Cooper Bussmann 858 User Manual

DOCUMENT 1025

REVISION B

July 14, 2011

Instruction Manual

Cooper Industries
Crouse-Hinds Division
Airport Lighting Products
1200 Kennedy Road
Windsor, CT 06095

Airside Guidance Sign AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

Copyright © 2011 Cooper Technologies Company

F

or Parts or Technical Service Call [phone]

1 Revisions

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Revision
Number

Issue/Reissue
Number Letter Description Checked Approved

A A211-188

B A211-218

Initial Release of AGS-LED 858 Sign Manual

Update to reflect new single conductor wiring

MEG 6/8/11

SD 7/14/11

ii

2 Limited Product Warranty

THE FOLLOWING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER
WARRANTIES, WHETHER EXPRESS, IMPLIED OR STATUTORY, INCLUDING, BUT
NOT BY WAY OF LIMITATION, ANY WARRANTY OF MERCHANTABILITY OR
FITNESS FOR ANY PARTICULAR PURPOSE.

Crouse-Hinds Airport Lighting Products (the “Company”) warrants to each original Buyer of
Products manufactured by the Company that such Products are, at the time of delivery to the
Buyer, free of material and workmanship defects, provided that no warranty is made with respect
to:

Any Product which has been repaired or altered in such a way, in Company’s judgment, as to
affect the Product adversely;

Any Product which has, in Company’s judgment, been subject to negligence, accident or
improper storage;

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Any Product which has not been operated and maintained in accordance with normal practice and
in conformity with recommendations and published specification of Company; and,

Any Products, component parts or accessories manufactured by others but supplied by Company
(any claims should be submitted directly to the manufacturer thereof).

Crouse-Hinds Airport Lighting Products’ obligation under this warranty is limited to use of
reasonable efforts to repair or, at its option, replace, during normal business hours, at any
authorized service facility of Company, any Products which in its judgment proved not to be as
warranted within the applicable warranty period. All costs of transportation of Products claimed
not to be as warranted and of repaired or replacement Products to or from such service facility
shall be borne by Purchaser. Company may require the return of any Product claimed not to be as
warranted to one of its facilities as designed by Company, transportation prepaid by Purchaser, to
establish a claim under this warranty. The cost of labor for installing a repaired or replacement
product shall be borne by Purchaser. Replacement parts provided under the terms of this
warranty are warranted for the remainder of the warranty period of the Products upon which they
are installed to the same extent as if such parts were original components thereof. Warranty
services provided under the Agreement does not assure uninterrupted operations of Products;
Company does not assume any liability for damages caused by any delays involving warranty
service. The warranty period for the Products is 24 months from date of shipment or 12 months
from date of first use whichever occurs first.

iii

3 Safety Notices

This equipment is normally used or connected to circuits that may employ voltages which are

dangerous and may be fatal if accidentally contacted by operating or maintenance personnel.

Extreme caution should be exercised when working with

precautions have been incorporated in this equipment, the following rules must be strictly

from Live Circuits

Operating and maintenance personnel must at all times observe all safety regulations.

perform maintenance on internal components or

DO NOT PERFORM MAINTENANCE ON INTERNAL

COMPONENTS

Maintenance personnel should familiarize themselves with the tech

manuals

this equipment. While practical safety

nique for resuscitation found

observed:

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3.1 Keep Away

WARNING

3.2 RESUSCITATION

in widely published

Do not

service with power ON.

WARNING:

OR SERVICE WITH POWER ON.

of first aid instruction.

iv

4 Safety Symbols

The hazard or unsafe practice will result in severe injury or death.

The hazard or unsafe practice

The hazard or unsafe practice could result in minor injury.

Possibly dangerous situation, goods might be damaged.

Helpful information.

could result in severe injury or death.

4.1 Danger

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DANGER

4.2 Warning

WARNING

4.3 Caution

CAUTION

DANGER:

WARNING:

CAUTION:

4.4 Warning: Notice

NOTICE

WARNING:

4.5 Warning : Important

IMPORTANT

WARNING:

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5 Test Equipment and Tools

There is a wide variety of tools and equipment needed to safely and correctly perform airfield lighting
equipment installation and maintenance. In addition to the obvious tools (screwdrivers, wrenches, etc.),
there is a specialized equipment needed to do the job.

Multimeter
One of the most important pieces of test equipment is the Multimeter. It is used to measure voltages,

currents, and resistances. Almost every single maintenance task requires the use of a multimeter at one
point or another. A quality meter in good repair and calibration is a must because airfield lighting power
distribution equipment produces non-sinusoidal waveforms, traditional average reading meters are
inaccurate and have very limited use. Checking or adjusting equipment based upon incorrect current
reading may dramatically reduce lamp life and adversely affect power equipment performance. A meter
with TRUE RMS measuring capability and a current clamp-on probe is needed to accurately measure
distorted or chopped waveforms. All meter manufacturers offer TRUE RMS measuring meters. The
following is a short list of TRUE RMS Multimeters from Fluke:

Manufacturer Model Number

Fluke 87V, 287

Our recommended meter is the Fluke 87V with the Fluke I800 current clamp.
Refer to the equipment manufacturer’s manuals for the proper use, maintenance and calibration (if

necessary) of all meters.

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6 Table of Contents

1 Revisions ............................................................................................................................... ii

2 Limited Product Warranty .................................................................................................... iii

3 Safety Notices ........................................................................................................................ iv

3.1 Keep Away from Live Circuits ....................................................................................... iv

3.2 RESUSCITATION ......................................................................................................... iv

4 Safety Symbols ....................................................................................................................... v

4.1 Danger .............................................................................................................................. v

4.2 Warning ............................................................................................................................ v

4.3 Caution ............................................................................................................................. v

4.4 Warning: Notice ............................................................................................................... v

4.5 Warning : Important ......................................................................................................... v

5 Test Equipment and Tools ..................................................................................................... vi

6 Table of Contents ................................................................................................................. vii

7 List of Figures and Tables .................................................................................................. viii

8 General Information ............................................................................................................... 1

8.1 General Description ......................................................................................................... 1

8.2 Classification of Signs...................................................................................................... 1

8.3 Part Numbers: .................................................................................................................. 2

9 Installation .............................................................................................................................. 3

10 Maintenance and Troubleshooting ......................................................................................... 6

10.1 General ............................................................................................................................. 6

10.2 Problem Solving Guide .................................................................................................... 7

10.3 Measuring Input Current (Signs Without Optional Power Switch) ............................... 10

10.4 Measuring Input Current (Signs With Optional Power Switch) .................................... 10

10.5 Checking Power Supply LED Cable .............................................................................. 11

10.6 Checking LED MODULE Cable Connections .............................................................. 12

10.7 Checking the First LED MODULE ............................................................................... 12

10.8 Checking the Second LED MODULE ........................................................................... 13

10.9 Continue Checking the Rest of the LED MODULES .................................................... 14

10.10 Replacing an LED MODULE ........................................................................................ 15

10.11 Sign PC Board P/N 62277 Calibration ........................................................................... 17

10.12 Replacing Sign Power Supply Board & Heat Sink P/N 62277 ...................................... 17

11 Figures and Tables ................................................................................................................ 20

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7 List of Figures and Tables

Figure 1. Single module sign ....................................................................................................... 20

Figure 2. Double module sign ...................................................................................................... 21

Figure 3. Three module sign ........................................................................................................ 22

Figure 4. Four module sign .......................................................................................................... 23

Figure 5. Distance Marker ........................................................................................................... 24

Figure 6. Sign Options ................................................................................................................. 25

Figure 7. Heat Sink/LED Assembly showing wiring input and output connections ................... 26

Figure 8. LED Array Wiring, One Module Signs ........................................................................ 27

Figure 9. LED Array Wiring, Two Module Signs ....................................................................... 28

Figure 10. LED Array Wiring, Three Module Signs ................................................................... 29

Figure 10. LED Array Wiring, Four Module Signs ..................................................................... 30

Figure 11. LED Array Wiring, Distance Marker ......................................................................... 31

Figure 12. Recommended Transformer Housing Location &Concrete Foundation/Pad Details 32

