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Installation, Operation, and Service Manual

1. H H H H H 9 Emn EN Y m 9 VN amom Ex 016992 LHS 1 LNAWNNYLSNI OL Appendix Wiring Schematics 81 Appendix JDUAAJUT 1 221A48 SS00FMS D21d amp T 2 665065 dvd 5 S1vO NnH any XNVHO NI LOH TINON NOILIN I 5 H3MOd LO3NNOO3H H31SVWTVNSIS HOLIMS ANY OL tdf 1 H3MOd XV v 001 H3 vaug TIM S39IA3Q 1 00V NOLLVTIV LSNI NMOHS v oe AH3LIVG OPA 04 O3N asna v Ov 01 01 9 D S 8 9 9 go 5 A 6 B o a Q S30vid9 gt gt 5 2 T asnadvi 2 2 n m d 25 d 2 e IVIH3S OL STVNDIS OPA S3HOLIMS 2 5 m gt 01982 LHS LSNI 335
2. 32 Installing the Hook On Mounting Kit Gutter HOOKS rera 33 Installing the HorFoor Lighted Mounting Brackets 34 Installing the Low Prohle Mounting 36 Installing the Keeper Plate Kit Part Number 8583193 uae b beide Gud don Hn gn 38 Chapter 5 Wiring the S2 in the 41 Lightbarin AIRTRAN DE TE 41 Mounting the Serial Interface enn tne notte 42 Wiring the Serial Interface Dude ie rita siat as LU ec ba reste sien das 45 Chapter 6 Maintaining and Servicing the RAYDIAN 52 53 Service th End DOMES 54 Servicing me ROC PCBs in the End epo PRU DONUM pU Uter dete dariniai 56 Servicing the Mambar ROC 21 Servicins the Maimbar 59 Servicing Lightbar C 61 Servicing the Mainbar 64 Cleaning the Lenses and End 67 ii Contents Servicing the HorPoOr Mounting BOIBEeUS
3. aaiae 68 52 Replacement Panis 70 Troubleshooting the LTBBIBBE Zh Chapter 7 Cloning Flash Patterns from Vehicle to Vehicle 73 Installing the Pisce raiser SoftWare usi qus Estu bn qui ans eta usi ratus n petia Reads 74 Connecting PrOBFARUIDOE 74 Cloning the Serial Interface Module sai ee rti 76 Appendix Wiring SCHEMANCS onera ausu sunto auus uu as E a ERR EGER AS E CECECKC ETE 79 Messages Topics covered m Safety Message to Installers and Service Personnel of Warning Light Equipment m Safety Message to Operators of Warning Light Equipment For your safety read this manual thoroughly before installing operating and servicing the RaypiAN S2 lightbar The safety messages presented in this chapter and through out the manual are reminders to exercise extreme care at all times To download copies of the manual go to www fedsig com or call the Federal Signal Service Department at 1 800 433 9132 7 to 5 pm Monday through Friday CT Safety Message to Installers and Service Personnel of Warning Light Equipment 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 prod uct In addition listed below are some other important safe
4. Description Part Number PCB Assembly Dome Configured Contact Federal Signal PCB Assembly Mainbar End Configured Contact Federal Signal PCB Assembly Center Configured Contact Federal Signal PCB Assembly Controller Configured Contact Federal Signal Seal Dome 8654234 Reflector 2 inch 8653106 Reflector Alley 8654258 Reflector 4 inch 8653104 Reflector 4 inch Takedown Worklight 8653163 Plate Assembly End Dome Bottom 8654240 Extrusion Side Lens Mainbar Clear RS242 42 inch lightbar 8654228 RS252 52 inch lightbar 8654228 39 Dome End Clear 8654100 Dome End Blue 8654100 03 N Dome End Red 8654100 04 Z Plug Vent 231242 E Fuse Controller 5 A 148181 03 E Fuse Controller 10 A 148181 05 Fuse Controller 20 148181 Fuse Holder Maxi 143137 Fuse Maxi 32 40 148182 01 6 Troubleshooting the Lightbar 71 Troubleshooting the Lightbar This section provides troubleshooting assistance for common problems If you have any questions left unanswered call the Federal Signal Service Department at 1 800 433 9132 7 AM to 5 PM Monday through Friday Problem Corrective Action The lightbar does not light Check that the lightbar s red power line BAT and the black ground power line NEG are properly connected to a good fully charged 12 volt battery Ensure that the ground connection from the lightbar controller to the aluminum extr
5. B Fd gt J H Exi uh ux o um N LO NM Sos nee INTERNAL SIGNALMASTER EXTERNAL SIGNALMASTER CONFIGURATION CONFIGURATION 290A5885 Figure 3 3 DIP switch settings in Serial Interface Module Preparing Raypian S2 for Installation 3 Bench Testing Reprogramming the Lightbar 19 Entering Program Mode To switch the module from Operation Mode to Program Mode 1 Unplug the 24 pin harness from the Serial Interface Module 2 On the Serial Interface Module move Switch 6 SW 2 to the down ON position Figure 3 3 on page 18 3 Plug the 24 pin harness into the Serial Interface Module NOTE When you press and release the SW 1 push button on the Serial Interface Module to select a pattern the lightbar briefly turns off and then displays the next pattern To cycle backwards to a previous pattern move Switch 5 to ON up position on SW 2 SW 2 DIP Switch Settings in the Serial Interface Module For the location of SW 2 see Figure 3 3 on page 18 Table 3 2 lists the DIP switch settings in the Serial Interface Module for programming flash patterns Table 3 2 SW 2 DIP Switch Settings Switch SW 2 Setting Switch Up Down Number OFF ON Function 1 FRONT REAR LEDs cut off turn off when 12 Vdc is applied their control wires Table 3 1 page 16 1 FRONT REAR LEDs enable turn when 1
