Pike RoboSign MK3 Manual

operator’s guide
PSL1285 issue 3 rev a
RoboSign
MK3

1
Contents
Introduction 2
Welcome 2
Important notes for operators 2
Cleaning 2
RoboSign features 3
Installation 4
Pre-installation checks 4
Setting up 4
High wind conditions 5
Operation 6
Operating the RoboSign system 6
One hour standby 6
Fault conditions 6
Operation sequence 6
Single sign operation 7
Troubleshooting 8
Batteries 9
Recharging the base units 9
Recharging the remote control 9
Replacing base unit batteries 10
Removing the electronics enclosure 11
Warranty 12
Environmental information 12
Disclaimers 12

2
Introduction
Welcome
THE RoboSign MK3 from Pike Signals provides a quick and
simple solution for controlling traffic through a temporary
works site.
Each RoboSign unit consists of a battery powered base box
topped with a pole-mounted Stop-Go board. Wireless signals are
used to link two RoboSign units with a remote control held by a
single operator.
With repeated presses of a single button, a sole operator can
progress the RoboSign units through their traffic phases in tune
with vehicle conditions and the availability of the shuttle lane.
All electronics enclosures of the RoboSign MK 3 system are
sealed and contain no user serviceable parts.
Caution
• Riskofexplosionifbatteriesarereplacedbyincorrecttypes.
• Disposeofusedbatteriesaccordingtotheinstructions.
• Seepage9forfurtherdetailsaboutbatterydisconnection.
• Thebaseunitsweighmorethan25Kg,donotattemptto
move one alone, always work together with a colleague.
• Signsmayrotateunexpectedly,alwaystakecarewhen
working near a base unit.
Cleaning
Wipetheexteriorofthebaseunitswithadampcloth.Donot
use pressure washers or steam cleaners.
Important notes for operators
Please ensure that you closely follow the instructions within this
manual when installing and operating the RoboSign MK 3 for
temporary traffic control. In particular, the following conditions
must all be met when operating the system:
• Itmustbedaylightwithgoodvisibility.
• Two-waytrafcowshouldnotexceed850vehiclesper
hour.
• Thebaseunitsmustbeplacednofurtherthan200metres
apart.
• Allrequiredpre-warningroadsignsmustbeinplace
according to the Regulatory Authorities guidelines covering
the use of manually operated Stop-Go board traffic control.
• Theoperatormusthaveasafeandcentralvantagepointwith
a clear view of both Stop-Go boards and oncoming traffic.
• Theoperatormustnotbemorethan100metresfromeither
base unit.
If any of these conditions cannot be met then the RoboSign MK
3 system must not be used. If any of these conditions change
during operation, you must cease using the system.
Thissystemmustbeinstalledandoperatedonlybyfullytrained
and experienced personnel. Always consult your supervisor
if you are in any doubt about correct procedures or if you are
concerned about safety. Equipment must only be repaired by
Pike Signals Ltd or authorised repair agents.

3
RoboSign features
TheRoboSignunitsandremotecontrolarecompactand
straightforward to set up and operate.
Stop-Go board
Corrosion-proof
materials used
throughout. Features
a quick release shaft
that prevents incorrect
alignment
(see page 5).
Radio antenna
Ensures good
signal linking
between units
(see page 4).
Sturdy handles
Designed to allow
straightforward
handling by two
people
(see page 4).
Outriggers
Provide stability against blow
overs. Sandbags can be added
in high wind conditions
(see page 5).
Front panel
RESET button (see page 4).
Charging connector (see page 9).
Battery volt meter (see page 4).
Direction arrow
Ensure the arrow points
towards the oncoming traffic
(see page 4).
Remote control
Controls two
RoboSign units
from distances up
to 100 metres
(see page 4).
Remote
control
Base
unit

