I. DESIGN

1. Visibility
  1. The LED-DOT Flipdisc is fabricated from corrosion resistant plastic substrate and covered with long life, diamond grade reflective yellow tape. These brightly coloured discs remain comfortable to read in any light, even direct sunlight glare.

  2. At night , the LED-DOT becomes illuminated with its own internal high intensity amber LED's from Hewlett Packard for unsurpassed legibility.

  3. The LED-DOT uses a rectangular shaped dot which hinges on a vertical axis. The rectangular dot provides a minimum of 16% more colour in a given space than round discs. This unique shape provides unsurpassed legibility in a minimum of space. In addition, the LED-DOT vertical hinge, as opposed to competitive horizontal hinges, provides a positive flipping action without any flutter vibration. This results in greater legibility, plus allows faster message updates.
2. Power Consumption
  1. Since the LED-DOT uses power only when flipping the discs, it uses up to 90% LESS electrical power than a conventional lamp matrix board. Less power means a smaller alternator, smaller engine, smaller fuel bills, and less maintenance - and solar powering!
  2. LED-DOT also is capable of 100% operation from its standard 12 volt battery pack. This feature allows silent operation, zero fuel bills, zero engine maintenance, and safe low voltage operation.
  3. Solar powering allows long periods of remote reliable operation. The Solar LED-DOT requires 5 hours of strong sunlight to power the sign for 24 hours running standard messages. These messages are defined as minimum 2.5 seconds on time, no blinking or blanking or moving arrows. An amps meter provides a guide to power consumption - a standard message will fluctuate for an average of around 2 amps (no lights operating). The Solar LED-Dot has large battery storage to operate for 7.5 days with no solar charging or to support non-standard message power needs.
3. Maintenance
  1. Lamp matrix boards are ON 100% of their operational life. Combine that with the inherently short life of lamps, and you can see why the normally OFF LED-DOT has a minimum operational life of at least 5 times that of the best lamp matrix boards.
4. Default Message
  1. When a lamp matrix board loses power, the sign goes completely blank resulting in a potentially dangerous situation. The LED-DOT, however, will continue on its battery bank for up to 7.5 days of uninterrupted operation under full load, including lights (assuming no sun light!). The on-board computer will then automatically change to any pre-selected default message. Since the LED-DOT uses no power in the default mode, the message remains highly visible until the problem is corrected, and your batteries are never fully discharged and shortened life.
4. Remote Control
  1. Signs are fitted with GSM modem which allows remote programming. When the modem connects and verifies correct password, battery level is displayed to assist routine maintenance. Board can display current message and all the software features are available; all from a single click on the telephone icon!


II. OVERALL DIMENSIONS

A. Height: Sign fully raised - 4,070 mm Sign in transport position - 2,750 mm
B. Length:Overall length - 3,840 mm
C. Width:Display Position - 2,870 mmTransport Position - 2,390 mm
D. Gross Weight:Maximum 1,440 KG


III. OVERALL SPECIFICATIONS

A. Wind:Transport Mode - Up to 90 kph highway towing speed; 3 G's of shock with no disruption of the disc state.
Display Mode - Gusts up to 130 kilometres per hour with all outriggers in place.
 
B. Paint:All exterior surface except sign - Sand blasted, etch primed, painted in Golden Yellow Acrylic (no fade 3 years).
Sign - Cleaned, finished with 1 coat corrosion inhibiting primer and 2 coats of flat black Alkyl Enamel baked to surface.
 
C. Temperature Range: Operational: -10° to +60°C
Storage: -10° to +60°C
Relative humidity: - 20% to 100%
 
D. Electrical Interference: The LED-DOT is unaffected by all types of RF interference.


IV. TRAILER

A. Material:ASTM A500 (B) UNS K0300 2" x 4" x 3/16" rectangular structural tubing.
B. Axle/Brakes:Single 1,600 KG capacity drop axle 45mm sq, 9 leaf spring sets, "C" type hydraulic brakes, a 9"x13/4" HQ brake sets (Mullins).
C. Hitch:2,700 KG GVWR capacity with 50 mm ball couplet.
136 KG maximum tongue load, and heavy duty safety chains.
Hitch height is 440 mm above pavement.
D. Tyres:Holden one tonne truck tyres or equivalent - steel belted radials.
E. Levelling Jacks:4 each 900 KG capacity jacks with crank type swivel.
Non-removable trailer mount.
Chain anchor points in each corner of trailer for transport by flat bed truck.
Standard fitting of heavy duty swivel type dolly wheel.
F. Wheel guards:Heavy duty square walk-on type.
G. Lights:Complete lighting to standard highway specifications.