Figure 12a. Expanded left section of Figure 12 ........................................................................... 33

Figure 12b. Expanded right section of Figure 12 ........................................................................ 34

Figure 12c. Expanded top section of Figure 12 ........................................................................... 35

Figure 14. Concrete Foundation/Pad configurations, Sizes 2 ...................................................... 37

Figure 15. Concrete Foundation/Pad configurations: Two 4-Module Signs, Side by Side ......... 38

Figure 16. Sizes 3, & 5 Concrete Foundation/Pad Configurations .............................................. 39

Figure 18. Power Supply Box ...................................................................................................... 41

Figure 21. Power Supply Wiring Diagram .................................................................................. 42

Figure 22. Checking the Power Supply Output Voltage After Turn-Off. .................................... 43

Table 1. Power Supply Switch and Jumper Selection (FERRO CCR) ........................................ 44

Table 2. Power Supply Switch and Jumper Selection (SERIES CCR) ....................................... 45

Table 3. AGS 858 LED Sign Style 2 VA Load & Matching Isolation Transformer (Ferro) ....... 46

Table 4. AGS 858 LED Sign Style 3 VA Load & Matching Isolation Transformer (Ferro) ....... 47

Table 5. AGS 858 LED Sign Style 5 VA Load & Matching Isolation Transformer (Ferro) ....... 48

Table 6. AGS 858 LED Sign Style 2 VA Load & Matching Isolation Transformer (Series) ..... 49

Table 7. AGS 858 LED Sign Style 3 VA Load & Matching Isolation Transformer (Series) ..... 50

Table 8. AGS 858 LED Sign Style 5 VA Load & Matching Isolation Transformer (Series) ..... 51

Table 9. Style 2 - Three step regulator currents ........................................................................... 52

Table 10. Style 3 - Five step regulator currents ........................................................................... 52

Table 11. Style 5 – Fixed regulator current ................................................................................. 52

Table 12. Power Supply Faults .................................................................................................... 53

Table 13. Parts List ...................................................................................................................... 54

Table 14. Estimated max sustained force on the sign body (Does not include safety margin) ... 55

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8 General Information

8.1 General Description

Crouse-Hinds Airport Lighting Products, “AIRSIDE” internally illuminated LED Taxiway and Runway
Signs provide outstanding message visibility, day or night. White on Red and Yellow on Black and Black
on Yellow color combinations may be ordered with any desired message. Signs are available as single or
double faced and are provided with retro-reflective sign face. For further information on Taxiway Signs
and their use, consult the latest revision FAA Advisory Circulars AC 150/5220-9, AC 150/5340-18, and
AC 150/5345-44.

8.2 Classification of Signs

The signs covered in this manual are designed and manufactured in accordance with the requirements of
FAA Advisory Circular AC 150/5345-44J. Specifications for Taxiway and Runway Signs and conform to
the following classifications as indicated in paragraph 1.2 of the above Advisory.

Type L-858Y – Direction destination and boundary sign – black legend on a yellow background.
Type L-858R – Mandatory instruction sign white legend on a red background.
Type L-858L – Taxiway and runway location sign yellow legend and border on a black background.
Type L-858B –Runway Distance Remaining sign with a white legend on a black background.
Type L858C – Taxiway Ending Marker sign yellow strips on black background (2 module sign only)
A sign may consist of multiple arrays of the above messages.
NOTE: Size 5 information in this manual is the same as the Size 3 single module unless noted
otherwise.
P/N Sizes
858S5-1X-X-X-X-XX Size 1 – 12 inch legend (small body)
858S5-2X-X-X-X-XX Size 2 – 15 inch legend (mid-size body)
858S5-3X-X-X-X-XX Size 3 – 18 inch legend (large body)
858S5-4X-X-X-X-XX Size 4 – 40 inch legend (large body DMS numerals and AGM symbol)
858S5-5X-X-X-X-XX Size 5 – 25 inch legend (large body DMS numerals only)

CAT. # FAA Styles

-3 Style 2 – For operation from a 3 step series lighting circuit (4.8 to 6.6 amperes)

-5 Style 3 – For operation from a 5 step series lighting circuit (2.8 to 6.6 amperes)

-1 Style 5 – A (fixed) 5.5 ampere series lighting circuit
Class 2 – For operation from -40ºC to +55ºC (+131ºF)
Mode 2 – Sign for use in areas subjected to wind speed of up to 200 mph (322 km/h)

1

8.3 Part Numbers:

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2

9 Installation

Sign foundations/pad and their design are the responsibi

installer and/or airport and recommendations/suggestions herein are

for guidance only.

series isolation transformers

isolation transformer secondary cable extend

consolidating harness

ground wire and connectors, floor flange anchor bolts and hardware

are not included as part of the sign.

from Crouse

18F section 14 for Taxiway Guidance Sign location and for the

perpendicular distance from the defined pavement edg

5345

perpendicular distance from the defined pavement edge to the near side of the sign

FAA specifications and Engineering Briefs may be obtained by

searching the FAA web

for suggested concrete foundation/pad. Concrete foundations/pads should be of

adequate mass, reinforcement, and psi strength rating for the

body and floor flange anchors must endure at its maximum plus a safe

foundation/pad should be installed in soil conditions that will help facilitate drainage and

dation/pad support. The floor

sustained force on the sign body

Table 14

Concrete foundations/pads should extend at least 12 inches below the local frost line. Contact your

al or regional building inspector if the depth is unknown for your area.

extend at least 1 foot beyond the sign body to minimize damage from mowers.

connector kits

series isolation

grounding rods,

tems may be ordered

Remaining Sign location and

maximum sustained force on

ty margin. The concrete

flange anchor bolt material should also meet the maximum

margin and must be ½ inch in diameter for use with the

sustained force on the sign body.

The foundation/pad should

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NOTICE

covers,

a. Refer to FAA AC 150-5345-

section 25 of FAA AC 150-

WARNING:

Transformer housing and baseplates

, primary

(if required), heat shrink kits,

Underlined i

-Hinds Airport Lighting.

e to the near side of the sign.

-18F for Runway Distance

WARNING:

er,

lity of the

and/or

, series

Similarly, see

.

IMPORTANT

b. See Figures 12-17

foun

25684-1 Floor Flange. See

c.

loc

site: www.faa.gov.

the sign

plus a safety

for estimated maximum

3

d.

The concrete foundation/pad should be not more than 1 inch above grade in or

inch maximum overall height above grade to the point of frangibility per FAA Engineering

79. See the Engineering Brief for acceptable grading around the foundation/pad. The foundation/pad

commended that the contractor who is to install the concrete foundation/pad use cast in place

anchor bolts. The threaded portion of the anchor bolts should be 1

maximum above the top of the concrete foundation/pad

the anchor bolts be installed accurately as shown in the concrete foundation/pad dimensions

The clearance holes on the floor flange are 5/8 inch diameter on a 4.75 inch diameter bolt circle

hor bolts.

The concrete foundation/pad should include the series isolation transformer housing. It is

recommended that this housing

isolation transformer and connections for ease of

This housing would be on the side closest to the Taxiway or Runway. A 2 inch conduit elbow

with threaded coupling attached at sign end would exit from the transformer housing side to the

and be flush with the with the top of the concrete foundation/pad

between the floor flange bolts nearest the Taxiway or Runway side of the sign. The sign as viewed

will have the circuit card box to the right on the “

or Runway side of the sign. If the location requires an add

messages, then the separation distance between these signs housings can be 3 inches minimum to 12

A AC 150

adjacent Taxiway) will have the circuit card box to the left on the “A” side of the sign. The sign side

identification is important with regards to its sign panel legend. A g

be installed at the end opposite the circuit card box in order to ground the sign housing. This

grounding rod must not be connected to the field counterpoise.

Lock out electrical power to the series loop

its source before attempting any electrical connections/splices.