6. NOY NI LOH vu 1 a1 1 GOW 14 9 955995 LHS LSNI 338 3901430 SNOLLO3NNOO SNINIVIA3H 115000255 S3O0VldZ WS0002SS SNOILOANNOO TWOIldAL SNA xpueddy Appendix Wiring Schematics 83 Appendix 42 041u02 u241 suoi22uuoo p y 6565062 GATIOWLNOO 1vIH3S Y 08 ISN4 TIIM 1 NOLLYTTVLSNI NMOHS v oe ZL 3Sf 07 SIV LHM 18 al LOH 996542 LHS LSNI 338 H3d ONINIVWAY 000079 8 39 1 2 3504 m c 1 3OVJH3LNI 1vIH3S NI LOH 18 LHM 14 418 044 DD oz E Bx 25 EC YALSVWIVNDIS NON SNOLLO3NNOO TWOIdAL 84 Appendix Wiring Schematics 41H VN3 AVAA LNOYA
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8. o 2 gt 4 7 8 Secure hook using three sheet metal screws 10 thread forming as shown in Figure 4 1 on page 33 Repeat steps 2 through 7 with the other hook Installing the HorFoor Lighted Mounting Brackets In addition to the parts listed in the table the kit for the HotFoot mounting brack et requires a gutter hook kit appropriate for the make and model of the vehicle Be fore installing the HotFoot Mounting Brackets install the gutter hooks described in Installing Hook On Mounting Kit Gutter Hooks on page 33 Table 4 2 Horroor mounting kit Qty Description Part Number 1 Kit Keeper Plate 8583193 2 Wedge 8654201 NOTE The RS242 42 inch lightbar has the HorFoor already positioned for mounting on the Ford Crown Victoria If you are mounting the lightbar on a Crown Victoria skip steps and 2 Loosen 3 8 16 hex nuts to allow mounting brackets to be adjusted in and out to fit the roof of the vehicle If you are installing the lightbar on a vehicle that has a roof with a steep forward slope install the wedges between the HorFoor and the bot tom aluminum extrusion of the lightbar on the forward track as shown in Figures 4 2 and 4 3 on page 35 Place the lightbar on the vehicle roof at the previously selected location where you installed the gutter hooks Adjust both mounting brackets in or out until
9. Preparing S2 for Installation Topics covered m Unpacking the Lightbar Bench Testing and Reprogramming the Lightbar Additional Mainbar Tests and Configurations Taking the preparatory steps in this chapter before mounting and wiring the lightbar to a vehicle will help ensure that your installation is fast easy and error free In addition to bench testing this chapter covers changing default settings and programming Unpacking the Lightbar Carefully unpack the lightbar assembly and any other products included in the shipment Inspect them for damage that may have occurred during shipping If a product has been damaged do not install or operate it Immediately file a claim with the carrier describing the damage Carefully check all envelopes shipping labels and tags before removing or destroying them If you are missing any parts contact Customer Support at 1 800 264 3578 7 Am to 5 pm Monday through Friday CT Bench Testing and Reprogramming the Lightbar Bench testing checks the lightbar for the reliability of its flash patterns and enables you to make any changes before you install the lightbar and controller equipment Although the lightbar is configured and programmed at the factory you may want change flash patterns and default settings before installation Before you begin decide if you want to change these default settings 13 14 Bench Testing Reprogramming the Lightbar