4
Setting up
1Ensure that no other RoboSign systems are within 1000
metres of your installation.
2 Ensure the supplied antennas are fitted to the two base units
and the remote control. If the Stop-Go boards are attached
to the base units, remove them.
3 At each end of the works zone, place a base unit where it will
be clearly seen by drivers but will not cause an obstruction
tovehiclesorpedestrians.Thebaseunitsshouldnotbe
morethan200metres(656feet)apart.
Note: Base units weigh more than 25Kg,
do not attempt to move one alone,
always work together with a colleague.
Ensure that the arrow sticker on the top
panel of each base unit points towards
the approaching traffic:
4On the remote control, press the ON/
OFFbuttontoswitchiton.Thecentre
green Status indicator should illuminate,
followed by the two red Status indicators
either side a few seconds later. If this
doesnotoccur,pleaseseepage8.
5On one of the base units, press the front
panel RESET button that is located next to the charging
connector.Thiswillswitchtheunitonandpromptittosearch
for the controller.
When the base unit and remote control make contact, the
red Base unit A status indicator on the remote control will go
out.
6Repeat steps 3and 5on the other base unit. When that base
unit and the remote control make contact, the red Base unit B
status indicator on the remote control will go out.
continued
Installation
Pre-installation checks
It is important to inspect all parts of the system before attempting
to use them for traffic control. Please carry out the following
checks:
• Conrmthatbothbaseunitsandtheremotecontrolareall
MK3(earliermodelscannotbemixed):
Remote control: Clearly
marked with RoboSign MK3
Base units: Clearly marked
with RoboSign MK3
• Checkthatbothbaseunitsandthecontrollerareproperly
charged:
Remote control: The top
centre green indicator
should be on, the lower
centre indicator should be
off (see page 7)
Base units: The volt meter
needle should be in the
green area. If not, the unit
needs to be charged (see
page 8)

5
Assistance may be required to perform this operation.
8 Afterperformingthechecksdescribedinstep5,theat
side of each base unit shaft should be facing towards the
approaching traffic.
When traffic conditions allow, attach a Stop–Go board to
eachbaseunitshaft.ThepoleofeachStop-Goboard
can only be fitted one way onto each shaft. Once fitted,
the Stop side of each board should be facing towards the
approaching traffic:
The flat (keyway) side of
each shaft is the side on
which the STOP sign will
be located.
7 Operatethesystemthroughonecompletecycle(seethe
Operationsectiononpage6)andcheckthattheshaftsof
the base units rotate in the correct sequence.
High wind conditions
In high winds each base unit can be stabilised by placing a
sandbag or similar on the frame outriggers.
8Once the poles are attached, your installation should be
ready. See the Operation section on page 6.
Align the keyed hole of
the pole with the base
unit shaft. Then slide the
pole all the way down
onto the shaft.
Important: Do not install or operate RoboSign units in bad
visibility or abnormal wind conditions.
Sandbags may be added
for additional stability in
high wind conditions

6
Operation
Operating the RoboSign system
1Ensure that you are in a safe, central vantage point with a
clear view of both Stop-Go boards and the oncoming traffic.
2 CheckthatbothStop-GoboardsaredisplayingSTOP to their
approaching traffic streams. If either unit is not doing this, do
not attempt to operate the system.
3Observe that the approaching traffic has stopped at both
ends of the work zone and that the shuttle lane is clear.
4Hold the remote control handset upright at roughly waist height
and press the OPERATE button. One of the base units will spin
its board through a half-turn to show a GO signal.
5After an appropriate period of time, and in response to traffic
conditions, press the OPERATE button to change to the next
state(seeOperation sequencerightfordetails).
Note: After each button press, the remote control will ignore
any further presses for four seconds.
6Repeat step 5to advance to the next step of the sequence.
One hour standby
If the system is not used for a period of one hour, the base units
and the remote control will automatically switch themselves off to
conserve battery power. Any base unit sign that is at GO will turn
toshowSTOP.
To re-activate the remote control
• PresstheON/OFF button on the remote control.
To re-activate each base unit
• PresstheRESET button on the base unit front panel.
Fault conditions
Duringoperationifafaultissensed(suchaspowerloss,radio
interference,etc.),thefail-safesystemwillautomaticallyensure
both units are returned to their STOP positions and an indication
maybegivenontheremotecontrol.SeetheTroubleshooting
sectiononpage8fordetails.
If the system is unable to be operated, the Stop-Go boards can
be removed from the base units and used manually.
Operation sequence
RoboSign systems operate in a strict and coordinated
sequence. Each press of the remote control OPERATE button
prompts one of the base units to change to the next step of
the sequence.
For added safety there is a four second delay after every
change of state before the next step of the sequence can be
activated.Duringthefoursecondperiod,afurtherpressof
the remote control OPERATE button will have no effect.

