connect trailer to truck using the ball hitch
coupler.
b. Crank the screw jack until the base is off
the ground.
c. Remove cotter pin.
d. While holding the base of the screw jack,
remove locking pin.
e. Raise the base until the bottom hole is lined
up with the main locking hole.
f. Put the locking pin in the screw jack locking
hole.
g. Put the cotter pin in the locking pin.
h. Repeat for all screw jacks.
15SECTION 4
4.3 M L L P
The main light post and horizontal mast arm will need to be manually lowered in the event of:
• Dead batteries
• Actuator failure (inoperable)
Note: Use traffic control persons to control traffic flow when lowering the main light
post and retracting the horizontal mast arm. There are TWO Models of Actuator, that
could be potentially installed on your unit. They have different take-down procedures.
Review the different models below before take-down.
WARNER LINEAR / THOMSON ACTUATOR
Tools Required: 3/16” Allen wrench, 1/4” drive ratchet with an extension or, to save
time, a drill with at least an 8” extension.
Remove silver access cap on the actuator motor housing using a 3/16” Allen wrench.
Using the 1/4” drive extension at least 8” in length, lower the main light post until it
reaches the holding bracket (to prevent stripping, set the drill to a low clutch setting).
If required, repeat the process for the horizontal mast arm to retract the light housing
extension.
PROGRESSIVE AUTOMATION ACTUATOR:
Tools Required: T 30 Torx bit, 6mm hex bit with an extension or, to save time, a drill with at
least an 8” extension.
Use the T-30 Torx bit to remove silver access cap on the actuator motor housing. Using the
6mm hex bit and drive extension, turning counterclockwise, lower the main light post until
it reaches the holding bracket (to prevent stripping use the drill set to “screw” mode or the
highest clutch setting). If required, repeat the process for the horizontal mast arm to retract
the light housing extension.
16SECTION 4
4.4 O L
Always check for overhead power lines or utility lines in the immediate area to avoid contact with the
trailer and light post. Also make sure there is enough clearance beside the machine when the mast arm is
swung open.
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CAUTION
!
• The PTL 2.4x weighs 2940 lbs (1334 kg). Ensure all lifting and rigging equipment is rated to lift the load.
• Failure to follow this instruction can result in damage to the trailer and associated equipment.
1. Open mast arm assembly to horizontal position (see Fig. 2, 3).
Note: Do not lift trailer with the light post in the vertical position.
2. Tilt the solar array to 60° (see Fig. 2, 3).
3. Connect straps as per trailer signal housing configuration (see Fig. 2, 3).
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Rigging
Rigging
Rigging
17SECTION 4
4.5 S H R
The PTL 2.4x signal heads have the ability to turn
180° and face the opposite direction. This allows
the unit to be placed on the opposite side of the
road in the event that there is little to no shoulder.
High-Low
1. Remove the cotter pin and locking pin from the
mast arm support.
2. Swing the mast arm towards the front of the
machine.
3. Remove the bolt shown from the signal housing
bracket. Loosen the other bolt if needed.
4. Pivot the signal head 180° and replace the bolt
back into the corresponding hole.
5. For the lower signal head on the main light
post, repeat steps 3-4.
High-High
1. Repeat steps 1-4 from the High Low instruction
for the outside signal head.
2. For the other signal head located on the mast
arm, remove both bolts as shown.
3. Stand up on the fender of the machine and flip
the signal head 180° and replace both bolts.
4. Ensure all bolts are tightened.
18SECTION 5
5 C N
5.1 C H
1. Soft Buttons – these 10 buttons
have no specific assigned values.
They will have a different value on
each screen.
2. BACK Button – returns to the
previous menu screen.
3. L.E.D. Status Lights:
ALERT - indicates whether there is a
fault or error message.
Note: Alert light will be illuminated for
15 seconds following power down of
the system.
BUSY - USB in use, settings being
saved or copied, unit warming up.
ON - power indication.
4. ENTER Button – used to
confirm a selected value or
open a parameter for editing.
5. Directional Buttons – allows the
user to toggle through menus,
various screens and cycling through
parameters open for editing.
6. USB Port – used to import/export
software files, traffic control plans
and fault/data logs.
7. J-Plugs (J1/J2) – I/O connections
to the terminal block by means of
wire harnesses.
8. Serial Port (J0) – connection to
radio transciever.
9. Speaker – emits audible notification
to user when buttons are pressed.
Also emits loud beeping when
batteries are low.
6
7 8 7
9
ALERT
ON
BACK
BUSY
Gen 3 Controller
ENTER
J1 J2J0
www.NorthAmericaTrac.com
2
1
5
4
3
Under Side
19SECTION 5
5.2 C S
The systems tray will display pertinent information that is always visible.
1. System Feedback – this will display any instructions, faults or error messages that occur.
2. Battery Voltage – displays the current battery voltage.
3. Unit Identifier – displays the machine designation, either Primary or Secondary X.
4. Radio Channel – will display the current radio channel or show if the machine is hardwired.
5. Radio Signal Strength – displays the signal strength percentage in 25% increments. This is a
combination of radio signal strength and rate of data transfer within the network.
6. Menu Path – this section displays where the user is located in the software.
7. Program Version – will display the model of the unit and software version number.
8. Date and Time – in the OPTIONS menu, the date and time can be set (HOME>OPTIONS PG 2).
5.3 S P
To create a new passcode, go into options and scroll down to SET NEW
PASSCODE . A prompt will appear to enter the
current passcode. From factory, this passcode is:
0 – 8 – 0 – 0
Once this is entered, a prompt will appear to enter a new passcode. If your custom passcode is ever
forgotten, call North America Traffic: 1-877-352-4626.
After a new passcode is set, in order to alter any settings, the software will need to be unlocked. This can
be accomplished either by unlocking the software via the OPTIONS menu or by selecting any option to
edit. Once selected, a prompt will appear to enter the passcode.
After assigning a custom passcode, if you wish to use additional
unit(s) in conjunction with the current unit in operation, you must
reprogram the additional unit(s) to the SAME SYSTEM PASSCODE.
FEB/01/17 09:53AM
PROGRAM: MODEL V##
HOMEBATTERY: 24.0 VOLTS
UNIT: PRIMARY RADIO CHANNEL: 03 RADIO SIGNAL:
DEFAULT ALL RED
PRESS START TO RESUME
26
54
3
17
8
D
ATE
&
TIM
E
FEB/01/17 09:53AM
PROGRAM: MODEL V##
HOME > OPTIONS PG 2
BATTERY: 24.0 VOLTS
UNIT: PRIMARY RADIO CHANNEL: 03 RADIO SIGNAL:
DEFAULT FLASH RED
PRESS START TO RESUME
CO
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FU
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FTWAR
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MP
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RT/EXP
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T
NEXT
P
A
GE
PREV
P
A
GE
LOC
K
SO
FTWAR
E
ENTER THE NEW
PASSCODE
TO MOVE CURSOR,
PRESS ENTER WHEN DONE
# # #
0
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