10. DOME SEAL PLASTIC LENS 25 SCREWS FRONT ROC 2 w ASSEMBLY e 290A5905 Figure 6 3 Lightbar with dome seal and end bracket removed N e Installing a Mainbar ROC Assembly lt p PROPERLY TIGHTEN SCREWS 5 To prevent damage to lightbar not overtighten screws S 1 Slide the mainbar ROC assembly onto the lightbar z 2 Remove all of the old RTV sealant from the dome seal and the end of the 0 lightbar 3 Apply new RTV sealant to the dome seal as shown in Figure 6 4 on page 59 6 Servicing the Mainbar ROC PCBs 59 Install the dome seal and end bracket under the retaining tab for the controller assembly Ensure that all the projecting ribs on the dome seal are properly mated with corresponding recesses in the extrusions Slide the end bracket into the dome seal ensuring cables and ground leads are properly routed through the windows in the dome seal and end bracket Ensure that the cables and ground wires are properly connected Secure the two 1 4 20 Phillips screws that fasten the end bracket and ground wires to the aluminum extrusion Reinstall the driver s side end dome as described in Installing an End Dome on page 55 APPLY RTV TO DOME SEAL IN AREAS SHOWN 290A5906 Figure 6 4 RTV sealant applied to areas on the dome seal Servicing the Mainbar ROC PCBs Servicing the mainbar ROC PCBs includes rem
11. SET TO ON SEE TABLE 3 5 AND FIGURE 3 6 26 29045887 Figure 3 5 Switch settings on the mainbar controller Testing the FLASH TAKEDOWN ALLEY Lights 1 Apply 12 Vdc BAT to the control wire for MODE 2 or 3 Table 3 1 on page 16 2 Apply 12 Vdc BAT to the red black control wire for the FLASH TAKEDOWN ALLEY lights The TAKEDOWN and ALLEY lights flash on both the mainbar and HorFoor if equipped 3 Remove 12 Vdc from the MODE and FLASH TAKEDOWN ALLEY control wires NOTE Work lights are just takedowns facing rear They operate identically through the Serial Interface Modules s white black TAKEDOWN wire and the red black FLASH TAKEDOWN ALLEY wire If the lightbar is equipped with takedown and work lights all come on Configuring the Flashing of the Mainbar LEFT and RIGHT ALLEY LEDs The default setting has the mainbar LEFT and RIGHT ALLEY LEDs flash when 12 Vdc is connected to a control wire for MODE 1 2 or 3 and the con trol wire for the FLASH TAKEDOWN ALLEY lights Table 3 1 on page 16 To change the default setting so that the LEFT and RIGHT ALLEY LEDs flash when 12 Vdc is connected only to MODE control wire Additional Mainbar Tests and Configurations 25 Remove the controller from the mainbar See Removing the Controller for Configuration or Fuse Replacement on page 61 On the controller move Switch 1 SW3 for the LEFT ALLEY DVR is the driver s si
12. 9 During cloning the EPICWin software displays a Programming progress bar E Bros d s Figure 7 8 Programming progress 10 When cloning is finished click OK and disconnect the programming cable from the target Interface Module Figure 7 9 Cloning complete click 11 Reinstall the covers on the source and target Interface Modules 12 To clone another target Interface Module repeat steps 6 through 10 Be sure to rein stall the cover when finished 13 After cloning test the light system to ensure that it is operating properly NOTE For troubleshooting help visit http www melabs com support epicfixs htm or contact the Federal Signal Service Department at 1 800 433 9132 7 to 5 pm Monday through Friday CT 78 Cloning the Serial Interface Module 9 9IU9A 0 9 9IU9A 1 79 Appendix Wiring Schematics Schematic Titles Schematic A 1 Typical connections with a SIGNALMASTER controller External control Schematic A 2 Typical connections with a SW400SS switch box Internal control Schematic A 3 Typical connections with a SMARTSIREN controller Schematic A 4 Typical connections with a PA640 siren controller Schematic A 5 Typical connections with a ToucHMASTER Delta FRONT REAR ENABLE Table A 1 Schematic Symbols Symbol Description Symbol Description Battery Ignition 41 Con
13. SicNALMAsTER Controls Control Wires Description LEFT Red Rear LEDs flash from right to left CENTER Green Rear LEDs flash from center out to both sides RIGHT Green Black White Rear LEDs flash from left to right WARN 1 Orange Green Outer LEDs alternate WARN 2 Orange Two outer LEDs alternate WARN Blue Red Outer LEDs and two inner LEDs alternate o WARN 4 Red Green Outer LEDs and two inner LEDs flash then the LEDs between the inner and outer LEDs 2 FAST White Red Operates the selected pattern 50 percent faster 2 HE iE ib Additional Mainbar Tests and Configurations 29 MODEL RS242 REAR LEDs LEFT 6543211 ERE RIGHT 2 4 5 6 WARN 1 WARN 2 111 2 2 WARN 3 1 2 2 1 WARN 4 290A5889 Figure 3 7 SigNALMasTER flash sequence six head example ZS NviaAvH eui 10 O 30 Additional Mainbar Tests Configurations N o Z lt lt tc D for Installation 31 Installing the RavpiaN S2 on Vehicle Topics covered Planning the Lightbar Installation Options for Mounting the Lightbar Installing the Hook On Mounting Kit Gutter Hooks Installing the HorFoor Lighted Mounting Brackets Installing the Low Profile Mounting Kit Installing the Keeper Plate Kit Part Number 8583193 Planning the Lig
