Installation Instructions for the Two-Channel LED
Contents
1. or death Installation Instructions Introduction The LED Corner Lighthead 416500 XX is designed to fit a variety of applications It may be mounted on an exterior surface into vehicle light housings or rear mounted through a 1 inch hole The LEDs use polycarbonate lenses for maximum light output and a zinc base for heat sinking The LED which is supplied with mounting hardware includes a flasher wired into the cabling The LED Corner System has an operating temperature range of 30 C to 65 C Unpacking the Kit After unpacking the product inspect it for damage that may have occurred in transit If the product has been damaged do not attempt to install or operate it File a claim immediately with the carrier stating the extent of damage Carefully check all envelopes shipping labels and tags before removing or destroying them Ensure that the parts in Figure are contained in the packing carton Figure 1 Kit contents Gasket and flange for mounting on an exterior surface Light assembly Includes lighthead lighthead lead cable 18 1 flasher box 0 90 x 5 43 and 4 conductor power cable Oo Gasket for rear mounting through a 1 inch hole or into a vehicle light housing 96 2 O Phillips head mounting screws 2 N Installing the LED into a Vehicle Light Housing To install the lighthead 1 Remove the vehicle s reflector assembly according to2. verify with the vehicle manufacturer if the seat needs to be recalibrated for proper airbag deployment A light system is a high current device For it to function properly a separate ground connection must be made If practical it should be connected to the negative battery terminal At a minimum it may be attached to a solid metal body or chassis part that will provide an effective ground path as long as the light system is used Locate the light system controls so the VEHICLE and CONTROLS can be operated safely under all driving conditions After the installation test the warning light system for proper operation Although your warning system is operating properly it may not be completely effective People may not see or heed your warning signal You must recognize this fact and continue driving cautiously Also situations may occur which obstruct your warning signal when natural or man made objects are between your vehicle and others such as when raising your hood or trunk lid If these situations occur be especially careful At the start of your shift ensure that the light is securely attached and operating properly The mounting system should be periodically inspected to ensure that it is securely attached to the vehicle File these instructions in a safe place and refer to them when maintaining or reinstalling the product Failure to follow all safety precautions and instructions may result in property damage serious injury
3. LED Corner System 416500 X Installation Instructions Figure 3 Typical rear mount installation Mounting surface with 1 inch dia hole F Supplied sheet S metal screws 2 Wiring the LED Lighthead For instructions on wiring one kit in a vehicle see Figure 4 For instructions on wiring two kits together see Figure 5 on page 5 AWARNING LIGHT HAZARDS To be an effective warning device this product produces bright light that can be hazardous to your eyesight when viewed at a close range Do not stare directly into this lighting product at a close range or permanent damage to your eyesight may occur NOTICE DO NOT CONNECT DIRECTLY TO 12 Vdc Connecting these LED lightheads directly to 12 Vdc will cause the immediate failure of the LED lightheads NOTICE DO NOT CONNECT TO A STROBE POWER SUPPLY Connecting these LED lightheads to a strobe power supply will cause the immediate failure of the LED lightheads and may damage the strobe power supply Figure 4 Wiring for one LED corner lighthead kit LED Lighthead Flasher To Vdc fuse 12 V at 3 A 24V at 1 5 A RED To Chassis Ground 00000000 BLACK Not used WHITE For flash patterns YELLOW Two Channel LED Corner System 416500 X Figure 5 Wiring for two LED corner lighthead kits Note In this configuration
4. E FEDERAL SIGNAL Public Safety Systems 25500130 REV AO 0613 Safety Message to Installers and Operators of Warning Lights 44 WARNING People s lives depend on your proper installation and servicing of Federal Signal products It is important to read and follow all instructions shipped with this product and the original product In addition listed below are some other important safety instructions and precautions you should follow To properly install the lighting system you must have a good understanding of automotive systems along with proficiency in the installation and use of safety warning equipment This product contains high intensity LED devices To prevent permanent eye damage DO NOT stare into the light beam at close range If mounted into a signal lens housing the LED color and the VEHICLE lens color must match Either use a clear lens or match the color of the LED with the lens Using an LED colored differently than the lens color will greatly reduce the light output and reduce the effectiveness of the light for emergency signaling purposes This product is intended for supplemental warning and for use in conjunction with an approved primary warning light system When drilling into a vehicle structure be sure that both sides of the surface are clear of anything that could be damaged Do not install equipment or route wiring in the deployment path of an airbag If a vehicle seat is temporarily removed
