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Page No. 1

PORTABLE TRAFFIC SIGNALSPORTABLE TRAFFIC SIGNALSPORTABLE TRAFFIC SIGNALS

OPERATIONAL MANUALOPERATIONAL MANUALOPERATIONAL MANUAL

Page No. 2

SaferoadsSaferoadsSaferoads --- Portable Portable Portable Traffic SignalsTraffic SignalsTraffic Signals

Operation and Maintenance ManualOperation and Maintenance ManualOperation and Maintenance Manual

TABLE OF CONTENTS

1. SYSTEM CONCEPT AND DESCRIPTION ..Page 3

2. RULES FOR SAFE OPERATION ..Page 3

3. INSPECTION AND MAINTENANCE ..Page 3

4. GUIDE TO USE

...Page 4

5. DEFINITION OF TERMS ..Page 5 6. SETUP PROCEDURES ON WORK SITES

6.1 Positioning of Signals ..Page 7 6.2 Vehicle Detectors ..Page 8 6.3 Limitations on use of microwave detectors ..Page 8

CS-200 (Control Computer) 1. OPERATIONAL FEATURES

..Page 10 1.1 Lantern Inhibit ..Page 11 1.2 Time displays ...Page 11 1.3 Min and Max Times .. .Page 11 1.4 No. of signal lanterns. .. ..Page 11 1.5 GREEN Running Period when in NORMAL mode .. .....Page 11 1.6 Maximum Reversion when in NORMAL Mode ...Page 11 1.7 State of signal Indicators . ..Page 11 1.8 Auxiliary Lamp .. ..Page 12 1.9 Transmitter ON facility .. .. .....Page 12 1.10 Hour Meter ...Page 12 1.11 RF Channel Selection . ..Page 12

2. FRONT PANEL INDICATORS

..Page 13

3. DESCRIPTION OF MODES ..Page 14

4. MODE SELECTION

..Page 16

5. ENTERING TIMES

..Page 17

6. ALARM CONDITIONS ..Page 18

7. MAINTENANCE LOG

..Page 19

8. TROUBLESHOOTING

..0

CS-TRH3 (Radio Remote Control) 1. OPERATIONAL REQUIREMENTS

..Page 22

2. POWERING ON ..Page 22

3. TURNING OFF

..Page 22

4. PROGRAMMING

. ..Page 23

5. STOP BUTTON

. ..Page 23

6. RETURN BUTTON

. ..Page 23

APPENDICES Appendix 1 - General Maintenance ..Page 25 Appendix 2 - Batteries . ..Page 26 Appendix 3 - Equipment Specifications . ..Page 27 Appendix 4 - Quick Reference/Programming Guide . ..Page 28 Appendix 5 - Warranty Statement ..Page 29 Appendix 6 - All-Red Clearance Graph .. .. ..Page 30 Appendix 7 - Lantern Specifications .. .. ..Page 31 Appendix 8 - Equipment Diagram ..Page 32

QUICK OPERATION GUIDE

... ...Pages 33 &34

Page No. 3

SafeRoadsSafeRoadsSafeRoads --- Portable Traffic SignalsPortable Traffic SignalsPortable Traffic Signals


1. SYSTEM CONCEPT AND DESCRIPTION

Portable traffic Signals are intended to be applied primarily to shuttle the control of vehicular traffic at road (or bridge) works where it is necessary to close a section of the carriage-way such that a single lane must be used alternatively by traffic from the opposite directions.

The equipment is comprised of two electronic controllers as MASTER and SLAVE mounted on a trailer unit capable of being split with each unit being positioned separately on the work site.

The portable Traffic Signals are capable of operating under manual or automatic control and each separate unit is self contained and powered by a bank of deep cycle batteries, recharged by solar energy.

Communications between the MASTER and SLAVE is by radio or cable link.

The Portable Traffic Signals have an inbuilt fail safe system that they will automatically revert to flashing yellow operation should a hazardous or incompatible conditions occur.

2. RULES FOR SAFE OPERATION

Failure to follow instructions may result in personal injury and/or property damage. Regain this operation manual and review frequently for continuing safe operation and instructing third party users.

The maximum operating distance between each unit of the system should not exceed 1000 metres.

The relationship between the ALL-RED clearance time and travel distance for a range of vehicle speeds is given in Figure 4.

The operation of the equipment and the setting of the on-site operational parameters should be restricted to a nominated operator to avoid problems resulting from fiddling and tampering by untrained and/or Inexperienced personnel.

Maximum visual range of Lanterns 100m System is designed to be operated on level ground. (See SETUP PROCEDURES ON WORK SITES)

3. INSPECTION AND MAINTENANCE

1. Check the trailer service lights before towing

2. Check tyre pressure and examine tyres for excessive wear before towing

3. Inspect all moving parts, joints and locking pins for excess wear, for correct adjustments and installation and for vandalism and/or damage before towing the trailers or raising the traffic signals

4. Check that traffic signal lantern doors are securely fastened

5. Check that signal lantern mountings are secure

6. Ensure that traffic signal lanterns are covered when in the travelling position as exposure to direct sunlight may cause the lens to melt.

7. Under normal operating conditions re-pack and adjust the wheel bearings annually

8. Clean all traffic signal lantern reflectors and inside and outside surfaces of the lenses with a soft cloth at regular periods, not exceeding three months

WARNING Do not attempt to operate the Portable Traffic Signals until you have read the operating Instructions thoroughly and understand completely all safety, operation and service instructions contained in this manual.

Page No. 4



4. GUIDE TO USE

SafeRoads Traffic Signals are designed and constructed in accordance with AS 4191:1994 - (Portable Traffic Signal Systems)

Different roads authorities have varying preferred operating parameters and may also often require the presentation of traffic management plans to the authority advising of their intended application and setup. It is recommended that the operator consult their local roads authority or council, prior to utilising your portable traffic signals.

Following is a guide where you may find operating guidelines in your local area: - Note some authorities do not have specific Guidelines.