7
Single sign operation
Inadditiontotheusualdualsignoperation(asexplainedonthe
oppositepage),youcanuseasingleRoboSignbaseunitto
control very short shuttle lanes where both traffic streams can
clearly see the sign.
1Ensure that no other RoboSign systems are within 1000
metres of your installation.
2Ensure the supplied antennas are fitted to the base unit and
the remote control. If the Stop-Go board is attached to the
base unit, remove it.
3Place the base unit where it will be clearly seen by drivers
but will not cause an obstruction to vehicles or pedestrians.
Note: The base unit weighs more than 25Kg, do not attempt
to move it alone, always work together with a colleague.
4On the base unit, press the front panel RESET button that is
locatednexttothechargingconnector.Thiswillswitchthe
unit on and prompt it to search for the controller.
Note: If the base unit is in the Go position*before you switch
it on, this will cause an error when it is powered on (forcing
it to automatically power down again). You will need to
manually turn it to the Stop position before powering it on.
When the base unit and remote control make contact, the red
Base unit A status indicator on the remote control will go out.
5 On the remote control, press and hold the OPERATE button
for approximately 10 seconds, until the Base unit B red status
indicator goes out.
 Thesystemisnowinsinglesignmode.Thesignwillrotate
with every press of the OPERATE button. Note: After each
button press, the remote control will ignore any further
presses for four seconds.
6Operatethesystem(withouttheStop-Goboard)throughone
complete cycle.
7When traffic conditions allow, attach the Stop–Go board to
thebaseunitshaft(thepolecanonlybettedonewayonto
theshaft).Theat(keyway)sideofeachshaftisthesideon
whichtheSTOPsignwillbelocated.
Notes:
• Baseunitsalwayspoweronintostandardmode,soevenif
it was last used in single sign mode, you will still need to go
throughthewholestartupprocessshownleft(steps4to7).
• Whenabaseunithasbeenusedinsinglesignmodeand
is then switched off in its Go position*, either automatically
or by the operator, then this will cause an error when it is
poweredon(forcingittoautomaticallypowerdownagain).
• IfthebaseunitiscurrentlyoffandintheGo position*, you
will need to manually turn it to the Stop position before
powering it on.
• Whenoperatinginsinglesignmode(ratherthanstandard
dualsignmode),thebaseunitwillreactdifferentlyifa
problem is discovered. Upon discovery of a problem, the
base unit will simply remain in its current position and power
down.
* The Go position is when the Go sign is pointing in the
direction of the arrow sticker on the top panel of the base
unit. If the sign is not fitted you will see that the flat keyway of
the shaft is facing away from the arrow sticker direction.