14. 9 A STANVd HOLIMS NIVHO 2610 9 5 N H H H H eX X 18 LHM N79 13A 9 Q3uU r18 H 9 6 7 au o pag Em p mw ee 1 adon ST ma 9 026982 LHS 16N a09 LH9N TANWd vi 1N3IAQIHLSNI OL YALSVWTVNDIS 1VNH3LNI SNOLLO3NNOO TVOIdAL 82 Appendix Wiring Schematics 826SV062 42 041u02 NAXISLYVNG D YJIM SUONIAUUOD 2 SdWv 09 SI LNSYYND GVO WLOL HV8 GATIOULNOO TVIH3S N3HM AINO aasn 1 sf os 08 1 5 01 X18 OL 8199 xa D m 5 gt 2 39V3H31NI 1VIH3S OL 2 STVNDIS 25 H3T1OH1NOO 115000258 303090 Om NB 822338 IIT OPA 21 01 vse Y H rd d
15. Sc So S gt 2 6 Servicing Mounting Brackets The optional mounting system can be ordered with two LED takedown and two LED alley lights or flashing colored LEDs The LED assemblies are replaceable For re placement parts call the Federal Signal Service Department at 1 800 433 9132 7 to 5 pm Monday through Friday CT Aiming a HotFoot LED Assembly The Horroor LED assemblies can be aimed horizontally 1 Remove the three Torx 10 32 screws and the hold down tab that secure the plas tic dome to the mounting bracket Figure 6 10 10 32 SCREWS E LOOSEN FOR 10 32 HORIZONTAL SCREW P ADJUSTMENT HOLD DOWN Tas PE A TAB HOLDER 290A5912B Figure 6 10 Hardware securing the HorFoor dome horizontal adjustment screw 2 Remove the dome 3 Loosen the horizontal adjustment screw Figure 6 10 4 Rotate the LED assembly to aim it NOTICE PROPERLY TIGHTEN SCREWS To prevent damage to lightbar do not overtighten screws 5 Tighten the horizontal adjustment screw 6 Reinstall the dome Servicing the HotFoot Mounting Brackets 69 Removing a HotFoot LED Assembly 1 Remove the three Torx 10 32 screws and hold down tab that secure the plastic dome to the mounting bracket Figure 6 10 on page 68 2 Remove the plastic dome 3 Remove the 8 32 adjustment screw and lockwasher securing the LED assembly to the Fi
16. up ON down ZS 9 10 O 22 Additional Mainbar Tests and Configurations Preparing Raypian S2 for Installation 3 FRONT REAR CUTOFF ENABLE The operational setting for FRONT REAR CUTOFF or ENABLE must be pro grammed after MODE and INTERSECTION The default setting is for CUT OFF in which the FRONT or REAR LEDs turn off when 12 Vdc BAT is applied to their control wires In contrast FRONT REAR ENABLE turns on these LED modules when BAT is applied to their control wires Both FRONT and REAR share the same operational setting and are not independent To program for FRONT REAR ENABLE 1 Unplug the 24 pin harness from the Serial Interface Module 2 Serial Interface Module move Switch SW 2 to the down position 3 Plug the 24 pin harness into the Serial Interface Module NOTE When set to ENABLE 12 Vdc must be applied to MODE control wire and the FRONT and or REAR ENABLE control wire for the lightbar to operate In a typical installation if you want only the REAR LED modules to flash in MODE 1 set the operation for ENABLE Connect the green white and blue white control wires to the MODE 2 connection and the orange black and blue control wires to the MODE 1 connection See Schematic A 5 on page 84 Exiting Program Mode When you are finished programming patterns switch the Serial Interface Mo
17. FRONT of the lightbar Green White Turns ON the FRONT of the lightbar REAR CUTOFF Turns OFF the REAR of the lightbar Orange Black REAR ENABLE Turns ON the REAR of the lightbar INTERSECTION Blue Black Typically a high activity pattern Overrides all three priority modes FLASH TAKEDOWN Red Black Flashes the ALLEY and TAKEDOWN lights in ALLEY MODES 1 2 or 3 LEFT ALLEY Green Black Turns on LEFT ALLEY lights Overrides the FLASH TAKEDOWN ALLEY lights RIGHT ALLEY Orange Red Turns on RIGHT ALLEY lights Overrides the FLASH TAKEDOWN ALLEY lights TAKEDOWN White Black Provides white light to the front Overrides FLASH TAKEDOWN ALLEY lights and FRONT CUTOFF LOW POWER White Black Red Dims the lights approximately 50 percent to prevent blinding approaching drivers LOW POWER is only available in MODES 1 and 2 and is disabled when switched to another flash pattern including MODE 3 and INTERSECTION LIGHTBAR TEST Black White Red Flashes the LEDs sequentially and then flashes the PATTERN TAKEDOWN and ALLEY lights Switch Settings The jumpers and switches to change default settings and reprogram flash patterns are on the PCB in the Serial Interface Module The switches are accessible through a window in the Interface Module To access the Internal External SIGNALMASTER jumper remove the cover from the Interface Module Figure 3 2 on page 17 Be sure to reattach the cover when you are finished You ca