Australia:

Victoria: VicRoads Worksite Traffic Management Code of Practice

www.vicroads.vic.gov.au

New South Wales RTA Technical Directions - Use of Portable Traffic Signals - www.rta.nsw.gov.au

Tasmania: Dept. of Infrastructure, Energy & Resources. Traffic Control at worksites code of practice www.transport.tas.gov.au/safety/traffic_control_code/

Queensland Department of Main Roads Part 3 Manual of Uniform Traffic Control Devices http://www.mainroads.qld.gov.au/

New Zealand

Transit New Zealand Code of Practice for Temporary Traffic Management (Section B5) - www.transit.govt.nz

Disclaimer: SafeRoads Portable Traffic Signal Systems are designed, constructed and operate in accordance with AS 4191-1994 (Portable Traffic Signal Systems) at present they have not been certified as complying with

this standard.

SafeRoads traffic signals have the ability to be coupled together. It is advised operators check local state roads laws, prior to towing the units together.

http://www.vicroads.vic.gov.au

http://www.rta.nsw.gov.au

http://www.transport.tas.gov.au/safety/traffic_control_code/

http://www.mainroads.qld.gov.au/

http://www.transit.govt.nz

Page No. 5

SafeRoadsSafeRoadsSafeRoads --- Portable Portable Portable Traffic SignalsTraffic SignalsTraffic Signals


6. SET UP PROCEDURES ON WORK SITES

(Slave or rear Trailer Section)

1. Remove lantern covers, and disconnect rear trailer light plug from between each trailer section. (Note keep the master trailer, connected to the towing vehicle)

2. Remove the pin located on the master trailer draw bar

3. Slide the rear trailer out of the master trailer to create some distance between the slave and master trailer

4. Lower the front stabiliser legs of the slave unit and completely remove master from slave

5. Adjust stabiliser legs to ensure trailer is secure

6. Connect radio aerial to its fitting located on the top lantern mounting bracket

7. Raise the traffic signal mast to your desired height using the up/down electronic actuator switch.

8. Ensure the traffic signal lanterns are aimed correctly -Vertical Alignment (By use of the levelling jacks ) - Horizontal Alignment (By positioning the trailer).

Trailer (Master or Front Trailer)

1. When towed into desired position, Un-couple master unit from trailer using jockey wheel to raise off tow coupling. Once disconnected and the trailer is stable, chains and trailer plug can be disconnected.

2. Remove trailer from towing vehicle

3. Follow steps 6 to 9 of the above slave section

4. Switch on the Master unit be depressing button labelled ON at the left hand side of Master unit, then switch on the slave unit.

Note: It is recommended that to save manual movement of trailers, to tow both trailers to proposed slave position first, so that slave trailer can be setup without having to be moved!

Fig 6.1 Fig 6.2

Page No. 6



6. SET UP PROCEDURES ON WORK SITES Cont..

6.1 Positioning of Signals

Normally one signal lantern is used on each approach, thereby requiring only one set of equipment for effective working on one road.

The lantern must be placed so as to give approaching drivers a conspicuous signal and also to be clearly visible to drivers stopped behind the

stop line. The signal aspects should be aimed towards the vehicular traffic: vertical adjustment is by adjusting the lantern on the stand, horizontal

adjustment is arranged by positioning the stand itself on the ground. In practice, the aiming of the vehicle detectors (if fitted, located on top

of the lanterns) is more critical than the lanterns, so the main emphasis of the aiming operation should be as detailed in Section 10.8.5, Vehicle

detectors.

Generally, the signal unit should be positioned so as to be as nearly as possible in the driver's line of sight. It is essential to locate signals so the

driver has sufficient sight distance to stop on a red display. The minimum sight distance to the signal lantern required for stopping depends

mainly on the vehicle type and vehicle speed in the approach to the work area.

Table 6.11 provides a guide to stopping sight distances on level bituminous or concrete surfaces

Vehicle speed (km/h)

Stopping sight distance (m)

Cars Trucks 50

60

70

80

90

100

110

60

80

100

120

140

170

210

80

100

130

160

190

230

270 Table 6.11 Stopping Sight Distances for Cars and Laden Trucks on level

Pavements

Page No. 7

Vehicle detectors are used to relay an electrical impulse to the controller when a vehicle approaches. One detector per approach is required.

Microwave detectors may be located on top of the traffic signal lantern and the beam from the transmitter is reflected back to its receiver

by the approaching vehicle. The microwave detector will only detect objects moving towards it. Care must be taken to ensure that unwanted

vehicles (eg. construction vehicles) do not actuate the detector.

Response of the microwave detector will be dependant upon the speed of movement and the size of the target object. In general terms the unit,

when positioned to look at an approach, should detect:-

* a motorbike moving within the range, 20 to 5 m from the unit

* other larger motor vehicles moving within the range, 30 to 5 m from the unit.

This is assuming that the detector is mounted at a height of between 2.5 and 3 m and the object being detected is moving at a s peed of greater than 5 km/h.

It must be emphasised that the detector should be positioned in such a way that its beam axis is pointed at the centre of the target area

and at a distance of approximately 25 to 35 m ahead of the unit. For single lane approaches it is suggested that the unit be aimed

more towards the road edge. This will result in an increased sensitivity

to the desired vehicular movements but at the same time decrease the

sensitivity to vehicles travelling away (on the departure side of the street). Although the departing vehicle will not produce a

detection output, it can cause a swamping or masking of a signal being reflected by an approaching vehicle.

In practice, aiming of the microwave detector is achieved by moving the complete stand (adjustment in the horizontal plane) and by tilting the

lantern by the adjustment at the top of the stand (adjustment in the vertical plane).

A visual indicator built into the rear of the detector case assists in the aiming operation. Vehicles should be able to be detected

(as indicated by the visual monitor) at a distance of 5 30 m ahead of the signal stand.

6.3 Limitations on use of microwave detectors

Microwave detectors will only register moving vehicles and so, if for any reason a demand is lost, stationary vehicles waiting at the lights may be ignored by the equipment.

A demand can be lost if vehicles are unable to move off a green display. If vehicles do not start to move within 15 seconds of receiving a green display the controller will terminate the phase and will ignore the waiting vehicles. To clear these vehicles it is necessary to either:-

a) wait until a new vehicle joins the queue and actuates the detector, or

b) change to manual operation (once traffic is running again, the controller can be returned to vehicle actuated operation), or

c) wait until the controller (or detector) puts in an artificial demand (it is programmed to place such an artificial

demand approximately 200 seconds after the phase was last demanded).