Make electrical connections to the series loop power using L

the primary connectors to the appropriate size L

These primary connections (single pin plug or receptacle) should have Heat Shrink Kits applied over

their connections to prevent disconnection and water from entering the cables. If two Series Isolation

rs are required to be attached in series to obtain the correct wattage required for the sign,

all primary lead connections should have Heat Shrink Kits applied. Two Series Isolation

Transformers connected in series together will require a Consolidating Ha

at the transformer secondary connectors (two pin receptacle) to series them

Use electrical tape around the connections to prevent accidental disconnection. The Series

der to maintain the 3

5/8 inches minimum to 1

This requires that

placed under the sign power leg to allow access to the series

See Figure

grade level centered

e sign, which is closest to the Taxiway

itional housing to accommodate

44J 3.2.5.2 a.). This first sign body housing (farthest from the

rounding rod and clamp should

that will power the sign at

823 Primary Connector Kits. Attach

(See Tables 3

(Crouse

pad must be level.

e. It is re

13.
for use with ½ inch anc

f.

12c).

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not be

-

(See Figures 12, 12a-12c).

troubleshooting and servicing (

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Brief no.

-7/8

Figure

s 12, 12a-

foundation/pad

inches maximum (FA

DANGER

g.

A” side of th

multiple

-5345-

DANGER:

-

-830 Series Isolation Transformer

-8).

Transforme

rness
Number 26811-27)
together.

4

-Hinds Part

Isolation Transformer should be pla

contact with metal.

The Series Isolation Transformer secondary cable should then be inserted from

inside the housing up the conduit elbow. Using the two 40762 retainers supplied with the sign

like a cupped washer with a slot), placing one below the secondary cable receptacle (L

looks like a ball), and one above. The bottom cupped washer sits on the conduit elbow top inside the

threaded conduit coupling and prevents the sec

The top cupped washer prevents the secondary cable from being pulled out of the ground allowing the

sign power cord to disconnect if the sign is impacted and shears off at its frangible couplings. If a

nsolidating harness is used or a secondary cable extension (use electrical tape around connecti

(split clamp with screws and hex nuts) retainer supplied with the sign. Secure

down away from

straight tube) that will exit the conduit elbow. The top of the secondary receptacle should be at least

¼ inch below the conduit elbow threaded coupling top surface.

Check the sig

check for damage prior to installation.

Lower the sign with the legs and flanges into place. Plug the sign power cable plug into the secondary

receptacle inside the conduit elbow while lowering.

. As an alternate

sign, unscrewing the frangible couplings from the floor flanges. Install the floor flanges onto the sign

anchor bolts. Level the floor flanges for ease of installation of the sign. A long carpenter’s level can

be placed across the top of the floor flanges to be sure they are all in line and level. Do not tighten the

tight) u

: Some vertical adjustments can be obtained by rotating the floor flanges a turn or

full

Shim and grout as required. Once the sign has been leveled, attach the sign tether to the closest

anchor bolt and tighten all the anchor nuts securely. (

hardware should be corrosion resistant. The sign body must not be bent or distorted due

to an uneven installation procedure. Install a bare #14 AWG minimum copper ground wire to the

sign ground stud (stud located on sign bottom extrusion exterior and acc

and the other end to the grounding rod clamp.

The sign is shipped set for a Ferro

sign power supply circuit card

Return power to series circuit and verify sign illuminates through all Regulator brightness steps.

in order to isolate the transformer

ondary cable from dropping back down the conduit.

823 Style 7, looks like a

n for shipping damage upon arrival and in all cases,

heck the sign itself with a long carpenter’s

frangible couplings from the

ntil the frangible couplings are installed back into to floor

pad before tightening the anchor bolts.

: Anchor hardware is not supplied with the

epts #4 through #14 AWG)

as illustrated in Table 1

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ced on a brick

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from direct

(looks

-823 Style 8,

co
required, use the 25003
this retainer, flat side

IMPORTANT

h.

level to be sure it is level

anchor nuts tight (only finger­flanges. Note
two on the frangible coupling.

on) is

sign, around the secondary end (L-

WARNING:

C

, remove the floor flanges and

i. Make sure all flanges are in

sign.) Anchor

j.

Regulator types, set

k.

contact and sit flush on the

Note

-resonant Type L-828 Regulator
jumper according to Table 2.

5

. For other

Troubleshooting

Remove Power Before Attempting Any Servicing.

Work on electrical circuits shoul

knowledge of airfield lighting circuits. Trouble

elimination. It should be checked that the

is reapplied. Then

etc. Repeat this until the problem is solved.

It is also assumed that the circuit is in proper working order from the isolation transformer

823 sty

Use of a calibrated true RMS

will aid in the trouble shooting of electrical circuits

Only use OEM replacement sign legend panels. The entire message

element must be replaced per FAA AC 150

proprietary process replacement panels meet the photometric and

wind loading requirement

Instruction Manual

d be done only by a qualified electrician with a working

shooting is accomplished by means of process of

and secured, and once one solution is

and secured and another solution tried,

all the way to and including the power source.

Only use OEM replacement sig

44J 3.2.5.10.2. Our

s of the sign as certified to FAA AC 150

-

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10 Maintenance and

WARNING

10.1 General

tried, POWER

secondary connector (L-

legend panels

WARNING:

-

POWER is OFF

POWER turned OFF

le 7or 8 receptacle)

-reading multi-meter with a current sensing clamp
. Warning:

on attachment

n

NOTICE

5345-44J.

WARNING:

6

-5345-

-

Do not over tighten hex nut on stud retaining bridge rectifier. 8in

(See Figure 18)

adhesive surfaces before installing.

When tightening cover screws, do not use power drivers as you may

exceed the maximum torque of

When replacing parts inside the circuit box or sign housing, lock out

series circuit po

No input current. (LEDs on Power

Supply board not lit)

Also, remover carriers from thermal pad

on the cover screws.

CORRECTIVE ACTION

Measure input current

according to Sections

. If the measured input

not within spec (see

, check CCR,

isolation transformer

primary power connections

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CAUTION

IMPORTANT

DANGER

max.

CAUTION:

WARNING:

75 in-lbs

DANGER:

wer at its source.

-lbs

10.2 Problem Solving Guide

PROBLEM

(P.1) Sign will
not light

POSSIBLE CAUSE

7

10.3 and

10.4
current is
Tables 9-11)

, and

.

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PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION

REV. B

(P.2) Sign will
not light

(P.3) Sign will
not light

(P.4) Sign will
not light

(P.5) Sign will
not light

(P.6) Sign will
not light

Input current is below or exceeds
specification. (Input current is
specified between 2.8 and 6.6
amps using a true RMS Ammeter.
L858 Power Supply indicator RED
LEDs D4 is ON, and D7 is OFF;
Table 12)

Optional ON/OFF switch in OFF
position

Power Supply Circuit Card +15V
supply failed (See Table 12)

Power Supply Circuit Card +3.3V
supply failed (See Table 12)

Loose/broken wire(s)/missing
connections

Adjust CCR current (See
Tables 9-11 and/or replace
isolation transformer with
appropriate wattage for sign
(see Tables 3-8).

Turn switch to ON position.

Verify Green LED D29 is lit.
Replace Power Supply Board
if D29 is not lit.(Section 10.12)

Verify Green LED D11 is lit.
Replace Power Supply Board
if D11 is not lit (section

10.12).

Verify Power Supply
connections match Power
Supply Wiring Diagram
(Figures 18 & 21).

(P.7) Sign will
not light

Output Electrical Open Circuit
(See Table 12)

Verify LED cable connectors
are properly seated in their
respective receptacles; reseat if
necessary (See Sections 10.5 &

10.6)

(P.8) Sign will
not light

LED MODULE(s) mounted/wired
incorrectly

Verify that LED MODULES
are mounted and wired
according to LED Array
Wiring Diagram. (See Figures
7-11 and Sections 10.7-10.9)

(P.9) Sign will
not light

LED MODULE(s) open circuit
failure (Assumes P.7 Action taken)

Replace suspected open circuit
LED MODULE with spare
known good LED

8

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PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION

MODULE(s) (See Sec 10.10)

REV. B

(P.10) Upon
applying power,
sign
momentarily
lights and then
turns off.

(P.11) Upon
applying power,
sign
momentarily
lights and then
turns off.

(P.12) Upon
applying power,
sign
momentarily
lights and then
turns off.

(P.13) Sign
flickering

Incorrect LED Power Supply
Circuit Board Switch
Configuration

LED MODULE Voltage has
dropped 25% below the calibrated
output voltage (See Table 12).