V. LIFT

A. Material:ASTM A500 (B) UNS KO3000 7"x7"x1/4" rectangular structural tubing base and 6"x6"x1/4" single telescoping inner member.
ASTM A500 (B) UNS KO3000 1"x2"x11" gauge rectangular structural tubing gussets.
B. Length of Lift: 1,400 mm total lifting distance.
8 seconds maximum time for full extension.
C. Method of Lift:Electro-hydraulic.
Locking brake to secure lift in place at full or partial extension.


VI. ENCLOSURE


3mm sheet metal cover for tamper and weather protection. Entire enclosure mounted on hinges for quick removal for non-routine maintenance.
Controls - All instrumentation mounted in a large lockable NEMA 4 enclosure.
  • IRS - Message Selector Switch (40 stored message sequences).
  • Auto, Manual & OFF sign switch and lighting switch (photo-cell).
  • Raise/lower sign mast switch.
  • Programmable 7 day sign timer.
  • Portable computer serial connection.
  • Panel light to illuminate controls at night.


VII. ELECTRICAL SYSTEM

A. Sign Batteries:6 x Trojan J185 or CY185 12V Deep Cycle batteries allowing 180 hours continuous operation with no charging from solar panels, with standard message duty (no blinking, blanking, arrows and normal display time of 2.5 seconds).
B. Battery Charging:4 BP solar modules feature high efficiency Môn crystalline square silicon cells; designed for maximum reliability and minimum maintenance; highly resistant to water, abrasion, hail impact and other environmental factors; 3mm toughened high transmission (92%) glass; ethylene vinyl acetate encapsulate; comply with international standards; reinforced mesh protection to underside. Panels easily rise to secured horizontal (60°, 90°, 120°) positions for maximum solar efficiency.
Maximizer ensures efficiency even in poor sunlight conditions, and provides controls showing system charging and draining information in real-time. It boosts charging current in wet &/or dull &/or windy &/or winter conditions typically by 20% to 30% to direct-connected systems. Like no other charge regulator, the maximizer converts higher PV maximum power voltages whenever panel temperatures drop, directly into extra charging current. It does this automatically at the times when the charging current needs boosting the most. By way of example, on a bright but cloudy day the panel temperature may typically drop by 20 degrees Celsius, with a 7% rise in panel maximum power voltage, from say 14.5V to 15.5V for a 36 cell panel. If the battery goes into a net discharge current state, as typically happens in cloudy or dull conditions, the battery voltage will also drop down to around 12.5V. The maximizer takes this 3V (15.5-12.5V) 24% difference and DC-DC converts it into a 24% increase in charging current, compared to direct-connected PV system alternatives.
70 or 105Amp 240VAC Canions/Standbury Scarfe battery charger with a 12 hour recharge from discharge cycle, the battery bank can be safely left connected to mains following charge.
C. Voltages:Photo Voltaic (PV) 12V panels are wired to deliver 48/72V allowing maximum efficiency and minimal cable loss, and preventing night back drain from the battery bank.
LED's operate on 12V with large capacitor, and sign operates on 24V through 12-24 upvertors.
D. Expanded Power Pack:2 extra solar panels PVs (6+6) [6 solar panels + 6 batteries] for greater autonomy in poor sunlight conditions are available as an option; as an economy option we offer (4+4) [4 solar panels + 4 batteries] configuration.