6. SET UP PROCEDURES ON WORK SITES Cont..

6.2 Vehicle Detectors

Page No. 8

Figure 6.31 Illustration of microwave detector operation



Page No. 9

1. OPERATIONAL FEATURES

* 1 way operation - Flash yellow - Manual - Auto (Time Mode) - Normal (Vehicle actuated mode)

* 2 way operation - Manual return - Auto Return (Not allowed in NSW)

* Cable Manual Controller can be operated up to 100m from the master unit

* Radio Remote Manual Controller is available as an option.

* Vehicle Actuation is available as an option

* Times displayed in seconds or minutes and seconds

* Operates for 3 days on battery power alone

* All times easily entered and stored automatically I computer memory (EEPROM)

* Demand indication for setting up vehicle detection.

* Battery charge indication and battery fail detection

* Flashing lanterns on signal heads indicating which unit is on red

* Accurate battery voltage of both master and slave available on the main control panel

* Fault description displayed on Liquid Crystal Display

* Radio or Cable interconnection

* Auxiliary lantern drives provided

* Inbuilt fault log

* Lanterns can be turned off for setup or maintenance

* Easy motherboard replacement

* Readily available components are used



CS-200

(Control Computer)

OPERATING INSTRUCTIONS

Page No. 10



1.1 LANTERN INHIBIT

The CS-200 may be placed into a condition where the system functions normally with the exception that the lanterns re main blacked out. The system must be in FLASH YELLOW before this mode can be selected and will return to FLASH YELLOW when lanterns are enabled again. The main use of this mode is in the setup and testing of the system while the units are positioned on the side of the carriageway. To select or de-select mode, select FLASH YELLOW then press:-

Enter: 800 YELLOW TIME (Lanterns OFF) 801 YELLOW TIME (Lanterns ON)

1.2 TIME DISPLAYS

The system is supplied with all times displayed in seconds but they may be displayed in minutes and seconds if required. The procedure to change displays is as follows:

Enter: 614 YELLOW TIME (Security Open) 640 YELLOW TIME (Minutes and seconds) 641 YELLOW TIME (Seconds) 651 YELLOW TIME (Security close)

1.3 Min. and Max. Times

Minimum and maximum times are factory set to NSW, RTA specifications.

1.4 No. of signal lanterns.

A separate connector is provided on the side of the CS-200 in both the Master and Slave to provide auxiliary drives to a second lantern. This lantern must provide its own power for the lamps.

1.5 GREEN Running Period when in NORMAL mode.

When a vehicle actuates a detector, the demand is processed and that phase will go to GREEN as soon as possible depending on the state of the opposite phase and the preset RED time. After the MIN. GREEN TIME has expired on the running phase, the GREEN aspect is extended by a vehicle while it is actuating the detector and for a period of 5 seconds following the termination of the vehicle detector output. At the end of this extension period, and if there have been no further actuations on the running phase in this time, this phase will go to RED. If a vehicle actuates a detector as it approaches a RED PHASE and the other phase is GREEN and being extended, a demand is stored and the MAX GREEN TIMER of the running phase is started. When this timer expires, the controller will service the other phase.

1.6 Maximum Reversion when in NORMAL mode.

In the event of the GREEN period being terminated by the operation of the MAXIMUM GREEN TIMER , a demand is stored for that phase and is acted upon as soon as traffic on the other phase permits.

1.7 State of signal indictors

On both Master and Slave, coloured ultra bright LED s (which represent the lanterns) provide indication of which aspect is on. Any faulty lantern will be indicated by an error display on the LCD.

E.g MASTER RED GLOBE FAILURE

Page No. 11



1.8

AUXILIARY LAMP

The auxiliary lamp is positioned behind the target board and provides indication to the operator when that uni is showing RED. To allow low power consumption at night, the Auxiliary lamp may be turned off and on as follows:

Enter: 500 YELLOW TIME (Aux lamp OFF) (Not in NSW) 501 YELLOW TIME (Aux lamp ON) (Not in NSW)

1.9 TRANSMITTER ON FACILITY

The transmitter can be forced to stay on for 15 seconds to allow the testing of its output as well as the condition of the aerial. To initiate this facility

Select FLASH YELLOW Enter: 614 YELLOW TIME (Security Open)

609 YELLOW TIME (Master Tx on) 610 YELLOW TIME (Slave Tx on) 611 YELLOW TIME (Remote Tx on) 615 YELLOW TIME (Close security)

1.10 Hour Meter

This facility is an option and may be purchased at any time. To reset meter

Enter: 614 YELLOW TIME (Security Open) 646 YELLOW TIME (Reset Meter) 615 YELLOW TIME (Close Security)

View 902 YELLOW TIME

1.11 RF Channel Selection

A separate connector is provided on the side of the CS-200 in both the Master and Slave to provide auxiliary drives to a second lantern. This lantern must provide its own power for the lamps.

Page No. 12



5. DEFENITION OF TERMS

Actuation the electrical action produced by a vehicle (by means of a vehicle detector) to enable

the controller to recognise its presence.

All red a period of time for the clearance of traffic

within the controlled areas, during which red displays are shown to all approaches

Aspect a single optical system of a signal lantern (i.e. a three aspect lantern has a red aspect

uppermost, a yellow aspect below it and a green aspect at the bottom).

Controller the device which regulates the order and duration of the displays of the signal lanterns.

Controlled area the area of roadway shared by conflicting traffic streams controlled by traffic signals.

Cycle Length the time interval between the start of the green display on two successive

cycles of the same phase.

Demand the request for a green signal by traffic on a phase which has a red signal display (ie. which does not have right of way on arrival).

Display an aspect which is illuminated.

Extension the additional green time allocated to a vehicle actuating the detector during the green period.

Gap

the time interval between the detection of two successive vehicles in a traffic stream.

Maximum green period the maximum time that a green display can show for one phase when a

demand has been made by traffic for another phase.

Minimum green period the shortest time for which the green display shows following the all red

period. No change of vehicle displays can occur during the Minimum Green Period.

Phase an interval which permits a particular traffic movement or combination of compatible movements.

Portable traffic light signals

traffic light signals and associated equipment used at work sites and

operated in one of the following modes:-

Manually Operated Mode (MAN) in which the duration and the sequence of displays, are varied by an operator

manually controlling the signals. MAN/1 refers to one way or shuttle manual control and MAN/2 refers to

two way manual control.