18. Halogen light bulbs and strobe tubes are pressurized and if broken can burst and result in flying glass Always wear gloves and eye protection when handling these components e Do not mount a radio antenna within 18 inches 45 7 cm of the lighting system Plac ing the antenna too close to the lighting system could cause the lighting system to malfunction or be damaged by strong radio fields Mounting the antenna too close to the lighting system may also cause the radio noise emitted from the lighting system to interfere with the reception of the radio transmitter and reduce radio reception Safety Message to Installers and Service Personnel of Warning Light Equipment Do not attempt to wash any unsealed electrical device while it is connected to its power source During Installation and Service DO NOT get metal shavings inside the product Metal shavings in the product can cause the system to fail If drilling must be done near the unit place an ESD approved cover over the unit Inspect the unit after mounting to be sure there are no shavings present in or near the unit DO NOT connect this system to the vehicle battery until ALL other electrical con nections are made mounting of all components is complete and you have verified that no shorts exist If the wiring is shorted to the vehicle body or frame high current conductors can cause hazardous sparks resulting in electrical fires or flying molten metal DO NOT install equipment
19. Preparing the Raypian S2 for Installation SIGNALMASTER Operation External default or Internal You can change the setting from External to Internal Internal operation uses the lightbar s on board SIGNALMASTER controller to generate directional warning pat terns With Internal operation an external SIGNALMASTER controller is not needed A standard low current switch box can activate the internal SIGNALMASTER controller MODE 1 2 3 and INTERSECTION MODES through 3 are most often selected by a progressive slide switch which enables the driver to turn on the lightbar without looking down You can select a pat tern for each mode from the lightbar s library of 26 patterns The INTERSECTION flash pattern is typically a high activity pattern that attracts attention to the vehicle as it approaches an intersection You can select a pattern from the library and choose one of three ways to turn on and off the pattern The INTER SECTION flash pattern overrides the three priority modes NOTE If the SIGNALMASTER flash pattern is turned on it overrides the current flash pattern FRONT and REAR lights CUTOFF default or ENABLE You set these options after you change the default settings for MODE and INTER SECTION flash patterns CUTOFF turns OFF the front or rear LEDs when 12 Vdc is applied to the FRONT or REAR light control wire ENABLE turns ON the front or rear LEDs when 12 Vdc is applied Making Initial Electrical Conn
20. To increase the safety of officers pedestrians and motor ists the lightbar has standard front and rear cutoff dimming and intersection warning Bright white LED alley and takedown lights are available in the lightbar LED alley and takedown lights are available in the patented HorFoor option Flash patterns are controlled through a 5 serial communication cable The cable con nects to the Federal Signal Serial Interface Module Model Number 8583446 With the Serial Interface Module the RAvpiAN S2 can be activated by Federal Signal lightbar con trollers SIGNALMASTER directional light controllers or by individual low current switch boxes gt gt gt lt al o z lt 2 lt 8 Product Features Product Features Additional features include End cap design provides superior 360 degree intersection warning Patented mounting brackets house powerful LED takedown and alley light assemblies Bright white LED takedown and alley lights are long life and significantly reduce power consumption Lightbar housing is tested to ensure durability at high speeds and maximum fuel efficiency Available LED colors are amber blue red green and white Built in SIGNALMASTER directional warning capability is standard SIGNALMASTER flash patterns can be activated with switched 12 Vdc or a SIGNALMASTER controller Five year warranty on LEDs Eas