8
Troubleshooting
Note: After any serious fault, follow the Setting up instructions
given on page 4.
If the system fails to operate, please follow these basic steps:
1Ensure that both base units have been switched on using
their RESET buttons on the front panels.
2Ensure that the battery power meter on each base unit shows
green or yellow. If not, the batteries of the unit will require
charging before the system will operate.
3If both the base units are not working, the problem may be
withtheremotecontrol.Changetheremotecontrolbatteries.
4 If the units still do not function the problem may be within the
remotecontrolhandset.Thisisasealedunitandcontainsno
userserviceableparts.ContactPikeSignals.
5 CheckthattheSTOPboardisfacinginthedirectionofthe
direction arrow label. If not, manually rotate the sign to the
STOPposition,thenpresstheRESET button.
Caution: If the sign rotates, it will do so with force.
If the board does not rotate it may be a problem with the
RESETswitch.Thiscanbecheckedvisuallybyremovingthe
four screws of the base unit cover and carefully removing
it. Inspect the back of the RESET switch and ensure that the
two wires are securely connected to it.
• Forinformationonsparesorrepair,contactPikeSignals.
• IfthereisnoproblemwiththeRESET switch, the problem
mustbewithinthesealedelectronicshousing.This
contains no user serviceable parts, contact Pike Signals.
6 Checkthatallantennasarettedandnotdamaged.
7 ChecktheremotecontrolindicatorsÜ
To reset the system
1Switch the remote control off and then on using the ON/OFF
button.
2Wait for remote control to display permanent green and red
indicators.
3Reset one of the base units: Press its front panel RESET button.
Note: If the original problem was a forced sign, when you
press the RESET button the sign may rotate; if so, once the
sign stops, repress the RESET button.
4Repeat step 3for the other base unit.
Normal operation
Communicationlosswithbase
unit A
Communicationlosswithbase
unitB
Low battery in remote control
(similarindicationforbaseunitsif
theAorBamberindicatorsash)
Fully discharged battery in remote
control(similarindicationsforbase
unitsiftheAorBamberindicators
arepermanentlylit)
Serious fault detected on base unit
A(similarindicationforbaseunitB)
PleasefollowtheTroubleshooting
steps shown left.

9
Batteries
Recharging the base units
TheRoboSignMK3systemissuppliedwithathreestage
charger to charge the internal batteries of each base unit.
IMPORTANT:
• NeveroperateaRoboSignunitwhilethebatteriesare
being charged.
• DonotuseachargerotherthanthatsuppliedbyPike
Signals for use with the RoboSign MK 3 system base
units.
• Thebaseunitsweighmorethan25Kg,donotattemptto
move one alone, always work together with a colleague.
• Thesignmayrotateunexpectedly,alwaystakecarewhen
working near a base unit.
To charge a base unit
1 Insert the plug from the supplied charger into the
corresponding socket on the front panel of the base unit.
2 Insertthemainsplugintoasuitableelectricitysocket
outletandswitchon.Thechargecycleforabaseunitis
approximately12–14hours.Thechargerwillautomatically
cease charging when the cycle is complete.
Note: The charger unit requires a 230VAC, 50Hz mains
supply. It has a power requirement of 125W.
 Thestatusoftherechargecycleisindicatedonthefrontof
the charger:
• Red – power is being supplied to the battery charger.
• Amber – the battery attached to the charger is being
charged.
• Green – the recharge cycle is complete.
Recharging the remote control
TheremotecontrolusesfourstandardAAtypebatteriesand
re-chargeable versions may be used, a battery charger is not
supplied to charge these batteries. Rechargeable AA batteries
will need to be removed and charged in a third-party charger
unit.
To remove and refit remote control batteries
1 UsinganSW3(3mm)hexkey,removethetwoboltsfromthe
rear panel of the remote control.
2 Removeandchargethebatteries.
3 Replace the batteries into the remote control, taking care to
ensurecorrectpolarity(asmarkedwithinthecasing).
4 Replacetherearremotecontrolpanelandthetwobolts.

10
Replacing base unit batteries
Each base unit uses two sealed lead acid rechargeable rated
at12V20Ahnon-maintenanceorequivalent.Theseprovidea
minimum, 100 hours of operation when fully charged.
IMPORTANT:You are recommended to replace the base unit
batteries as a pair. Do not use any other battery or charger
than those supplied by Pike Signals.
To replace the base unit batteries
1 Remove the four fixing screws holding the yellow top cover to
the main frame.
2 Carefullylifttheyellowtopcover(takecareasthefrontpanel
iswiredtothemainchassis)andplacenexttotheunit.
3 Locate the batteries and their fixing straps:
4 Removethenegative(black)andthenlive(red)connections
to the batteries.
5 Removetheboltsfrombothendsofeachbatterystrap.
6 Remove the old batteries and replace them with ones of the
same specification.
7 Replacethebatterystrapsandbolts.
8 Replacethelive(red)andthennegative(black)connections
to the batteries.
9 Replace top cover onto base frame.
10 Replace four fixing screws to hold top cover onto main
frame.
11 Perform a full test of the base unit in a safe environment
before placing it back into service.
Batteries