Vehicle actuated mode (VA) in which the duration and the sequence of displays vary automatically in relation to the

traffic flow into the controlled section

Fixed time mode (FT) in which the duration and the sequence of displays are preset and do

not vary with traffic flow.

Shuttle working the traffic arrangement used where a portion of the roadway is closed,.

Signal lantern an assembly of one or more signal aspects.

Vehicle detector the equipment which senses the presence or passage of vehicles.

Page No. 13



2. FRONT PANEL INDICATORS

The indicators used are solid state Ultra Bright, 5mm dia. LED s mounted in black plated brass bezel. All the indicators listed below are provided on both Master & Slave.

Power Indicators

Charge

Lantern Indicators

These indicators show the condition of the lanterns for both the Mater and Slave. They have been arranged and coloured to represent each signal lantern.

Status Indicators

Transmit - Indicates that the unit is transmitting data

Receive - Indicates that the unit is receiving valid data

Demand - Indicated the actual demand received from the vehicle detector, Used to test and adjust the vehicle detector.

Remote - Indicates that the unit is receiving valid data from the Radio Manual Controller and is used to check the operation of this unit.

(Radio Manual Controller is an option)

Page No. 14



3.

DESCRIPTION OF MODES

One Way Operation

Flash Both Master and Slave flash yellow

Manual-1 traffic signals are under the control on the Manual Controller

Auto Traffic signals are under the control of Preset Timers

Normal Traffic signals are under the control of Vehicle Detectors but times are limited by the pre-set timers.

Flash Yellow There are three ways the system can enter this mode:-

1. When the Master or Slave is turned on, this mode is automatically selected 2. If fault condition is detected 3. Selected by pressing the FLASH mode button

Manual-1 A small handled cabled controller is used to control all manual functions. It is connected to the Master Control panel via a 50 meter 4 core cable which can be extended to 100 meters. The manual controller has three buttons:-

-STOP -MASTER GREEN - SLAVE GREEN

Indication of the state of the traffic lights is also provided. This indication will flash if a button is operated while the system is in a MINIMUM TIME period of RED CLEARANCE TIME. This is important due to the fact that the minimum green and red times cannot be over ridden and some indication needs to be given the operator that the system has received the command but is waiting for a minimum time.

To select this mode, press the MANUAL mode button on the Master unit. The system is now under the control of the manual controller. Pressing the STOP button will terminate the running phase which will go to RED. Both phases will stay on RED until a MASTER GREEN or SLAVE GREEN button is pressed. (Note that the pre-set RED TIMES cannot be overridden.) While the Master is green, pressing the SLAVE GREEN BUTTON WILL HAVE NO EFFECT AND VICE VERSA.

AUTO (Time Mode) This mode is used to control a single lane of traffic where preset timers are used to regulate stop and go times. Times are entered via the key pad and assigned to appropriate timers.

All times are displayed on the LCD and automatically stored in memory when the system is turned off. This alleviates the need to re-enter the times every time the system is turned on.

Before the mode, RED and GREEN times must be determined and entered into the Master Unit. To set, use the keypad at the Master unit to enter the time, then press required TIME SETTING key. (Eg. Master Red Time)

Once the times have been entered, press the AUTO mode button. If the system is in FLASH YELLOW when the AUTO button is pressed then both phases will go to RED and traffic will be controlled in accordance with the present times. If the system is in NORMAL mode when the AUTO button is pressed, then the present cycle will be allowed to finish before the AUTO mode takes control

Page No. 15



NORMAL (Vehicle-actuated mode)

This mode is used to control a single lane of traffic where vehicle detectors are used in conjunction with preset timers. When a moving vehicle is detected a demand is stored, displayed on the LCD and used to control traffic flow.

Before entering this mode, RED and GREEN times must be determined and entered into the Master unit. To set, use the key-pad at the Master unit to enter the time, and then press the required TIME SETTING key. (Eg. Master Red Time)

Once the times have been entered, press the NORMAL mode button. The system automatically registers an artificial demand for each phase for the first cycle, and then allows the control of traffic in accordance with the detected vehicle flow and the times that have been preset.

If the vehicle detector in not connected an alarm will occur and the system will not select this mode.

NOE: 1:- The type of vehicle sensor used will detect movement only. It is therefore possible for a vehicle to be waiting and not have been detected. If this deemed to be the problem, the sensor can be modified to produce a pulse every 2.5 minutes. Contact supplier for details.

NOTE: 2:- Systems are supplied with detectors operating on a frequency of 10.525 GHz which do not require an individual license. Systems may be supplied (ON REQUEST) with detectors operating on a frequency of 10.587 GHz, but these units will require an individual license.

NOTE: 3:- Check at lest once a year that frequencies and licenses are still valid.

Two Way Operation

Manual 2 Manual return

This mode of operation is used where traffic is flowing in both directions and ROAD PLANT requires crossing, or having access to the carriage-way. Both the master and slave are normally showing GREEN allowing traffic flow in both directions. When the Master receives a STOP command, both the Master and Slave go to RED. This condition will remain until the Master receives a GO command where upon the Master and Slave go back to GREEN.

Manual 3 Auto return

This mode of operation is used where traffic is flowing in both directions and ROAD PLANT or other vehicles are leaving a work area and find it difficult to enter a busy carriage-way. The CS-200, when in this mode, would have the CABLED MANUAL CONTROLLER or PORTABLE RADIO MANUAL CONTROLLER (optional) positioned so the driver of the vehicle wishing to enter the carriage-way can operate the STOP button. Both the Master and Slave normally show GREEN allowing traffic flow in both directions. When the driver presses the STOP button the Master and Slave go to RED. After a preset time, set by the Master Red Time , the Master

and Slave go back to Green.

Lantern Inhibit Operation

The CS-200 may be placed into a condition where the system functions normally with the exception that the lanterns remain blacked out. The system must be in FLASH YELLOW. Before this mode can be selected and will return FLASH YELLOW when lanterns are enables again. The main use of this mode is in the setup and testing of the system while the units are positioned on the side of the carriageway.

Page No. 16



4. MODE SELECTION

One Way Operation

When the system is turned on, 1 way operation and FLASHING YELLOW are automatically selected. NORMAL , TIME or MANUAL-1 modes cam be selected by pressing the required mode button.