21. matches the number of SIGNALMASTER heads on the lightbar If SIGNALMASTER operation is not activated by a control head or external controller the SIGNALMAsTER LED heads flash with the selected priority mode MODE 1 2 or 3 of operation ZS NVIGAVY eui BuulM 9 9IU9A Y 48 Wiring the Serial Interface Module N o z 4 5 lt So pm gt 5 External SiaGNALMAsTER The Serial Interface Module is preset for the External SIGNALMASTER option External operation uses the Serial Interface Module to drive each SIGNALMASTER directional warning head independently through an external Federal Signal SIGNALMASTER controller or 5520005 series siren Figures 5 3 and 5 4 on page 49 Either device provides an independent ground signal to turn on each head To cross reference external SIGNALMASTER wiring to a Federal Signal controller or the SM2000SM series siren see Table 5 1 Internal SiaNALMAsTER Internal operation uses the lightbar s built in SIGNALMASTER controller to generate directional warning patterns With internal operation an external SIGNALMASTER controller is not needed A standard low current switch box can activate the lightbar s internal SIGNALMASTER controller For the jumper setting in the Serial Interface Module see Selecting Inter nal SicNaLMasrER Control on page 17 To activate the lightbar s internal SIGNALMASTER controller apply 12 Vdc
22. mounting screws to pierce the wires or cables 1 Ensure that the lines are adequately fused as shown in the wiring schematics in the Appendix on pages 79 though 84 From the lightbar route the CATS control cable into the vehicle s cab or trunk near the eventual location of the Serial Interface Mod ule An input cable is also provided with the Interface Module NOTICE REVERSE POLARITY MISWIRING Reverse polarity or incorrect voltage may damage the light To avoid damage to the light ensure that the battery voltage is the same as the voltage rating of the light and that the correct polarity is observed If you are connecting to a ciga rette lighter plug connect the positive wire to the center terminal and connect the negative wire to the outer terminal 2 Route and connect the lightbar s black lead to the vehicle battery ground NEG terminal 3 Route and connect the lightbar s red lead through the supplied 40 ampere Maxi fuse holder at the source which is the BAT positive terminal Mounting the Serial Interface Module The Serial Interface Module communicates between a user supplied lightbar siren con troller SIGNALMASTER controller or a switch box and the RAyDIAN S2 To minimize number of discrete wires to the lightbar control lead functions are wired to the Interface Module through a 3 foot long 24 conductor cable harness Table 3 1 on page 16 The information is converted to a digital format and commu
23. the rubber mounting pads rest near the edge of the roof or gutter where the roof is most rigid Center the lightbar so that the end of the assembly and edge of the roof are equidistant on each side of the vehicle IMPORTANT Plan all cable routing before completing the next step To allow for replacing the lightbar with another model of Federal Signal serial con trolled lightbar tuck an additional 18 in to 24 in 46 to 61 cm loop of power ground and 5 cable under the vehicle headliner Remove the lightbar from the vehicle s roof To avoid scratching the domes place the lightbar assembly upside down on soft rags or cardboard NOTICE TIGHTEN NUTS PROPERLY To prevent damage to the lightbar do not overtighten the nuts Installing the HotFoot Lighted Mounting Brackets 35 Tighten the 3 8 16 hex nuts four on each mounting bracket to 20 ft lb Place the lightbar on the vehicle roof in its original position To fasten the mounting hook and complete the installation see Installing the Keeper Plate Kit Part Number 8583193 on page 38 LIGHTBAR END DOME BOTTOM ALUMINUM EXTRUSION OF LIGHTBAR ZS NviaAvH y uo WEDGE o 290A5891 Figure 4 2 Wedge installed between HorFoor and lightbar TOP VIEW FRONT CAR INSTALL WEDGE WITH OPEN END UP AND SMALL HOLES TO THE FRONT O O 290A5892 Figure 4 3 Wedge ins