LED MODULE Voltage is greater
than 125% of the expected
calibrated output voltage (See
Table 12).

Incorrect LED Power Supply
Circuit Board Jumper Setting.

Verify/Set Power Supply
Board Switches and jumpers
are set according to Table 1
(Ferro CCR) or Table 2 (Series
CCR)

Replace any LED
MODULE(s) with non-lit
LEDs and re-calibrate the LED
Power Supply. (See Sections

10.10 & 10.11)

Verify/Set Power Supply
Board Switches and jumpers
are set according to Table 1
(Ferro CCR) or Table 2 (Series
CCR)

Verify/Set Jumpers JP1 and
JP2 according to the Table 1
(FERRO CCR) or Table 2
(Series CCR)

(P.14) Sign
flickering

Incorrect Isolation Transformer Replace with Isolation

transformer that matches sign
type, size, #modules. (See
Tables 3-8)

9

10.3

Measuring Input Curre

Failure to turn off power to the sign and wait five minutes could result

in severe injury or death.

by turning off

ait five minutes after sign power is turned off

stored in Power Supply

multimeter set to DC Volts, verify that the Power Supply

(Positive lead) and TP3 (Negative Lead) as indicated in Figure 22. If the Power Supply Output Voltage

VDC, then you must wait until the Power Supply Output Voltage drops below 30

u proceed with the next step.

(See Figure

Supply Board. (Note: When removing female crimp

acle from CN18 and connect to CN17. Place current clamp around

primary power wire and connect to a true rms

ARMS and 6.7

Upon completing the measurement of the input current, turn off power to the CCR.

crimp receptacle at CN17 and reconnect to CN18. Reconnect the female

crimp receptacle attached to wire BRPH to CN18.

Measuring Input Current (Signs

Failure to turn off power to the sign and wait five minutes could result

in severe injury or death.

Turn off power to sign by toggling sig

ait five minutes after sign power is turned off

will allow any residual high voltage

your multimeter set to DC Volts, verify that the Power Supply Output Voltage is less than 30

TP6 (Positive lead) and TP3 (Negative Lead) as indicated in Figure 22. If the Power Supply Output

Constant Current Regulator (CC

. This will allow

. ) With your

Output Voltage is less than 30

Disconnect female crimp receptacle at CN17 from Power

receptacle, grasp by the terminal, not the wire.)

meter. Turn on power to the CCR. Current should

ARMS depending on the CCR current level or current step.

Remove the current

.

to service the sign

bleed off

DOCUMENT 1025

REV. B

Instruction Manual

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

nt (Signs Without Optional Power Switch)

WARNING

Turn off power to the sign
(WARNING: W

any residual high voltage

is greater than 30­before yo

Open Power Supply cover

Disconnect female crimp recept

measure between 2.7-

clamp. Disconnect the female

the corresponding

18).

current

-

WARNING:

to service the sign

PCB components to bleed off

Close the Power Supply Box cover.

R) power.

-VDC at TP6

-VDC

10.4

WARNING

to the sign. (WARNING: W

n power switch to the off position (See Figure 6)

stored in Power Supply PCB components to

With Optional Power Switch)

WARNING:

10

Turn off power

. This

. ) With

-VDC at

Voltage is greater than 30-

VDC, then you must w

VDC before you proceed with the next step.

Open the Power Supply Box cover. Place current clamp around one of the wires connected to the switch

labeled with switch marker PWR. Connect the current c

the input current. Current should measur

Upon completing the measurement of the input current, remove current clamp and close

Power Supply

Failure to turn off power to the sign and wait five minutes

in severe injury or death.

WARNING

. This will allow any residual high voltage

With your multimeter set to DC Volts, v

ead) and TP3 (Negative Lead) as indicated in Figure 21.

Supply Output Voltage is greater than 30

VDC before you proceed with the next step.

over bolts and then lift the top cover

LED

in CN9

cable connector connect

connector housing

pointing and outward pointing black arrows, respectively,

ait until the Power Supply Output Voltage drops below

lamp to the true RMS current meter. Measure

ARMS depending on the CCR

r is turned off

PCB components to

erify that the Power Supply Output Voltage is less

VDC, then you must wait until the Power Supply Output

the sign. Remove the front face from the

Power Supply

Verify that

LED MODULE

output connector

on the

30-

current level or current step.

Box cover.

DOCUMENT 1025

REV. B

Instruction Manual

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

e between 2.7-ARMS and 6.7-

Power Supply

10.5 Checking

WARNING

Turn off power to the sign. (

the sign
bleed off. )

than 30-VDC at TP6 (Positive l

Voltage drops below 30-

Remove the sign top c
sign. Check the Power Supply
connector is properly seated
Supply LED
seated in the input
clearly marked with inward
MODULE PCB (see Figure 7).

LED Cable

WARNING:

: Wait five minutes after sign powe

stored in Power Supply

-

from

Cable for visible damage. Make sure the

at the Power Supply Board (see Figure 18).

s to the input connector of the first
. The LED MODULE input connector and the

could result

to service

If the Power

LED cable

the Power

and is properly

are

LED

11

10.6 Checking

LED MODULE

Failure to turn off power to the sign and wait five minutes could result

in severe injury or dea

Turn off power to the sign by turning off the corresponding Constant Current Regulator (CCR) power.

ait five minutes after sign power is turned off

stored in Power Supply

multimeter set to DC Volts, verify that the Power Supply Output Voltage is less than 30

(Positive lead) and TP3 (Negative Lead) as indicated in Figure 22. If the Power Supply Output Voltage

VDC, then you must wait until the Power Supply Output Voltage drops below 30

before you proceed with the next step.

are electrically wired in series. This means that if

spective

and subsequently the sign will not light. Therefore, verify that all cable connectors

are properly seated in their housing and that the output of one

LED MODULE

(indicated by the inward pointing arrow at the

in the series string is terminated

Verify that

LED MODULE

LED MODULE

Failure to turn off power to the sign and wait five minutes could result

in severe injury or death.

. This will allow

.) With your

of the cable connectors are

housing, then no current can flow through

(indicate

) is connected to the input of the next

Figure 7

return connector & cable

is properly inserted into the

ward pointing arrow).

DOCUMENT 1025

REV. B

Instruction Manual

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

Cable Connections

WARNING

(WARNING: W
any residual high voltage

is greater than 30-

The LED MODULES
improperly seated in their re
the LED MODULES

pointing arrow at the
MODULE

The Last LED MODULE
assembly(See Figure 7-11).
connector housing at the Last

WARNING:

th.

to service the sign

PCB components to bleed off

LED MODULE

LED MODULE

connector Figure 7

LED MODULE connector-

with a black

the black terminator cable connector

output connector (indicated by the in

-VDC at TP6

-VDC

any

any of

d by the outward

LED

).

10.7 Checking the First

WARNING

WARNING:

12

Turn off power to the sign by turning off the corresponding Constant Current Regulator (CCR) power.

ait five minutes after sign power is turned off

stored in Power Supply

multimeter set to DC Volts, verify that the Power Supply Output Voltage is

(Positive lead) and TP3 (Negative Lead) as indicated in Figure 22. If the Power Supply Output Voltage

VDC, then you must wait until the Power Supply Output Voltage drops below 30

next step.

black return cable connector

the output cable connector in the first

Turn on main power. If the firs

and the Power Supply LED cable and Power Supply board are operating

Turn off main power to the sign. Wait five minutes for the power supply voltages to dissipate.

VDC with a multimeter as described in the opening paragraph of this

black return cable connector

If the sign does not light at all, then re

to the input of LED MODULE #

LED MODULE

to turn off power to the sign and wait five minutes could result

in severe injury or death.

Turn off power to the sign by turning off the corresponding Constant Current Regulator (CCR) power.

ait five minutes after sign power is turned off

stored in Power Supply

multimeter set to DC Volts, verify that the Power Supply Output Voltage is less than 30

ve Lead) as indicated in Figure 22. If the Power Supply Output Voltage

VDC, then you must wait until the Power Supply Output Voltage drops below 30

before you proceed with the next step.

black return cable connector

eplace the output cable connector in the second

. Turn on main power to the sign.