Two Way Operation MANUAL 2- Manual Return

To enter this mode, put the system into FLASH YELLOW AND PRESS THE No 2 key on the keypad twice followed by the MANUAL button . The display will read:-

MODE: MANUAL 2 (TWO WAY)

The function of the buttons on the controller are:-

STOP Both Master and Slave go to RED. MASTER GREEN Both Master and Slave go to GREEN. SLAVE GREEN Both Master and Slave go to GREEN.

MANUAL 3 Auto return To enter this mode, put the system into FLASH YELLOW and press the No 3 key on the keypad twice followed by the MANUAL button. The display will read:-

MODE: MANUAL -3 (TWO WAY)

The function of the buttons on the controller are:-

ALL STOP Both Master and Slave go to RED MASTER GREEN No effect SLAVE GREEN No effect

Lantern Inhibit To select or de-select this mode, select FLASH YELLOW and press:-

Lanterns OFF 800 YELLOW TIME

Lanterns ON 801 YELLOW TIME

Low Battery Audible Alarm Inhibit To turn the low battery audible alarm ON and OFF, press:-

Alarm OFF 700 YELLOW TIME

Alarm ON 701 YELLOW TIME

Programming the Radio Manual Remote The remote has to be programmed by the Master unit before it can control the system. To do this select FLASH YELLOW , hold down the MANUAL/AUTO button on the remote and press:-

Program 600 YELLOW TIME

Page No. 17



5. ENTERING TIMES

MASTER RED TIME

Time to clear the carriage-way before the Slave goes GREEN.

To set - Using the Keypad at the Master unit enter the time, then press MASTER RED TIME

SLAVE RED TIME

Time to clear the carriage-way before the Master goes GREEN.

To set - Using the keypad at the Master unit enter the time, then press SLAVE RED TIME

MASTER GREEN TIME

Period of time the Master will remain on GREEN

To set - Using the keypad at the Master unit enter the time, then press MASTER GREEN TIME

SLAVE GREEN TIME

Period of time the SLAVE will remain on GREEN

To set - Using the keypad at the Master unit enter the time, then press SLAVE GREEN TIME

YELLOW TIME

Period of time yellow aspect on the Master and Slave will remain on when the system is changing between GREEN and RED

To set - Using the keypad at the Master unit enter the time, then press YELLOW TIME

Page No. 18



6. ALARM CONDITIONS

System Error

The audible alarm is sounded and the display will have description of the fault. The audible alarm may be turned off by pressing the CLEAR this does not affect the display.

Reliability Error

If 5 errors have been detected in a so minute period, then this alarm will be displayed.

Fatal Error

If the main electronic system stops or it has detected that two aspects are not at the same time then this condition will be invoked.

This alarm is indicated by flashing all the status lamps on the front panel. (The display may or may not indicate this error.)

Page No. 19



7. MAINTENANCE LOG

The CS -200 has an inbuilt logging system which can be helpful for field maintenance but is intended mainly for base maintenance. Access is from the keypad by entering a special code to select the required information. To prevent the System Unreliable alarm being invoked during setup or testing, a Fault Free period of 3 minutes has to expire before

faults are counted for this alarm.

To Clear System Log Enter 999 YELLOW TIME

To select System Log Enter: 900 YELLOW TIME

Codes

Description

M DEAD VOLT Master battery below 10v M LOW VOLT Master battery below 11v M LINK FAIL Master not receiving Slave M RED FAIL Master red globe failure M YELLOW FAIL Master yellow globe failure M GREEN FAIL Master green globe failure M SENSOR FAIL Master vehicle sensor not completed M LANTERN FAIL Master lanterns not connected or inverter failure M REMOTE FAIL Master remote lantern failure M FATAL ERROR Master fatal error. (System dead or two globes on)

S DEAD VOLT Slave battery below 10v S LOW VOLT Slave battery below 11v S GEN FAIL Slave generator stopped during normal operation S LINK FAIL Slave not receiving Master S RED FAIL Slave red globe failure S YELLOW FAIL Slave yellow globe failure S GREEN FAIL Slave green globe failure S SENSOR FAIL Slave vehicle sensor not completed S LANTERN FAIL Slave lanterns not connected or inverter failure S REMOTE FAIL Slave remote lantern failure S FATAL ERROR Slave fatal error. (System dead or two globes on)

UNRELIABLE Five alarms have occurred in the last 20 minutes

Page No. 20



8. TROUBLE SHOOTING

If you hear an alarm:-

Look around the site and notice:-

A. What type of day - Hot (Temp?) - Cold

- Wet

B. Any big trucks near units? - Yes - No

C. How far apart are the units? -

D. Are the units. - Inline of site? - Over a hill? - Around a treed corner? - Around a hill?

E. Was there anyone transmitting nearby. - What frequency?

F. Are the controllers in direct sunlight? -Yes - No

G. Are the aerials connected? -Yes -No

H. - Has the slave been turned on properly -Yes -No

2. Turn alarm off by pressing clear

3. Press 902 YELLOW TIME and record - Software version - Serial Number

4. Press 900 YELLOW TIME and record log - 3 - 2 - 1

A. -M DEAD VOLTS OR S DEAD VOLTS

Indicates that the battery is below 10v and the system will turn itself off.

Possible Causes - System running too long on batteries - Battery terminals making poor connection.

B. M LOW VOLTS OR S LOW VOLTS

Indicates that the battery is below 11v and the system will automatically go to FLASH YELLOW

Possible Causes - Flat Batteries - Batteries in poor condition - Solar panels not charging batteries - Battery terminals making poor connection

Page No. 21



C. M LINK FAIL OR S LINK FAIL

Indicates that the radio communication between the master and slave is faulty.

How far you can receive a signal depends on:- 1. - Frequency - Lower the frequency the further the transmission 2. - Power output - Higher the power the further the transmission 3. - Aerial - Better the aerial the further the transmission 4. - Ground plane - Larger the ground plane the further the transmission.

(Ground is the metal area at the base of the signal) (Some aerials are designed to work without a ground plane.)

5. - Receiver sensitivity - Better sensitivity the further the transmission. NOTE: - If the transmission path is obstructed by earth or rocks then the system will be unreliable

OBSERVE Is the receive light on the SLAVE unit flashing? (Helps us to know where to look)

CHECK - Aerials/Aerial leads - Does the system work if the units are closer together?