24. the white black control wire for the TAKEDOWN lights Apply 12 Vdc BAT to the control wire for either the LEFT or RIGHT ALLEY LED Table 3 1 on page 16 The LEFT or RIGHT alley lights turn on in both the mainbar and HorFoor if equipped The TAKEDOWN lights turn on in both the mainbar and if equipped Additional Mainbar Tests and Configurations 27 NOTE Work lights are just takedowns facing rear They operate identically through the Serial Interface Modules s white black TAKEDOWN wire and the red black FLASH TAKEDOWN ALLEY wire If the lightbar is equipped with takedown and work lights all come on Testing the LOW POWER Function SAFE USE OF LOW POWER MODE Enabling the Low Power Mode in the lightbar causes the light output of the lightbar to fall below current light output standards and guidelines for emer gency warning lights Use extreme caution when using this mode Ensure that the ambient light conditions are low enough that you are seen and that the re duction of glare from the lightbar is safer than full light output in the situation Failure to heed this warning may result in serious injury or death to you or oth ers in your vicinity The LOW POWER function dims the mainbar LEDs approximately 50 percent to prevent blinding approaching drivers NOTE The LOW POWER function only operates in MODE 1 or MODE 2 It is dis abled when the lightbar is turned off or switched to another flash pattern includi
25. to the REAR CUTOFF control wire the selected MODE operation is deactivated to the rear of the lightbar Only the FRONT LEDs flash NOTE The operational setting for FRONT and REAR CUTOFF are not indepen dent The default setting is for 12 Vdc BAT to be applied for the lightbar s front and rear light heads to turn them off CUTOFF To change the default setting to turn on these LEDs when 12 Vdc is applied ENABLE see FRONT REAR CUTOFF or ENABLE on page 22 INTERSECTION When 12 Vdc BAT is applied to the INTERSECTION control wire and a MODE control wire it turns on the INTERSECTION pattern When 12 Vdc is removed the lightbar returns to its previous state FLASH TAKEDOWN ALLEY When 12 Vdc BAT is applied to the FLASH TAKEDOWN ALLEY control wire and a MODE control wire the TAKEDOWN and ALLEY lights flash LEFT and RIGHT ALLEY Lights When 12 Vdc BAT is applied to the LEFT or RIGHT ALLEY control wire the appropriate ALLEY LEDs turn on The LEFT and RIGHT ALLEY lights override the FLASH TAKEDOWN ALLEY lights Wiring the Serial Interface Module 47 TAKEDOWN Lights When 12 Vdc BAT is applied to the TAKEDOWN control wire the TAKEDOWN LEDs turn on TAKEDOWN overrides FLASH TAKEDOWN ALLEY and FRONT CUTOFF LOW POWER USE LOW POWER FUNCTION PROPERLY Enabling the LOW POWER function in the lightbar will cause the light output to fall below current light output standards and guidelines for emergency warn in
26. to the SIGNALMASTER control wires Table 5 1 Cross reference for controller leads 24 Harness from the SicNaLMasrER Wire SS2000SM Wire Serial Interface Module Figure 15 Figure 16 Red White White 1 Green Brown Brown 2 Green Black White Green Green 3 Orange Green Orange Orange 4 Orange Purple Purple 5 Blue Red Gray Gray 6 Red Green Yellow Yellow 7 White Red Blue Blue 8 Wire colors as described in the controller s installation instructions Wiring the Serial Interface Module 49 SIGNALMASTER CONTROLLER 331105 SHOWN RED GREEN GREEN BLACK WHITE ORANGE GREEN ORANGE BLUE RED RED GREEN TO J1 ON INTERFACE MODULE NOTE FOLLOW THE CONTROLLER S INSTALLATION INSTRUCTIONS FOR POWER GROUND AND OTHER POSSIBLE FUNCTIONS 290A5899 Figure 5 3 SieuaLMAsrER 331105 controller External IM 3090 5 5 lt gt 52 0 TO J1 ON FUSE INTERFACE MODULE SAMP NOTE FOLLOW THE 2000 SERIES INSTALLATION INSTRUCTIONS FOR OTHER WIRING 290A5900 Figure 5 4 5520005 Series controller External 50 Wiring the Serial Interface Module BLACK RED 1A BLUE WHITE BLUE c BLU RED WHITE O BLUE BLACK RED BLACK c ORANGE RED c GREENIBLACK WHITE BLACK c GREEN WHITE ORANGE BLACK WHITE BLACK RE
27. turns on for 2 seconds with the exception of the designated STEADY BURN LEDs JO UY cS NVIGAVY lt 12 1 lt 2 272 22 lt lt lt lt lt lt lt 2 lt 22 22 2 2227 27 2 7 lt 2227 lt 2 10 Product Specifications Product Specifications Operating and technical specifications for the RAYDIAN 52 are listed in this section by lighting option and model Warning Lights Mainbar Current Lamp Lighting Option Draw Technology Reflector Style 5 S2 LED 10 A Six GEN high Offset compound curve polished Takedown Light brightness LEDs spot beam reflector 52 LED 10 A Six GEN high Offset compound curve polished Alley Light brightness LEDs spot beam reflector S2 two i 4 Three high Offset compound curve polished inch flashing 0 5 on brightness LEDs reflector positions SOLARIS 52 four Six GEN high Offset compound curve polished five inch 1 0 de brightness LEDs reflector flashing positions Amperage in STEADY BURN mode 5 20 9 Current Lamp ae 2 ga Lighting Option Draw Technology Reflector Style Takedown Light 0 5 A Three GEN high Offset compound curve polished 2 br