Instruction Manual

. This will allow

.) With your

less than 30

output cable connector

with the

momentarily lights and then turns off,

output cable connector.

place the LED MODULE #1 and/or the cable connecting from the

. Then

. This will allow

) With your

output cable connector (see Figure

black return cable

momentarily light and then turn off

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

DOCUMENT 1025

REV. B

(WARNING: W

any residual high voltage

is greater than 30­before you proceed with the

Remove the
Figures 7-11 & 20). Replace
cable connector.
then the first LED MODULE
normally.

the output voltage is less than 30­section. Replace the

output of the Power Supply
described above in this section.

10.8 Checking the Second

PCB components to bleed off

from the last LED MODULE

t LED MODULE

with the first LED MODULE

1(see Section 10.10)

to service the sign

LED MODULE

-VDC at TP6

-VDC

(see

black return

Verify that

repeat the test

Failure

WARNING

(WARNING: W
any residual high voltage

(Positive lead) and TP3 (Negati
is greater than 30-

Remove the

20). R
connector

WARNING:

PCB components to bleed off.

from the last LED MODULE

LED MODULE with the

If both LED MODULES

13

to service the sign

-VDC at TP6

-VDC

or stays lit, then the second

LED MODULE

are operating normally.

Turn off main power to the sign. Wait five minutes for the high voltage to dissipate.

VDC with a multimeter as described in the opening paragraph of this

black return cable connector

black return cable connector

n does not light at all, then

LED MODULE

this

hecking the

LED MODULES

For signs with more than two

numerical

Last). Use the same method as we have outlined in

we have a sign with 6 LED

LED MODULES

lit. Then we would use the following procedure to test the

Failure to turn off power to the sign and wait five minutes

in severe injury or death.

Turn off power to the sign by turning off the corresponding Constant Current Regulator (CCR) power.

ait five minutes after sign power is turned off

stored in Power Supply

multimeter set to DC Volts, verify that the Power Supply Output Voltage is less than 30

(Positive lead) and TP3 (Negative Lead) as indicated in Figure 22. If the Power S

VDC, then you must wait until the Power Supply Output Voltage drops below 30

before you proceed with the next step.

black return cable connector

). Replace the output cable connector in the

LED MODULE

output cable connector.

t LED MODULE.

and/or the cable connecting from

(see Section 10.

have been checked successfully as described in

the remaining

LED MODULE

Modules, Figure 9)

and found that the sign momentarily

. This will allow

.) With your

upply Output Voltage

output cable connector (see Fig

black return cable connector

LED MODULE

output voltage is less than 30­section. Replace the
Replace the

If the sig
the output connector of
repeat the test outlined above in

Instruction Manual

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

and the cable from the first

with the first LED MODULE

in the output connector housing of the las

replace the second LED MODULE

#1 to the input of LED MODULE #2

section.

DOCUMENT 1025

REV. B

to the second

Verify that the

10). Then

10.9 Continue C

It is assumed that the first two
two sections.
MODULES one at a time and in
MODULE #

For example, suppose
have checked all the

WARNING

(WARNING: W
any residual high voltage

Rest of the LED MODULES

LED MODULES, continue checking

sequence (e.g. LED MODULE #3,

previous section.

MODULES (See Size 2, 2-

in sequence from 1 to from 4

5th LED MODULE.

WARNING:

to service the sign

PCB components to bleed off

previous

LED

#4….LED

and we

could result

-VDC at TP6

is greater than 30-

Remove the
20

from the 6th LED MODULE

LED MODULE #5 with the

14

-VDC

ure

.

Turn on main power to the sign.

If LED

and the cable from the

Failure to turn off power to the sign and wait five minutes could result

in severe injury or death.

Turn off main power to the sign. Wait five minutes for the high voltage to dissipa

Power Supply Output Voltage measures less than 30

LED MODULE

connector housing

then replace

LED MODULE

section.

LED MODULE

LED MODULE

INSTRUCTIONS FOR REPLACING AN

The following instructions assume that the sign front face is removed and that

has been previously identified

Failure to turn off power to the sign and wait five minutes could result

in severe injury or death.

Turn off power to the sign by turning off the corresponding Constant Curre

ait five minutes after sign power is turned off

will allow any residual high voltage

ntarily light and then turn off,

LED MODULE

te. Verify that

Replace the

Replace the

and/or the cable connecting from the

(see Section 10.

has failed and needs to be replaced use the following instructions:

the failed

nt Regulator (CCR)

to service the sign

PCB components to

the LED MODULE #5
normally.

Instruction Manual

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

MODULES #1 to #5 mome

LED MODULE #4 to the

DOCUMENT 1025

REV. B

then

#5 are operating

WARNING

return cable connector with the
cable connector into the output

If the sign does not light at all,
output connector of
repeat the test as described in this

10.10 Replacing an

In the case where an

WARNING:

-VDC, as described above.

#5 output cable connector.

of the 6th LED MODULE.

the LED MODULE #5

#4 to the input of LED MODULE #5

black

black return

10). Then

LED MODULE

MODULE

WARNING

1.

power. (WARNING: W

.

WARNING:

stored in Power Supply

15

LED

bleed off.)

. This

2.

With your multimeter set to DC Volts, verify tha

VDC at TP6 (Positive lead) and TP3 (Negative Lead) as indicated in Figure 22. If the Power Supply

Output Voltage is greater than 30

VDC before you proceed with the next step.

Carefully remove the input and output cables from the failed

LED MODULE

is denoted by a black arr

Loosen and remove the nuts on the

bracket bolts with one hand while support the

LED MODULE

LED MODULE

heat sink are aligned with the mounting bracket holes. (Note: The replacement

r should be closest to the marked input cable connector.)

Push the mounting bracket bolts through the mounting bracket and the

Attach nuts to the mounting bracket bolts and tighten.

Gently slide the input cable connecto

Likewise, slide the output cable connector into the replacement

replacement is complete

Power Supply Board must be re

Power Supply Board must be re

t the Power Supply Output Voltage is less than 30

VDC, then you must wait until the Power Supply Output Voltage

. (Mark the cable

The input connector on the

(see Figure 7).

mounting bracket bolts. Remove the

with your other hand.

mounting bracket.

into the mounting bracket such that the holes in the

LED MODULE

connector input housing.

output connector

er replacing an LED MODULE (see Section 10.

calibrated after replacing an

drops below 30-

DOCUMENT 1025

REV. B

Instruction Manual

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

-

-

3.
connected to the

MODULE

4.
MODULE

5. Carefully remove the failed

6. Mount the replacement
MODULE
MODULE input connecto

7.
holes.

8.

9.

10.
housing.

11. The LED MODULE

12.

LED MODULE

input connector. Note:

ow pointing toward the input connector

LED MODULE

LED MODULE

from the LED MODULE

r into the replacement LED MODULE

LED MODULE

.

-calibrated aft

LED

LED

LED

LED

heat sink

11).

IMPORTANT

LED MODULE (see Section 10.11).

WARNING:

-

16

62277

PC Board doesn’t normally need to be cal

In this section, it is assumed that the Sign PC Board P/N 62277 is

correctly configured for this particular sign (see Table 1or 2) and

that the sign lights continuously when m

the normal mode of operation (SW3

INSTRUCTIONS FOR CALIBRATION OF

Turn off main power to the sign.

Open the Power Supply Cover and locate SW3

oard, set switch SW3

Green LED D3 will flash ON/OFF slowly for approximately three

seconds to indicate the beginning of the calibration process. During calibration, D3, will remain

FF. At the conclusion of the calibration process, D3 remain

If D3 does not light and remain constant

under WARNING above, replace the power supply board (See sect

Turn off the main power to the sign.

1 to the OFF position.

The Power Supply Board is now calibrated to the sign.

Replacing Sign Power Supply Board

the

replacement of the Power Supply Board.

REPLACING

LED MODULE

ain power is applied in

1 = OFF).

1 on the Power Supply Board (See Figure

(see Figure 18)

Based on the assumption listed

ng guide recommends

DOCUMENT 1025

REV. B

Instruction Manual

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

10.11 Sign PC Board P/N

The 62277
replaced.