VIII. MESSAGE DISPLAY BOARD

A. Overall Sign Dimensions:Three 8 character lines mounted in a single case: 1930mm high x 2870mm wide x 254mm deep.
B. Weight: 279 KG.
C. Speed of Message Change:Complete change of all 3 lines: 100 milliseconds maximum.
D. Legibility:Each character displayed in each line is clearly visible from 275 metres.
At angles up to 45º, the characters are legible from 245 metres.
At extreme angles up to 82º, the characters are legible from 43 metres.
E. View Angles:The sign rotates a complete 360º atop the lift mechanism, convenient locking brake prevents weather veining during rising and lowering and secures sign direction. This allows for various display angles and easy transport. When fully extended, the sign can be rotated and locked into various viewing angles as determined best for approaching motorists by the sign operator. Locking of the sign is via a collar brake. The sign is rotated parallel to the direction of towing for minimum wind loading.
F. Sign Failure:Mean Time Between Failures - tested to over 200 million operations without failure. Mean Time to Replace Character Module - less than 10 minutes. Automatic sign default message in the event of sign power failure.
G. Operating Principles/Method of Construction:Each sign consists of 3 lines of individually changeable characters.
Line Spacing - 170mm separation between adjacent lines.
Lines:
  • Each line is made up of 8 characters.
  • Each alpha-numeric character (also called a module) is individually removable from the line and is completely interchangeable with all other characters. Three interchangeable Row Drivers control the sign rows, and 24 Column Drivers complete the display electronics. Any one of these items are easily changed within a ten minute period.
  • Character Separation - 114mm from adjacent characters.
    Enclosure:
  • The sign is housed in weather tight aluminium housing with extruded aluminium framing.
  • The front is covered with a clear polycarbonate hinged cover for ease of service.
    Wiring:
  • Each line is connected to the other via a daisy chain 16 conductor ribbon cable.
  • Each line is connected to the battery via a daisy chain 5 conductor 12 gauge jacketed cable. In addition, a single 3 conductor 22 gauge jacketed cable connects the sign to the operator controlled computer.
    Illumination:
  • The sign contains 2 amber LED's per pixel for night operation.
  • The LED's are automatically dimmed for ambient light conditions.
  • High intensity amber LED's from Hewlett Packard.
    Characters Modules:
  • Each character is made up of 35 individual disks and 70 LED's.
  • The 35 disks are arranged in a 7 disk high x 5 disks wide matrix.
  • Each 5x7 disk matrix measures 457mm high x 228mm wide.
    Character Drive Electronics:
  • Each character has its own column driver board attached to the rear.
  • Each column driver board is easily removable via a plug-in type socket.
  • Each column driver board is inter-changeable with all others.
  • Each column driver board is completely covered with a conformal coating for protection against moisture.
  • Each character, along with the associated column driver board, is easily serviced and changed from the front side of each line through the hinged front cover.
    Row Drive Electronics:
  • Each row of characters has its own row driver board (3 per sign).
  • Each row driver is located behind the sheet metal panel between characters 7 and 8 on each row. They are easily removable via plug- type connectors.
  • Each row driver is interchangeable with all other row driver boards.
  • Each row driver is completely covered with a conformal coating for protection against moisture.
    Disks:
  • Each disk measures 63.5mm high x 20mm wide.
  • Disks are fabricated from flat black plastic and covered with diamond grade fluorescent yellow tape on one side.
  • Disks hinge on their vertical axis, flipping 1/2 of disk to reverse colour (yellow to black or vice versa).
  • Disk comes to rest in flat position for maximum readability.
  • Each disk will flip in approximately 100 milliseconds.
  • Disks pivot hinges need no lubrication and operate in excess of million operations without failure.
  • Each disk consists of 3 main components: a flipper, an indicator, and an electro-magnet located behind the indicator. (i) The flipper is made up of 3 parts: the plastic body, diamond grade yellow fluorescent tape, and 2 permanent magnets. (ii) The indicator is fabricated from a black plastic material with diamond grade yellow fluorescent tape affixed to 1/2 of the indicator. (iii) Two electro-magnets are located directly behind the indicator. By changing the electro-magnet polarity, the magnet field reacts with the permanent magnets on the flipper which causes flipper to flip. (iv) The polarity of the electro-magnet is controlled by sending an electrical pulse through the coil surrounding the electro-magnetic core. The 1 millisecond electrical pulse charges the core which then retains its charge (thus the position of the flipper) until pulsed again.