5. ROPERLY To avoid damage to the lighthead do not overtighten the screws 7 Insert and tighten the 6 screws using care not to tilt the LED lighthead 8 To protect against moisture seal the perimeter of the LED lighthead with RTV 9 Reinstall the vehicle s reflector assembly and repeat the installation on the other side of the vehicle Figure 2 Typical installation into vehicle light housing Mounting screw holes l I r LED Lighthead 1 Supplied sheet metal screws l 1 inch dia hole L Gasket l b Installing the LED on an Exterior Surface To install the lighthead 1 Select a flat mounting surface on the exterior of the vehicle Use the oval mounting gasket as a template to mark center of the three holes Drill the 1 inch mounting hole and two holes for the 0 116 32 mounting screws Deburr the holes gt p gt The mounting surface must be clean and dry for the mounting gasket to adhere properly If necessary use isopropyl rubbing alcohol and water to clean the mounting surface 5 See Figure 3 on page 4 With the lighthead and gasket on the outside of the vehicle route the light cable and flasher box though the gasket and 1 inch hole 6 Place the platic flange over the lighthead Align the two pegs on the reverse side of the flange with the holes on the metal heatsink Ensure that the drainage hole faces down 7 Secure the assembly with the two 6 screws Two Channel
6. Unit1 alternates with Unit2 YELLOW Z Unit2 Flasher O WN BLACK WHITE to GND ON OFF See Figure 3 FUSE To synchronize two LED lighthead kits e Both kits must be set at the same pattern Installation Instructions installer supplied e Connect the yellow wires together CHASSIS e Connecting the WHITE wire from one of the flashers to Vdc enables the patterns from Flasher 1 to alternate with the patterns from Flasher 2 Selecting a Flash Pattern See Table 1 To select a flash pattern momentarily apply Vdc to the YELLOW wire once for the next pattern To reset apply Vdc quickly three times NOTE The flasher might not be factory set at Pattern 0 Table 1 Flash patterns Pattern Number 0 Random Single split Double split Quad split Quint split Mega split Ultra split Single Quad split Single H L split Single all Double all Quad all Quint all Mega all Ultra all Single Quad all Single H L all Steady 2 CA Steady 4 all Flash Patterns 1 2 3 4 5 6 7 8 9 Two Channel LED Corner System 416500 X Installation Instructions Getting Technical Support and Service For technical support and service please contact Service Department Federal Signal Corporation Phone 1 800 433 9132 Fax 1 800 343 9706 Email empserviceinfo fedsig com 7 AM to 5 pm Monday through Fr
7. iday Central Time Returning a Product to Federal Signal Before returning a product to Federal Signal call 800 264 3578 800 433 9132 or 800 824 0254 to obtain a Returned Merchandise Authorization number RMA number 7 am to 5 pm Monday through Friday Central Time To expedite the process please be prepared with the following information e Your Federal Signal customer or account number e The purchase order number under which the items were purchased e The shipping method e The model or part number of the product being returned e The quantity of products being returned e Drop ship information as needed e Any estimate required When you receive your RMA Number e Write the RMA number on the outside of the box of returned items e Reference the RMA number on your paperwork inside of the box e Write the RMA number down so that you can easily check on status of the returned equipment Send all material with the issued RMA Number to Federal Signal Corporation 2645 Federal Signal Drive University Park IL 60484 3167 Attn Service Department RMA Two Channel LED Corner System 416500 X de FEDERAL SIGNAL Public Safety Systems 2645 Federal Signal Drive University Park IL 60484 3167 Tel 800 264 3578 Fax 800 682 8022 www fedsig com O 2013 Federal Signal Corporation
8. the directions in the vehicle manufacturer s service manual LED LIGHTHEAD DAMAGE Mounting the Corner LED near a headlamp or other bulbs may cause permanent damage Mount the Corner LED as far away as possible from other bulbs NOTICE 2 Because vehicle reflectors may vary choose a mounting location so that the lighthead is oriented to achieve the optimum lighting effect The flat mounting location should have an area 1 1 2 inch in diameter for sealing 3 Use the round mounting gasket as a template to mark the center of the three holes DRILLING PRECAUTIONS Before drilling holes check the area into which you plan to drill to ensure you do not damage vehicle components while drilling All drilled holes should be de burred and all sharp edges should be smoothed All wires going through drilled holes should be protected by a grommet or convolute split loom tubing Two Channel LED Corner System 416500 X Installation Instructions 4 Drill the 1 inch hole then use a 32 drill bit to drill the two 0 116 inch mounting holes Deburr the holes and thoroughly clean the housings to remove all chips 5 The mounting surface must be clean and dry for the mounting gasket to adhere properly If necessary use isopropyl rubbing alcohol and water to clean the mounting surface 6 Apply the gasket to the LED lighthead and insert the lighthead into the housing with the mounting holes properly oriented TIGHTEN SCREWS P
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