IMPORTANT

1.

2.

3. On the Power Supply B

4. Apply main power to the sign.

Calibration

ibrated in the field unless an

WARNING:

62277 PC BOARD:

-

-1 to the ON position.

is

-

18)

O

5.

5.

6. Set SW3-

7. Close the Power Supply cover.

8.

10.12

In this section, it is assumed that

INSTRUCTIONS FOR

constant ON

, then calibration has failed.

& Heat Sink P/N 62277

sign has failed and the trouble shooti

62277 PC BOARD & HEAT SINK:

17

.

ion 10.12)

Power Supply Board must be re

Turn off power to the sign by turning off the corresponding Constant Current Regulator (CCR)

ait five minutes after sign power is turned off

will allow any residual high voltage

Failure to turn off power to the sign and wait five minutes could result

in severe injury or death.

With your multimeter set to DC Volts, verify that the Power Supply Output Volta

VDC at TP6 (Positive lead) and TP3 (Negative Lead) as indicated in Figure 22. If the Power Supply

Output Voltage is greater than 30

VDC before you proceed wit

input power cabling at CN1, CN2, CN3, CN11, CN17,

LED Power Supply Cable at CN9

Remove the three nuts that secure the main heat sink to the Power Supply Box.

screws that fasten the Power Supply Board onto the Power Supply Box.

Remove the Power Supply Board

studs extending from the side of the Power Supply Box.

new Power Supply Boa

Fasten board to the Power Supply Box with six mounting screws.

Attach the three nuts that secure the heat sink to the studs extending from the side of the Power

Connect the LED Power Supply cable at CN9.

Connect the input power cabling at CN1, CN2, CN3, CN11, CN17, & CN18.

for the sign style, size, and number of modules as shown in Table 1 or 2.

Instruction Manual

replacement

to service the sign

PCB components to

ge is less than 30

VDC, then you must wait until the Power Supply Output Voltage

(See Figure 15)

off the mounting

rd onto the mounting studs extending from the side of the Power

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

DOCUMENT 1025

REV. B

IMPORTANT

1.
power. (WARNING: W

WARNING

2.

drops below 30-

stored in Power Supply

WARNING:

-calibrated after

(see Section 10.11).

.

bleed off.)

. This

WARNING:

-

­h the next step.

3. Remove

4. Remove

5.

6. Remove the six

7.

8. Slide the
Supply Box.

9.

10.
Supply Box.

11.

12.

13. Set the jumpers JP1 & JP2
(For locaction, see Figure 18)

& CN18

(See Figure 15).

Assembly by sliding the attached main heat sink

18

.

DOCUMENT 1025

Instruction Manual

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

14. Set DIP switches SW1, SW2, & SW3for the sign style, size, and number of modules as shown in
Table 1 or 2. (For locations Figure 18)

15. The Power Supply Board and Heat Sink replacement is complete

REV. B

19

11 Figures and Tables

DOCUMENT 1025

REV. B

Instruction Manual

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

igure 1. Single module sign

F

20

Instruction Manual

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

DOCUMENT 1025

REV. B

Figure 2. Double module sign

21

Instruction Manual

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

DOCUMENT 1025

REV. B

Figure 3. Three module sign

22

Instruction Manual

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

DOCUMENT 1025

REV. B

Figure 4. Four module sign

23

Instruction Manual

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

DOCUMENT 1025

REV. B

Figure 5. Distance Marker

24

Instruction Manual

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

DOCUMENT 1025

REV. B

Figure 6. Sign Options

25

Instruction Manual

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

DOCUMENT 1025

REV. B

Figure 7. Heat Sink/LED Assembly showing wiring input and output connections

26

Instruction Manual

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

DOCUMENT 1025

REV. B

Figure 8. LED Array Wiring, One Module Signs

(Reference Figure 7 for LED array orientations)

27

Instruction Manual

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

DOCUMENT 1025

REV. B

Figure 9. LED Array Wiring, Two Module Signs

(Reference Figure 7 for LED array orientations)

28

Instruction Manual

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

DOCUMENT 1025

REV. B

Figure 10. LED Array Wiring, Three Module Signs

(Reference Figure 7 for LED array orientations)

29

Instruction Manual

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

DOCUMENT 1025

REV. B

Figure 10. LED Array Wiring, Four Module Signs

(Reference Figure 7 for LED array orientations)

30

Instruction Manual

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

DOCUMENT 1025

REV. B

Figure 11. LED Array Wiring, Distance Marker

(Reference Figure 7 for LED array orientations)

31

Instruction Manual

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

DOCUMENT 1025

REV. B

Figure 12. Recommended Transformer Housing Location &Concrete Foundation/Pad Details

32

Instruction Manual

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

DOCUMENT 1025

REV. B

Figure 12a. Expanded left section of Figure 12

33

Instruction Manual

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

DOCUMENT 1025

REV. B

Figure 12b. Expanded right section of Figure 12

34

DOCUMENT 1025

REV. B

Instruction Manual

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

Figure 12c. Expanded top section of Figure 12

35

DOCUMENT 1025

REV. B

Instruction Manual

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

Figure 13. Concrete Foundation/Pad configurations, Size 1

36

DOCUMENT 1025

REV. B

Instruction Manual

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

Figure 14. Concrete Foundation/Pad configurations, Size 2

37

DOCUMENT 1025

REV. B

Instruction Manual

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

Figure 15. Concrete Foundation/Pad configurations: Two 4-Module Signs, Side by Side

NOTE, IF 3 SIGNS ARE USED IN AN ARRAY, MAKE SEPARATION DISTANCE 12 INCHES TO ALLOW CIRCUIT CARD BOX DOOR TO
OPEN IN THIS SPACE WHEN ANOTHER CIRCUIT CARD BOX IS MOUNTED IN THIS SAME SPACE UTILIZED ON ADJACENT SIGN. THIS
WILL ALLOW THIS SEPARATION DISTANCE TO REMAIN WITHIN THE FAA SPECIFICATION.

38

Instruction Manual

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

DOCUMENT 1025

REV. B

Figure 16. Sizes 3, & 5 Concrete Foundation/Pad Configurations

39

Instruction Manual

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

DOCUMENT 1025

REV. B

Figure 17. Size 4 Concrete Foundation/Pad Configurations

40

Instruction Manual

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

DOCUMENT 1025

REV. B

Figure 18. Power Supply Box

41

Instruction Manual

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

DOCUMENT 1025

REV. B

Figure 21. Power Supply Wiring Diagram

42

Checking the Power Supply Output Vo

DOCUMENT 1025

Instruction Manual

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

REV. B

Figure 22.

43

ltage After Turn-Off.

L858 AGS

Output Current

Setting

Instruction Manual

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

Input voltage
configuration

Output LED Configuration

Calibration

Mode/

Normal

Operation

DOCUMENT 1025

REV. B

Ferro CCR

Size #Mods

1 1 x ON OFF ON ON ON ON ON ON ON/OFF

1 2 x ON OFF ON ON ON ON ON OFF ON/OFF

1 3 x ON OFF ON ON ON ON OFF ON ON/OFF

1 4 x ON OFF ON OFF ON ON OFF OFF ON/OFF

2 1 x x ON ON ON ON OFF ON ON ON/OFF

2 2 x x ON ON ON ON OFF ON OFF ON/OFF

2 3 x x ON ON OFF ON OFF OFF ON ON/OFF

2 4 x x ON ON OFF ON OFF OFF OFF ON/OFF

3 1 x ON OFF ON ON OFF ON ON ON ON/OFF

3 2 x ON OFF ON OFF OFF ON ON OFF ON/OFF

3 3 x ON OFF ON OFF OFF ON OFF ON ON/OFF

3 4 x ON OFF OFF OFF OFF ON OFF OFF ON/OFF

4 2 ON OFF OFF ON OFF OFF OFF ON ON ON/OFF

SW1-4 SW1-5 SW1-6 SW2-1 SW2-2 SW2-3 SW2-4 SW2-5 SW2-

6

SW3-1 JP1 JP2

Table 1. Power Supply Switch and Jumper Selection (FERRO CCR)