    • IX. CONTROLLER

    A. Type:The LED-DOT sign is controlled by a specially designed microprocessor based Single Board Computer controller. This unit is based on the 64180 processor, which is a high performance CMOS version of the Z-80 chip, with NOVRAM programmable chip designed by Vultron Inc. for use with intelligent rotary message selector switch.
    B. Power Supply:The controller is powered by the LED-DOT 12 VDC battery system with 24 V upvertors.).
    C. Message Memory:The controller allows permanent storage for 400 Pages (screens) in 40 Frames (sequences) each of up to 10 pages with variable on-times in .1 second intervals. Features allow screen wiping and message line blinking, and moving arrows.
    D. Download:Message download is via any IBM PC-AT or equivalent and Laptop PC running Microsoft Windows via a DB9 serial interface (RS232) located in the lockable NEMA enclosure. Standard RS232 cable (male to male pins 2,3,5 pin to pin); windows based software is simple and easy to use and requires a minimum of computer knowledge and is capable of downloading via fitted gsm cellular modem.
    E. Software:The controller uses custom designed software from Vultron Inc. The software utilizes multi-tasking protocol to provide communications support while allowing a local operator to input commands for local sign control. In addition, battery condition is monitored at all times.
    The software provides for storage of up to 40 sequences for display on the sign. Each sequence consists of up to ten 3 line by 8 character messages. A display on-time for each message is contained in the sequence, as well as information to control blinking of separate lines of a message and screen wiping between messages.
    The software allows for variable modification of message page on-times, in 0.1 second increments, to adjust sequence for specific traffic speeds.The software allows a user-defined default message stored in Frame 0. This user definable message is displayed in the event of low battery voltage. In a default condition, the controller software automatically switches the trailer to a minimum power mode to preserve batteries.
    The software provides for display of large moving arrows for arrow-board type applications.
    The software provides for remote message download via gsm cellular modem.
    F. Message Operation:Following message download, local message selection is by rotary dial - so simple for field use and a major feature of DIGI-DOT signs.


    X. LITERATURE


    The following operations information is provided with the ADDCO DOT-SIGN:
    • Operating Manual
    • Parts Manual
    • Wiring diagrams
    • Trouble Shooting Guide


    XI. MAINTENANCE


    The ADDCO LED-DOT requires no special scheduled maintenance other than those items detailed in the operating manual. These items are those normally encountered with battery powered portable equipment. Addco board parts are designed to remove/replace within a maximum of 10 minutes.


    XII. WARRANTY


  • ADDCO warrants that each new changeable message sign will be free from defects in material and workmanship for a period of two (2) years from date of delivery, subject to the conditions and restrictions of the current ADDCO written warranty.
  • Copies of our standard Warranty are available on request.
  • Complete sign spare parts are held in Perth and may be sent by overnight air-freight to all Australian Capital Cities.
  • No warranty is provided on batteries since their condition relies exclusively on proper care by the operator.
  • Training is a critical element of our quality control; two half day training sessions are conducted by ADDCO.
  • A local professional auto electician will be trained to effect routine service during the warranty term.


    • XIII. ADVANCED OPTIONS

    A. Remote Control: Our standard software ‘Cell-change’ DSC (Digi-Dot Sign Control) is capable of supporting modem communication. Telephone Land Line Operation allows the operator to download new messages via modem and remotely located IBM PC compatible computer at 9600 Baud Rate. Cellular and other radio phones allow similar communication depending on strength and quality of signal.
    ‘Cell-change’ DSC software package enables remote communication and time scheduling of up to 20 trailers using a GUI approach. There have been dramatic changes in computers and telecommunications in the last 5 years, and the next 5 years will be even more dramatic as the number of variable message signs grow in the Australian market.
    Our customer AHPlant have developed their own ‘Tele-change’ digital remote communications suite with our support on sharing communication protocols which demonstrates our customer focus in meeting the challenges ahead in a positive spirit of cooperation.
    B. Radar Speed Detection: Fitting of radar allows automatic sign default to pre-recorded message of up to 3 pages for a variable time in seconds. This allows 'normal' operation of the sign until the speed default is exceeded, in which case the sign immediately displays a default message sequence.
    DOS based sign software provides for two options; 1. constant, 2. your speed. This means you may either have the sign default to stored legends as option 1, or if option 2 is selected, the sign will default displaying any stored legend together with the actual speed of oncoming vehicle exceeding the variable threshold speed i.e. when an oncoming vehicle exceeds the threshold speed, the display could display YOUR SPEED : [68] KP/H or any variation of text and emphasis (blinking,blanking etc). Similarly, over-height detection devices can provide the necessary signal to achieve similar default message selection.
    Sign is designed for easy hook-up for radar application.
    Radar can monitor traffic speeds and counts with/without speed display. Our signs are capable of performing as Speed Observation Sign (SOS); a speed detection device which displays the road speed of passing vehicles. A radar sensor is fitted to detect the road speed which is displayed on the sign. The information is stored in the onboard data logger. The SOS can be set to display speeds with a cut off for excessively high speeds. All speeds will be logged but the display will not show speeds over the cut off. Vehicles will be logged, both approaching & departing. The data that is recorded is the speed, the time of day and the direction. Logged data can be downloaded locally & remotely. The SOS can be used to record data without displaying the speed. This provides an effective way to monitor motorist's road speed which can be used to assist Traffic Planners with Road Management.
    C. Time Scheduling: Standard sign message timer allows a chosen message to start and stop at pre-determined times. In some applications, it may be required for different message sequences to be displayed at pre-determined times of the day. This can be easily affected by an operator in the field dialling up the required message sequence, or automatically with the TIME SCHEDULING option included in our DSC software.