D. M RED FAIL OF S RED FAIL (also for yellow and green lamps)

Indicate that the red lamp or wiring to the red globe is open circuit

CHECK - Lamp - That the lamp socket is not corroded - Wiring in lantern connector is ok - Swap the controllers eg. Put the master controller in the slave trailer and vice versa. Does the fault stay with the controller? Yes - No

E. M SENSOR FAIL OF S SENSOR FAIL

Indicates that the vehicle detector is not connected to the controller. Will only occur in NORMAL mode.

CHECK - All connectors are tight - Wiring is ok

NOTE: The audible alarm is inhibited when you first select Normal mode

F. M LANTERN FAIL OS S LANTERN FAIL

Indicates that the lanterns are not connected to the controller

G. M FATAL ERROR OF S FATAL ERROR

Indicates : 1. The computer inside the controller is faulty 2. Two or more lamps are on at the same time.

CHECK - Lantern connector (wiring) - Lantern Wiring

Swap the controllers eg; - Put the master controller in the slave trailer and vice versa. Does the fault stay with the CONTROLLER? - Yes

- No Unreliable

Occurs when there has been 5 errors on the last 20 minutes. Indicates that the transmission path is not reliable and should be attended to.

Page No. 22



CSCSCS---TRH3TRH3TRH3 Radio Remote ControllerRadio Remote ControllerRadio Remote Controller

1. Operational Requirements

* The controller should be operated while the unit is held in the hand and preferably in line of

sight of the Master Control Unit. Control range is up to 1km, depending on conditions. The controller may be used from vehicles but the range of control will be reduced.

* KEEP OUT OF DIRECT SUNLIGHT. Should this happen for an extended period, the display will go black and render itself unreadable. It will usually recover when the controller cools down, but it cannot be guaranteed.

* Unit should only be recharged with the Battery Charger provided.

LCD Display Screens

CS-200 : v1.03

Is displayed on initial turn on and indicates the software version

Remote not receiving

Indicates the Master Controller is turned off or that the serial number of the system has not been programmed into the controller.

PROG SN xxx

Indicates that the serial number of the system is being programmed into the controller.

(MODE)

Indicates the mode in which the system is currently running

Wait TIMING Indicates that a button on the controller has been pressed but the system is waiting for a minimum time to expire before the function can be implemented.

2. Powering On Unit

To turn on the remote controller, momentarily press any button the controller. The LCD display will read CS-200 : V1.03 and then display the condition of the system or REMOTE NOT REVEIVING . If this is

displayed, the probable cause will be that the serial number of the system needs to be programmed into the controller (See Programming) The first operation of any button is used to turn the unit ON. The second operation is transmitted as per normal.

3.

Turning Off

The remote controller has been designed to turn itself OFF 5 Minutes after the last button was pressed. The serial number of the system is automatically stored in memory so programming is only required to be done once for any particular system. If the unit is running on external power the Controller will remain ON until the power is removed.

Page No. 23



CSCSCS---TRH3TRH3TRH3 Radio Remote ControllerRadio Remote ControllerRadio Remote Controller

4. Programming

When the remote controller is turned on and the LCD displays REMOTE NOT RECEIVING , the probable cause will be that it requires to be programmed. With the serial number of the system it is to control. The procedure to do this is as follows :-

1. Turn on the CS-200 Traffic Light Controller and select FLASH YELLOW on the MASTER

2. While holding down the RETURN on the remote controller, key in the following code on the MASTER key pad:-

600 YELLOW TIME

The display on the remote controller will indicate that it is being programmed and show the serial number of the system.

5. Stop Button

When the system is in MANUAL 1 and the STOP button is pressed, both the Master and Slave will go to RED. If the system is in FLASH YELLOW , AUTO OR NORMAL , MANUAL 1 is automatically selected with the Master and Slave showing RED. The MASTER GREEN and SLAVE GREEN buttons are no operational and it will operate the same as the cable manual controller.

6. Return Button

This button has two functions :- 1. Used for programming the remote. (See programming) 2. Returning the system back to the previous mode of operation. Eg:-

Assume the system is in NORMAL mode. The STOP button on the remote controller is pressed and the system goes to MANUAL 1 After controlling the system in MANUAL mode, and you wish to return to the NORMAL mode, press the RETURN button. The system automatically selects NORMAL and continues

on without any disturbance to traffic flow. This feature only works when the system is in ONE WAY OPERATION and the previous mode was either NORMAL or AUTO modes (Cannot go back to FLASH YELLOW

Page No. 24



Page No. 25



Appendix 1

GENERAL MAINTENANCE

SafeRoads portable traffic signals are designed and manufactured to provide years of trouble free service, while demand-ing a minimum amount of care and maintenance. Aside from keeping the lanterns and the solar array clean and free from debris, your signals will consume very little of your equipment maintenance resources!

The signal lanterns should be cleaned periodically as required to maintain optimum visibility of the display. Use plenty of water to minimise scratching of the surface by abrasive dust and debris that may accumulated. A mild detergent can be used to remove any accumulated oil or grease deposits. Rinse the surface thoroughly to completely remove the dirt and detergent residue. Avoid using strong alkali detergents or petroleum-based solvents. Certain solvents will cause severe damage to the polycarbonate surface and are not necessary for effective cleaning.

The solar panels used in the solar array have a tempered glass upper surface and can be cleaned using the same techniques as those employed in cleaning the signal lanterns In the event that the solar array becomes covered with snow or ice, the excess residue should be removed as soon as possible. It is not necessary, nor desirable, to aggressively scrape frozen snow or ice accumulation from the panels.

General overall cleaning of the entire unit is recommended as a part of the routine maintenance schedule to optimise the performance and life expectancy of the traffic signals. A mild detergent and plenty of water is all that should be required to remove accumulated dust and road film. Avoid using strong alkali or abrasive cleaning compounds. They are not necessary and may damage the finish.

Although, under typical operating conditions, very little lubrication service is required, it is still an important aspect of maintaining trouble free operation and minimising rust and corrosion problems.

The dolly wheel and stabilising jacks should be lubricated regularly. Apply a small amount of chain lube at the hole located at the top of the swivel jack outer tube to lubricate the internal screw mechanism. Lubricating these and other pivot points not only ensures that these mechanisms remain free and easy to operate, but also that rust and corrosion are kept to a minimum.