11
Removing the electronics enclosure
In certain circumstances it may be necessary to remove and
replace the electronics enclosure.
Note: The electronics enclosure is a sealed unit and does not
contain any user serviceable parts. Do not attempt to open it
under any circumstances as this will invalidate your warranty.
To remove the electronics enclosure
1 Remove the four fixing screws holding the yellow top cover to
the main frame.
2 Carefullylifttheyellowtopcover(takecareasthefrontpanel
iswiredtothemainchassis)andplacenexttotheunit.
3 Locate the electronics enclosure:
4 Disconnecttheantennaandcontrolconnector
connections(twisttheirlockingcollarsanti-
clockwisetorelease)fromtheelectronics
enclosure.
5 RemovethetwoM4boltsthatsecurethe
electronics enclosure to base main frame.
6 Extract the electronics enclosure from the base
unit.
Electronics enclosure
Locking collars
Antenna connection
Control connection

12
Environmental information
EU directive 2002/95/EC on the Restriction of the use
of certain hazardous substances in electrical and
electronic equipment (RoHS)
It is Pike Signals Limited’s desire to meet customer requirements
with respect to the RoHS initiative. We are actively working
to achieve the important objective of making our products
compliantwiththeEURoHSdirective(andsimilarinitiatives)
through efficient product design that reduces unnecessary
waste; the use of recyclable materials throughout, and a transfer
to lead-free components and solder.
EU directive 2002/96/EC on Waste Electrical and
Electronic Equipment (WEEE)
Pike Signals Limited is focussed on developing
a compliance program for the European
Union(“EU”)DirectiveonWasteElectricaland
ElectronicEquipment,Directive2002/96/EC.
UndertheEUWEEEDirective,manufacturersof
covered electronic equipment are obligated to
take back such products at the end of their useful
life.
Pike Signals Limited is committed to meeting or exceeding
environmental standards in the production of all products and is
engaged in a comprehensive, company-wide effort towards full
compliancewiththeEUWEEEDirective.
Warranty
RoboSign base units and the remote control are guaranteed
against failure subject to fair wear and tear, correct operation
and return to our works carriage paid. We undertake to repair or
replace this equipment free of charge providing:
• Ithasbeenmaintainedingoodconditionandoperatedwith
due care, and
• Anyfailuresaredirectlytraceabletofaultymaterialor
workmanship.
However, we cannot entertain any claims for labour or other
expenditure in connection therewith. Items or components
subject to another manufacturer’s guarantee are subject to the
terms of that guarantee only.
Any warranty given is void if seals on equipment are
subsequently found to have been broken without prior permission
by Pike Signals Limited.
Any item of equipment repaired by Pike Signals Limited is
guaranteed from failure for three months from the date of repair,
provided that the item has been subjected to fair usage and
regular maintenance.
Disclaimers
Pike Signals Ltd reserves the right to change or alter product
specicationswithoutpriornotice.Theinformationcontained
within this guide is subject to copyright and may not reproduced
in part or in full without prior written permission by Pike Signals
Ltd. While every effort has been taken to ensure that this guide
provides accurate information, no liability shall be accepted for
any errors or omissions.
ItisapolicyofPikeSignalsLtdtoseekregistereddesignand/or
patent protection for its products.
www.ctxd.com
Documentation by:

Start Traffic Ltd
Units 30, North Bank, Berry Hill Ind Est
,
Droitwich, Worcestershire, WR9 9AU
tel: [phone]
email: [email protected]
www.starttraffic.uk