    XIV. DISPLAY TECHNOLOGY

    A. Electro-magnetic Flip Disc: Flip Disc systems consist of individual hinged metal flaps, which with reversal of magnetic polarity, are made to "flip" to one side or the other. In so doing, they adopt the chosen colour, or display the background and are consequently not seen. The discs are built up into a matrix display, with the message displayed by a fluorescent colour on a mat black background. Such signs can be either externally or internally lit.
    The discs are activated by passing a small pulse of current through a magnet, which then either repels or attracts the disc. Flip Disc signs are now commonly used in transit signs, traffic control systems and information signs throughout the United States and in Europe.
    Flip Disc provides immense scope in terms of design, and has a distinct advantage over other methods in areas of power consumption, since current is only used to change the message. In the event of power failure or interruption, the message will continue to be displayed, subject to any overriding systems designed into the sign which responds to this eventuality.
    With each disc typically designed to operate reliably for in excess of 20 million changes, Flip Disc technology provides optimum reliability, ease of maintenance, and other cost advantages.
    Flip Disc has been selected for a wide range of applications in addition to traffic uses for reasons, in addition to those above, of clarity and visibility. Such other applications include score-boards, promotional displays and message centres.
    The aesthetics of these displays are also an important point. Whether aesthetics are of prime importance or not, it is a factor which will play a part in ensuring efficient communication.
    B. Digi-Dot: Digi-Dot is the trade mark under which the special flip disc system designed and developed by Vultron Inc. is marketed. Digi-Dots are light reflective elements. The colour, Saturn yellow, has a fluorescent pigment, and is achromatic. This means that as the eyes move further away, the colour appears as white. Digi-Dots are therefore able to provide maximum readability in all conditions - not just at night but in daylight as well. Reflections, glare and direct sunlight do not impede the visibility and readability of a Digi-Dot sign.
    Digi-Dots require power only to change a message, a power failure will not remove a message being displayed. The individual flip discs in a Digi-Dot matrix sign are rectangular. This allows far fewer gaps in letters and graphics, increasing the visibility and impact of the message.
    Digi-Dot provides a number of key demonstrable advantages over competitive flip disc systems. These include:
    • Higher Fill Factor - Digi-Dot are rectangular and hinged on the side. This means that there is no cut out as is required on a rotating system. The fill factor for Digi-Dot is 92%.
    • Higher Viewing Angle - Digi-Dot provides for a flat display, which greatly increases the viewing angle from all sides. Other systems are angled to one side or the other. In a practical sense, a Vultron sign can be easily read from either side with a viewing angle of 140 degrees.
    • Plastic Flippers - These have been introduced to replace Mylar flippers which are normally used. Mylar has two principal disadvantages, being both subject to the effects of static electricity and to warping under extremes of temperature. Flippers are more reliable, more easily serviced and replaced, and have a life expectancy of up to twice that quoted for Mylar.
    • Pixel Colour - Vultron flippers are coated with a specially developed diamond grade film, manufactured by the 3M corporation. The colour is a fluorescent "Saturn" yellow, which has an extremely long life before any fading can be discerned. The use of the film also adds to the flat display, colour consistency (when compared to paint) and enhances the high fill factor mentioned above.
    • Solid Construction - The pixel is hinged flat rather than in a pivot, which means that they are less prone to vibration disturbance, and are far easier to maintain in a dust free condition. This latter advantage can have significant cost savings in maintenance, because cleaning can be facilitated by the use of compressed air jet, without fear of disturbing the pixel fixing system.
    • Larger Character - The use of a rectangular pixel allows for a larger character in a given width, especially when compared to alternative round pixels. This adds to clarity and readability, especially since we are taught from early in primary school that printed information is always higher than it is wide.