Close Close

Close Close

Close Close

Close Open

Close Close

Close Close

Close Open

Close Open

Close Close

Close Open

Close Open

Open Open

Close Open

44

L858 AGS

Output Current

Setting

Instruction Manual

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

Input voltage
configuration

Output LED Configuration

Calibration

Mode/

Normal

Operation

DOCUMENT 1025

REV. B

Series CCR

Size #Mods

1 1 x ON OFF ON ON ON ON ON ON ON/OFF

1 2 x ON OFF ON ON ON ON ON OFF ON/OFF

1 3 x ON OFF ON ON ON ON OFF ON ON/OFF

1 4 x ON OFF ON OFF ON ON OFF OFF ON/OFF

2 1 x x ON ON ON ON OFF ON ON ON/OFF

2 2 x x ON ON ON ON OFF ON OFF ON/OFF

2 3 x x ON ON OFF ON OFF OFF ON ON/OFF

2 4 x x ON OFF OFF ON OFF OFF OFF ON/OFF

3 1 x ON OFF ON ON OFF ON ON ON ON/OFF

3 2 x ON OFF ON OFF OFF ON ON OFF ON/OFF

3 3 x ON OFF OFF OFF OFF ON OFF ON ON/OFF

3 4 x ON OFF OFF OFF OFF ON OFF OFF ON/OFF

4 2 ON OFF OFF ON OFF OFF OFF ON ON ON/OFF

SW1-4 SW1-5 SW1-6 SW2-1 SW2-2 SW2-3 SW2-4 SW2-5 SW2-

6

SW3-1 JP1 JP2

Table 2. Power Supply Switch and Jumper Selection (SERIES CCR)

Close Close

Close Close

Close Close

Close Open

Close Close

Close Close

Close Open

Open Open

Close Close

Close Open

Open Open

Open Open

Close Open

45

Instruction Manual

CCHALP

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

DOCUMENT 1025

REV. B

Style Sign Size # Modules CCR type

CCHALP

Sign VA
(Primary
Isolation

Xfrmr@

6.6A)

Sign

Watts
(Primary
Isolation
Xfrmr @

6.6A)

CCHALP

Power

Factor
(Primary
Isolation

Xfrmr)

CCHALP
Sign VA

(Secondary

Isolation

Xfrmr@

6.6A)

CCHALP

Sign Watts

(Secondary

Isolation
Xfrmr @

6.6A)

CCHALP

Power
Factor

(Secondary

Isolation

Xfrmr)

CCHALP

Isolation

Transformer

Type

2 1 1 Ferro 53 45 0.85 35 29 0.83 65W
2 1 2 Ferro 57 50 0.88 39 34 0.86 65W
2 1 3 Ferro 64 54 0.84 48 41 0.84 100W
2 1 4 Ferro 67 58 0.87 52 45 0.87 100W
2 2 1 Ferro 51 44 0.86 34 29 0.85 65W
2 2 2 Ferro 58 50 0.87 41 35 0.86 65W
2 2 3 Ferro 62 55 0.88 47 42 0.89 100W
2 2 4 Ferro 68 61 0.89 53 48 0.90 100W
2 3 1 Ferro 57 50 0.88 39 34 0.86 65W
2 3 2 Ferro 67 58 0.87 52 45 0.87 100W
2 3 3 Ferro 77 69 0.90 62 56 0.90 100W
2 3 4 Ferro 102 88 0.86 77 68 0.89 200W
2 4 2 Ferro 74 66 0.90 60 53 0.88 100W

Table 3. AGS 858 LED Sign Style 2 VA Load & Matching Isolation Transformer (Ferro)

46

Instruction Manual

CCHALP

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

DOCUMENT 1025

REV. B

Style Sign Size # Modules CCR type

CCHALP

Sign VA
(Primary
Isolation

Xfrmr@

6.6A)

Sign

Watts
(Primary
Isolation
Xfrmr @

6.6A)

CCHALP

Power

Factor
(Primary
Isolation

Xfrmr)

CCHALP
Sign VA

(Secondary

Isolation

Xfrmr@

6.6A)

CCHALP

Sign Watts

(Secondary

Isolation
Xfrmr @

6.6A)

CCHALP

Power
Factor

(Secondary

Isolation

Xfrmr)

CCHALP

Isolation

Transformer

Type

3 1 1 Ferro 53 45 0.85 35 29 0.83 65W
3 1 2 Ferro 57 50 0.88 39 34 0.86 65W
3 1 3 Ferro 64 54 0.84 48 41 0.84 100W
3 1 4 Ferro 67 58 0.87 52 45 0.87 100W
3 2 1 Ferro 51 44 0.86 34 29 0.85 65W
3 2 2 Ferro 58 50 0.87 41 35 0.86 65W
3 2 3 Ferro 62 55 0.88 47 42 0.89 100W
3 2 4 Ferro 68 61 0.89 53 48 0.90 100W
3 3 1 Ferro 57 50 0.88 39 34 0.86 65W
3 3 2 Ferro 67 58 0.87 52 45 0.87 100W
3 3 3 Ferro 77 69 0.90 62 56 0.90 100W
3 3 4 Ferro 102 88 0.86 77 68 0.89 200W
3 4 2 Ferro 74 66 0.90 60 53 0.88 100W

Table 4. AGS 858 LED Sign Style 3 VA Load & Matching Isolation Transformer (Ferro)

47

Instruction Manual

CCHALP

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

DOCUMENT 1025

REV. B

Style Sign Size # Modules CCR type

CCHALP

Sign VA
(Primary
Isolation

Xfrmr@

5.5A)

Sign

Watts
(Primary
Isolation

Xfrmr

@5.5A)

CCHALP

Power

Factor
(Primary
Isolation

Xfrmr)

CCHALP
Sign VA

(Secondary

Isolation

Xfrmr@

5.5A)

CCHALP

Sign Watts

(Secondary

Isolation
Xfrmr @

5.5A)

CCHALP

Power
Factor

(Secondary

Isolation

Xfrmr)

CCHALP

Isolation

Transformer

Type

5 1 1 Ferro 42 36 0.86 29 25 0.84 65W
5 1 2 Ferro 47 42 0.88 34 30 0.88 65W
5 1 3 Ferro 51 46 0.89 39 35 0.90 65W
5 1 4 Ferro 56 51 0.91 45 41 0.91 65W
5 2 1 Ferro 43 38 0.87 30 26 0.86 65W
5 2 2 Ferro 49 44 0.89 35 32 0.89 65W
5 2 3 Ferro 54 49 0.90 43 39 0.89 100W
5 2 4 Ferro 60 55 0.91 49 44 0.91 100W
5 3 1 Ferro 47 42 0.88 34 30 0.88 65W
5 3 2 Ferro 56 51 0.91 45 41 0.91 65W
5 3 3 Ferro 68 62 0.91 56 52 0.92 100W
5 3 4 Ferro 82 75 0.91 70 64 0.91 100W
5 4 2 Ferro 43 38 0.87 30 26 0.86 65W

Table 5. AGS 858 LED Sign Style 5 VA Load & Matching Isolation Transformer (Ferro)

48

DOCUMENT 1025

Sign

REV. B

Instruction Manual

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

Style Sign Size # Modules CCR type

Sign VA
(Primary
Isolation

Xfrmr@

6.6A)

Watts
(Primary
Isolation
Xfrmr @

6.6A)

Power

Factor
(Primary
Isolation

Xfrmr)

Sign VA

(Secondar

y Isolation

Xfrmr@

6.6A)

Sign Watts

(Secondar

y Isolation

Xfrmr @

6.6A)

Power
Factor

(Secondar

y Isolation

Xfrmr)

2 1 1 Series 180 87 0.49 87 67 0.77 200W
2 1 2 Series 181 90 0.50 89 70 0.78 200W
2 1 3 Series 182 92 0.50 92 71 0.78 200W
2 1 4 Series 183 93 0.51 94 73 0.78 200W
2 2 1 Series 180 88 0.49 41 37 0.89 200W
2 2 2 Series 181 91 0.50 90 70 0.78 200W
2 2 3 Series 182 93 0.51 93 73 0.79 200W
2 2 4 Series 183 94 0.51 95 75 0.79 200W
2 3 1 Series 181 90 0.50 89 70 0.78 200W
2 3 2 Series 183 93 0.51 94 73 0.78 200W
2 3 3 Series 186 98 0.53 99 77 0.78 200W
2 3 4 Series 277 101 0.36 102 82 0.80 300W
2 4 2 Series 185 97 0.52 97 77 0.79 200W