The trailer axle wheel bearings should be cleaned and repacked with a good grade of lithium-based bearing grease at least once a year, more frequently if the trailer is used heavily, particularly in excessively dusty environments or if the axle has been submerged in water. Remove the dust cap from the axle hub, remove and discard the cotter key , and remove the castle head nut. Remove the wheel and hub from the axle spindle, being careful to prevent the bearings from falling and becoming contaminated with dirt. Clean the old grease from the bearings, hub and spindle. Repack with clean wheel bearing grease and reassemble. Always replace the cotter key with a new one to ensure secure retention of the spindle nut

Page No. 26



Appendix 2

BATTERIES

When servicing the batteries, as with any lead acid type battery, there are a few precautions that should be observed:

1. Never expose the area over and around an open battery compartment to a spark or open flame. Lead acid type batteries produce hydrogen gas during a recharge cycle and an accumulation of the gas exposed to a spark or flame could result in an explosion! Since hydrogen gas is much lighter than air and dissipates very quickly, the only area of concern is immediately above and around the battery compartment.

2. Always exercise extreme care when using metal tools around the battery terminals. The batteries used in your sign have an extremely large energy storage capacity and can generate several thousand Amperes of current if the terminals are shorted out by a metal too. This high current will cause the tool to heat up very quickly and possibly spray molten metal at the point of contact. The battery bank operates at a very low voltage level, specifically 12 volts, which is not high enough to present any danger of electrical shock. However, the battery bank s ability to generate very high current necessitates the exercising of extreme caution when working around t he battery terminals

3. The electrolyte used in lead acid batteries, whether liquid or gel, is highly corrosive and can cause skin irritation and burns. Use caution, whenever batteries are being serviced or re placed, to avoid spillage or case damage. If any of the electrolyte comes into contact with skin or clothing, remove it immediately by flushing with plenty of clean water.

The batteries, in general, require very little care and maintenance. The most important aspect of optimising the service life of the batteries is fluid level maintenance. The electrolyte level must always be maintained at a level above the plates inside the battery. If the electrolyte level drops below the tops of the plates, the portion of the plates that have been exposed will be permanently damaged. The electrolyte level is very easily maintained by simply adding distilled water as needed.

Simply remove the vent caps from each cell of the battery, check the level of the fluid, and add Distilled water, if necessary, to bring the electrolyte level up to the indicator ring located in the opening. A battery water dispenser, available at most auto parts stores, will expedite and simplify the process.

Battery fluid level should be checked every three to four months in temperate climates and every 30 days in very warm climates. Remember!, if the fluid level is not maintained, the useful life of the batteries will be dramatically shortened!

The only other maintenance items that should be performed on the batteries can be completed at the same time that the electrolyte level is being checked. Make sure that the fasteners holding the cables on the battery terminals are tight and that any fluid or residue build up on the tops of the batteries is removed. Use a damp cloth or sponge to wipe off any build up. This will help prevent corrosion of the terminals and the battery compartment and minimize breakdowns due to loose or corroded electrical terminals.

Gloves and safety goggles should be worn anytime service or repair work is being performed on the batteries or electrical terminals!

Page No. 27



Appendix 3

EQUIPMENT SPECIFICATIONS

DUAL TRAILER

Construction 50mm x 50mm x 4mm arc welded steel channel 1.6 gauge steel sheet

Length (Overall) 3400mm

Width (Overall) 1650mm

Height (Travel Position) 2165mm

Height (Operating Position) 2165mm

Weight 1000kg

Wheels 355mm

Tyres 185 x 75 x 14

Coupling 50mm Quick Release

POWER

Voltage 12 Volt

Solar 21x 125 Watt Solar Panels

Battery 4 x 200AH Deep Cycle Batteries

TRANSMITTER

Power Output 1 watt

Carrier Freq 151.4MHz (or as requested)

Deviation 3.0KHZ

Modulation FM

Data format 1.3 KHz

VF Freq 2.1 KHz

Page No. 28



Appendix 4

QUICK REFERENCE GUIDE

MAXIMUM DISTANCE BETWEEN UNITS

1 km

MAXIMUM VISUAL RANGE OF LANTERNS

100m

MAXIMUM OPERATIONAL TIME ON BATTERY POWER ALONE

5 Days

QUICK PROGRAMMING GUIDE

Clear System Log 999 YELLOW TIME

System Log 900 YELLOW TIME

System Times 901 YELLOW TIME

System S/N 902 YELLOW TIME

Lamps OFF 800 YELLOW TIME

Lamps ON 801 YELLOW TIME

Low Battery alarm OFF 700 YELLOW TIME

Low Battery alarm ON 701 YELLOW TIME

Program Manual Remote 600 YELLOW TIME

(while holding down the MANUAL/AUTO button on the Remote.)

To clear the Audible Alarm of any errors press the CLEAR button

Page No. 29



Appendix 5

WARRANTY STATEMENT

1. SafeRoads Traffic Equipment P/L (SAFEROADS) warrants that each product sold will be

free from defects in material and workmanship for a period of two years from date of supply, subject to the conditions and restrictions contained herein.

2. SAFEROADS further warrants all parts furnished under this warranty for a period which expires upon termination of the warranty onto which these parts were installed. All parts furnished outside of the warranty are warranted for a period of thirty days from supply date.

3. This warranty does not apply to a product that has not been installed or maintained in accordance with SAFEROADS S instructions, been subjected to damage in an accident, abused or neglected during operation, repaired or modified by persons not approved by SAFEROADS, or failed to have normal maintenance.

4. SAFEROADS S responsibility in respect to warranty claims is limited solely to repair or replacement, our option, of product found by SAFEROADS to be defective. SAFEROADS does not pay for labour charges, transportation charges or any incidental or consequential damages connected with removal of a product deemed to be defective or with installation or replacement of repaired product. Further, SAFEROADS disclaims any liability for, any incidental or consequential damages, including lost or duplicated time or expense, accruing for any reason to the owner or user of any products sold by SAFEROADS, whether claim is made in contract or tort or under any warranty or in negligence or otherwise.

5. SAFEROADS reserves the right to make changes in its products without incurring any obligations to incorporate such improvements in any products previously sold or in service.