    In 1993 Vultron developed a LED-Dot flip disc product which combines all the advantages of the Digi-Dot flip disc, with the addition of 2 high intensity amber LED's per pixel manufactured by Hewlett Packard. The LED-Dot allows for ambient viewing during daylight hours, and LED's for night time and in poor daylight conditions. Night time visibility is provided by means of yellow LED's built into each flipper disc. LED's are automatically turned on as soon as the discs are uncovered. Low energy (LE) was developed and introduced in 1998 for solar operations. As well as its outstanding legibility, the low power consumption compared has resulted in the development by ADDCO of the Solar LED-Dot - 100% Solar Powered Mobile Message Display Trailers.


    XV. DISPLAY TECHNICAL FEATURES

    The Display Board is comprised of three lines, each with 8 characters per line using Vultron LED Digi-Dot proven low energy electro-magnetic Flipdisk outdoor display.
  • Angles at which Sides and Bottom Edges of the Display Face are Fully Visible.
    Sides - Greater than 45 degrees. Bottom Edges - Greater than 30 degrees.
  • Display Technology
    Vultron Digi-Dot electro magnetic Flipdisk with LED enhanced lighting utilizing 2 LED'S per pixel.
    The viewing angle for the LED is a 30 deg. cone centred around the optical axis of the LED (+/- 15 degrees), and 140 deg. for the reflective Flipdisk.
  • Size of Character Display Module
    Single module of 7H x 5W x 63mm pixels - character display area, 457mm x 230mm.
  • Minimum Legibility Distance
    Using the industry recognised standard of 25.4mm of character height = 15.24 metres of legibility, then our 457mm 5 x 7 character legibility will be 274 metres. This distance will hold true for both Day and Night.
  • Total Time for Display Change
    Always less than 200 milliseconds.
  • Number of Message Frames
    Current capacity allows 400+ frames to be stored.
  • Number of Message Strings
    Current capacity allows 40+ frames selection via Rotary Control Switch.
  • Colour of Active Pixel
    Saturn yellow pixel with amber LED's.
  • Maximum Power Demand
    The maximum power demand = 350 watts for < 200ms (all LED's lit and all dots updating). Typical power consumption with an average message (LED's operating) = 60 watts.
  • Power Conditioning Provisions and Effects of Spikes and Over-Voltage
    Single board computer in sign, spike tolerance = 600v peak to peak for 250 microseconds. Over voltage = +/- 10% of input voltage i.e. 264vac / 216vac.
  • Temperature Sensitivity
    Maximum temperature operating range +85º C to - 40º C.
  • Details of Luminous Intensity and Intensity Distribution of LED's.
    2 Candela per pixel LED luminosity plus the reflective disc contribution (depends on the ambient light). Intensity distribution = 2:1 (aggregate of the 4 dimmest V the 4 brightest)
  • Details of Life Cycle Calculations
    LED = 100,000 hours (11.4 years).
    Reflective discs = 50 Million operations (that's 137 years at 1000 operations per day!!).
  • Warranties Offered
    Two year parts and labour. See separate warranty statement for further details.
  • Typical Design Details
    The signs will be based on our standard Vultron LED-Dot highway sign in a three line 8 character per line configuration. Over 4,000 similar displays operate today.
  • Availability of Sample Element for Evaluation
    Ex-stock availability; from Australia's leading hire firms.
  • Location of Working Sign for Evaluation
    Currently providing outdoor real-time communications in all States & Territories of Australia.


    • ADDCO welcomes your comments... email us.

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