Isolation

Transforme

r Type

Table 6. AGS 858 LED Sign Style 2 VA Load & Matching Isolation Transformer (Series)

49

Instruction Manual

Sign

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

DOCUMENT 1025

REV. B

Style Sign Size # Modules CCR type

Sign VA
(Primary
Isolation

Xfrmr@

6.6A)

Watts
(Primary
Isolation
Xfrmr @

6.6A)

Power

Factor
(Primary
Isolation

Xfrmr)

Sign VA

(Secondar

y Isolation

Xfrmr@

6.6A)

Sign Watts

(Secondar

y Isolation

Xfrmr @

6.6A)

Power
Factor

(Secondar

y Isolation

Xfrmr)

Isolation

Transforme

r Type

3 1 1 Series 180 87 0.49 87 67 0.77 200W
3 1 2 Series 181 90 0.50 89 70 0.78 200W
3 1 3 Series 182 92 0.50 92 71 0.78 200W
3 1 4 Series 183 93 0.51 94 73 0.78 200W
3 2 1 Series 180 88 0.49 87 68 0.78 200W
3 2 2 Series 181 91 0.50 90 70 0.78 200W
3 2 3 Series 182 93 0.51 93 73 0.79 200W
3 2 4 Series 183 94 0.51 95 75 0.79 200W
3 3 1 Series 181 90 0.50 89 70 0.78 200W
3 3 2 Series 183 93 0.51 94 73 0.78 200W
3 3 3 Series 186 98 0.53 99 77 0.78 200W
3 3 4 Series 277 101 0.36 102 82 0.80 300W
3 4 2 Series 185 97 0.52 97 77 0.79 200W

Table 7. AGS 858 LED Sign Style 3 VA Load & Matching Isolation Transformer (Series)

50

Instruction Manual

Sign

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

DOCUMENT 1025

REV. B

Style Sign Size # Modules CCR type

Sign VA
(Primary
Isolation

Xfrmr@

5.5A)

Watts
(Primary
Isolation
Xfrmr @

5.5A)

Power

Factor
(Primary
Isolation

Xfrmr)

Sign VA

(Secondar

y Isolation

Xfrmr@

5.5A)

Sign Watts

(Secondar

y Isolation

Xfrmr @

5.5A)

Power
Factor

(Secondar

y Isolation

Xfrmr)

Isolation

Transforme

r Type

5 1 1 Series 108 56 0.52 54 46 0.85 200W
5 1 2 Series 109 58 0.53 55 47 0.86 200W
5 1 3 Series 111 60 0.54 57 49 0.85 200W
5 1 4 Series 112 63 0.56 60 52 0.87 200W
5 2 1 Series 110 56 0.51 53 45 0.85 200W
5 2 2 Series 110 59 0.53 55 48 0.87 200W
5 2 3 Series 111 61 0.56 59 51 0.86 200W
5 2 4 Series 112 65 0.58 62 54 0.86 200W
5 3 1 Series 109 58 0.53 55 47 0.86 200W
5 3 2 Series 112 63 0.56 60 52 0.87 200W
5 3 3 Series 116 70 0.61 67 59 0.88 200W
5 3 4 Series 121 78 0.65 76 66 0.88 200W
5 4 2 Series 115 69 0.60 66 57 0.87 200W

Table 8. AGS 858 LED Sign Style 5 VA Load & Matching Isolation Transformer (Series)

51

DOCUMENT 1025

REV. B

Instruction Manual

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

Regulator Setting Current Range (A, RMS)

B10 4.7-4.9 (4.80 nominal)

B30 5.3-5.7 (5.50 nominal)

B100 6.4-6.7(6.60 nominal)

Table 9. Style 2 - Three step regulator currents

Regulator Setting Current Range (A, RMS)

B1 2.7-2.9(2.80 nominal)

B2 3.3-3.5(3.4 nominal)

B3 4.0-4.2(4.10 nominal)

B4 5.0-5.4(5.20 nominal)

B5 6.4-6.7(6.60 nominal)

Table 10. Style 3 - Five step regulator currents

Regulator Setting Current Range (A, RMS)

Fixed 5.4-5.6(5.50 nominal)

Table 11. Style 5 – Fixed regulator current

Note: See page vi for a list of meters that would be suitable for these measurements.

52

DOCUMENT 1025

REV. B

Instruction Manual

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

D4

(Red)

ON ON ON ON Output open circuit

ON OFF ON ON Output Voltage is less than or equal to 75% of Calibrated

OFF ON ON ON Input current < 2.5A or Input current > 6.7A

OFF OFF ON OFF +3.3 Volt Supply Failure

OFF OFF OFF OFF +15 Volt Supply and/or +3.3 Volt Supply Failure (assumes

D7

(Red)

D11

(Green)

D29

(Green)

Output Voltage or Output Voltage is greater than or equal

to 125% of Calibrated Output Voltage.

the main AC power is applied to the power supply board)

Fault

Table 12. Power Supply Faults

53

DESCRIPTION

Instruction Manual

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

PART
NUMBER

DOCUMENT 1025

REV. B

USED ON

Frangible Coupling 62245-1

62245-2
62245-3
62245-4

Power Supply PCB (located

62277 All Sizes

Size 1
Size 2
Size 3 & 5
Size 4

inside circuit box)

Heatsink/LED Assembly

62288 All Sizes

(located inside sign housing)

Filter PCB (located inside

62279 All Sizes

circuit box)

Bridge Rectifier and Thermal

62314 All Sizes
Pad Replacement Kit (located
inside circuit box)

Sign Face Panel (w/Legend) 62290-X Contact Factory with legend

information

Sign Panel, Black 60668-X Contact Factory with sign size

and number of modules

LED Array to LED array input
wire, white

62278-1(48”)

62278-2(12”)

62278-3(6”)

All sizes
All sizes except size 3
1,2,3,4 module and size 5
All sizes except size 1 & 2
1,2,3,4 module and size 4

Last LED array to power
supply PCB CN9, return wire,
black

62317-1(67”)

62317-2(85”)

62317-3(105”)

62317-4(92”)

62317-5(120”)

62317-6(144”)

62317-7(131”)

62317-8(162”)

62317-9(192”)

62317-10(158”)

62317-11(196”)

62317-12(232”)

62317-13(118”)

Table 13. Parts List

Size 1, 1 module
Size 2, 1 module
Size 3 & 5, 1 module
Size 1, 2 module
Size 2, 2 module
Size 3, 2 module
Size 1, 3 module
Size 2, 3 module
Size 3, 3 module
Size 1, 4 module
Size 2, 4 module
Size 3, 4 module
Size 4 DMS

54

DOCUMENT 1025

Instruction Manual

AGS-LED

858 LED Series

Sizes 1, 2, 3, 4 and 5

Sign Size/#Mod Force in Newtons Force in Lbs

Size 1, 1module 3,080 692

Size 1, 2modules 6,186 1,391

Size 1, 3modules 8,984 2,020

Size 1, 4modules 12,531 2,817

Size 2, 1module 4,773 1,073

Size 2, 2modules 9,587 2,155

Size 2, 3modules 14,442 3,247

Size 2, 4modules 19,420 4,367

Size 3&5, 1module 7,107 1,598

REV. B

Size 3, 2modules 13,657 3,070

Size 3, 3modules 20,573 4,625

Size 3, 4modules 27,664 6,220

Size 4 DMS 11,582 2,604

Table 14. Estimated max sustained force on the sign body (Does not include safety margin)

ி

Based on: C

D =

ଵ/ଶ௣ ௏మ ஺

ವ

V = 89,408 M/S

p = 1.2047 Kg/ M3 (@ 20°C dry)
CD = 1.16 for 1 module & size 4 and 5 DMS, 1.165 for 2 module, 1.17 for 3 module, and

1.18 for 4 module.

55