6. The terms and conditions or this warranty cannot be altered without the written approval of SAFEROADS.

7. This warranty does not apply to any product which has not been paid for according to the terms under which the product has been invoiced. In addition, SAFEROADS will not honour any warranty claim from a customer whose account is not current according to SAFEROADS S payment terms.

8. SAFEROADS does not warrant batteries, lighting elements, and electrical ballast and items considered to be expendables in the text of operating the equipment.

9. The foregoing warranty is exclusive and in lieu of all other express, statutory and implied warranties including those of merchantability and fitness for any particular purpose.

Page No. 30

100

90

80

70

60

50

40

30

20

10

0

0 100 200 300 400 500 600 700 800 900 1000

10km/h 20km/h 30km/h

40km/h

50km/h

60km/h



Appendix 6

RELATIONSHIP BETWEEN ALLRELATIONSHIP BETWEEN ALLRELATIONSHIP BETWEEN ALL---RED CLEARANCE TIME AND RED CLEARANCE TIME AND RED CLEARANCE TIME AND

TRAVEL DISTANCE FOR A RANGE OF VEHICLE SPEEDSTRAVEL DISTANCE FOR A RANGE OF VEHICLE SPEEDSTRAVEL DISTANCE FOR A RANGE OF VEHICLE SPEEDS

TRAVEL DISTANCE (metres)

AL

L-R

ED

TIM

E (

seco

nds)

Page No. 31



Appendix 7

LANTERN SPECIFICATIONS

Page No. 32

PORTABLE TRAFFIC SIGNALS

QUICK OPERATION GUIDE

ONE WAY OPERATION (USED FOR CLOSURES OF ONE LANE OR OF TWO WAY ROAD)

There are three ways to control the lights in this mode.

1. Auto 2. Manual 3. Normal (Used with vehicle sensors)

1.

Auto

This is the most common mode of operation for the signals. This mode is used to control a single lane of traffic where preset timers are used to regulate stop and go times. Times are entered via the key pad and assigned to appropriate timers.

All times are displayed on the LCD and automatically stored in memory when the system is turned off. This alleviates the need to re-enter the times every time the system is turned on.

Before the mode, RED and GREEN times must be determined and entered into the Master Unit. To set, use the keypad at the Master unit to enter the time, then press required TIME SETTING key. (Eg. Master Red Time)

Once the times have been entered, press the AUTO mode button. If the system is in FLASH YELLOW when the AUTO button is pressed then both phases will go to RED and traffic will be controlled in accordance with the present times. If the system is in NORMAL mode when the AUTO button is pressed, then the present cycle will be allowed to finish before the AUTO mode takes control

2. Manual

A small cabled controller is provided with the traffic lights to control all functions manually. It is connected to the Master Control panel via a 50 metre cable. Also available is a radio remote controller that undertakes the same Functions. The manual and radio controller has buttons including STOP, MASTER GREEN AND SLAVE GREEN. On both controllers an indication of the state of the traffic lights is provided. This is important due to the fact that the minimum green and red times cannot be over ridded and some indication needs to be given to the operator that the system has received the command but is waiting for a minimum time.

To select this mode, press the MANUAL mode button on the Master unit. The system is now under the control of the manual or radio controller. Pressing the STOP button will terminate the running phase which will go to RED. Both phases will stay on RED until a MASTER GREEN or SLAVE GREEN button is pressed. (Note that the pre-set RED TIMES cannot be overridden.) While the Master is green, pressing the SLAVE GREEN BUTTON WILL HAVE NO EFFECT AND VICE VERSA.

3. Normal (Vehicle Actuated Mode)

This mode is used to control a single lane of traffic where vehicle detectors are used in conjunction with preset timers. When a moving vehicle is detected a demand is stored, displayed on the LCD and used to control traffic flow.

Before entering this mode, RED and GREEN times must be determined and entered into the Master unit. To set, use the keypad at the Master unit to enter the time, and then press the required TIME SETTING key. (Eg. Master Red Time)

Once the times have been entered, press the NORMAL mode button. The system automatically registers an artificial demand for each phase for the first cycle, and then allows the control of traffic in accordance with the detected vehicle flow and the times that have been preset.

If the vehicle detector in not connected an alarm will occur and the system will not select this mode.

Page No. 33

QUICK OPERATION GUIDE CONTINUED

ENTERING TIMES

MASTER RED TIME

- Time to clear the carriage-way before the Slave goes GREEN.

To set - Using the Keypad at the Master unit enter the time, then press MASTER RED TIME

SLAVE RED TIME - Time to clear the carriage-way before the Master goes GREEN.

To set - Using the keypad at the Master unit enter the time, then press SLAVE RED TIME

MASTER GREEN TIME - Period of time the Master will remain on GREEN To set - Using the keypad at the Master unit enter the time, then press MASTER GREEN TIME

SLAVE GREEN TIME - Period of time the SLAVE will remain on GREEN To set - Using the keypad at the Master unit enter the time, then press SLAVE GREEN TIME

YELLOW TIME - Period of time yellow aspect on the Master and Slave will remain on when the system is changing between

GREEN and RED To set - Using the keypad at the Master unit enter the time, then press YELLOW TIME

RELATIONSHIP BETWEEN ALLRELATIONSHIP BETWEEN ALLRELATIONSHIP BETWEEN ALL---RED CLEARANCE TIME AND RED CLEARANCE TIME AND RED CLEARANCE TIME AND TRAVEL DISTANCE FOR A RANGE OF VEHICLE SPEEDSTRAVEL DISTANCE FOR A RANGE OF VEHICLE SPEEDSTRAVEL DISTANCE FOR A RANGE OF VEHICLE SPEEDS

100

90

80

70

60

50

40

30

20

10

0

0 100 200 300 400 500 600 700 800 900 1000

10km/h 20km/h 30km/h

40km/h

50km/h

60km/h

TRAVEL DISTANCE (metres)

AL

L-R

ED

TIM

E (

seco

nds)

Example: If the distance between the signals is 800m on the worksite and the traffic is travelling at 40kph, the Master Red Times are Set to approx 72 seconds

Note to select 60 seconds press 060

This is the most important item, as it ensures that the traffic within the workzone have enough time to clear the workzone before the other lights turn green

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