28. 2 Vdc is applied to their control wires 2 Keep in OFF position 3 Keep in OFF position 4 External controller 4 4 SieNALMasrER Internal controller 5 Cycle forward through the selection of flash patterns 5 J Cycle backward through the selection of flash patterns 6 6 Program Mode 7 Switch for INTERSECTION operational settings Table 3 3 on page 21 8 Switch for INTERSECTION operational settings Table 3 3 ZS NviaAvH 10 O 20 Bench Testing Reprogramming the Lightbar Preparing Raypian S2 for Installation 3 Programming Priority MODES 1 2 3 and INTERSECTION The three modes operate with MODE 3 having the highest priority MODE 3 overrides MODE 2 and MODE 2 overrides MODE 1 When the lightbar oper ates in one of these modes the SIGNALMASTER modules keep sequence with the flash pattern You can change default MODE flash patterns by programming each mode with one of 26 patterns in the lightbar s library A typical setup would be MODE I REAR LEDs MODE 2 FRONT REAR LEDs e MODE 3 siren SMARTSIREN or Federal Signal compatible and FRONT REAR LEDs and FLASH TAKEDOWN ALLEY LEDs on the mainbar MODES and 2 FRONT REAR CUTOFF NOTE If the lightbar needs to be programmed after you connect a progressive slide switch the programming sequence must be MODE 3 MODE 2 M
29. 4 4 Low Profile bracket attached to lightbar Installing the Low Profile Mounting 37 Repeat steps 2 and 3 with the other foot pad bracket Press the mounting pads onto the foot pad brackets until the buttons on the pads lock in the holes in the brackets Loosen the four 3 8 16 nuts on each mounting foot only enough to allow adjust ment in or out Figure 4 4 on page 36 POSITION BOLTS AT BOTTOM OF SLOTS FOOT PAD BRACKET MOUNTING PAD LOW PROFILE 5 16 18 MOUNTING MOUNTING FOOT BRACKET BOLTS 290A5894 Figure 4 5 Bolts positioned at bottom of slots on bracket Attaching the Lightbar to Vehicle Roof SECURE MOUNTING If the mounting foot is improperly assembled the light assembly could fly off the vehicle causing injury or damage Ensure that the mounting hardware is properly installed and tightened securely To attach the lightbar to the vehicle with the Low Profile mounting feet Place lightbar on vehicle roof at its previously selected location where the gutter hooks are installed Typically you should install the lightbar so that the mounting hooks attach at or immediately behind the door center post If necessary adjust both mounting foot assemblies in or out until the rubber mounting pads rest near the edge of the roof or gutter where the roof is most rigid Center the lightbar so that the end of the assembly and edge of the roof are equidistant on each side of the vehicle IMPO
30. 5 1 Unplug the 24 harness from Serial Interface Module 2 2 Interface Module use a 1 4 inch driver to remove four 8 32 x 1 4 hex 2 gt head screws and remove cover o 3 the Interface Module PCB move JP 1 from EXT to INT see Figure 3 3 page 18 O 18 Bench Testing Reprogramming the Lightbar 4 Reinstall the cover on the Interface Module 5 Move Switch 4 on SW 2 to the down ON position 6 Plug the 24 pin harness into the Serial Interface Module Selecting External Control To return to External SIGNALMASTER control factory default 1 Unplug the 24 pin harness from the Serial Interface Module 2 On the Serial Interface Module to be cloned copied use a 1 4 inch driver to remove the four 8 32 x 1 4 hex head screws and remove the cover On the Serial Interface Module PCB move JP 1 from INT to EXT Figure 3 3 Reinstall the cover on the Interface Module Move Switch 4 on SW 2 to the up OFF position 0 Plug 24 pin harness into Serial Interface Module BACK OF SERIAL INTERFACE MODULE PUSH 12345678 SERIAL INTERFACE MODULE PCB SWITCHES 1 2009090
31. A Ly 1A BLUE RED WARN 3 0 RED GREEN WARN 4 1A WHITE RED FAST i WHITE BLACK RED LOW POWER 1A OO BLACKWHITE RED LIGHTBAR TEST IGNITION WHITE GROUND 1 BLACK WHITE GROUND 2 IGNITION POWER INCLUDES POWER THE CRANKING POSITION 290A5902 Figure 5 6 SiaNaLMAsrER control functions wired to 12 for Internal control 52 Wiring the Serial Interface Module N 42 4 lt To lt m gt gt 5 53 6 Maintaining and Servicing the Raypian S2 Topics covered Servicing the End Domes Servicing the ROC PCBs in the End Domes Servicing the Mainbar ROC Assemblies Servicing the Mainbar ROC PCBs Servicing the Lightbar Controller Servicing the Mainbar Lenses Cleaning the Lenses and End Domes Servicing the HorFoor Mounting Brackets Replacement Parts Troubleshooting the Lightbar Establishing a regular maintenance schedule for the RAypIAN 52 extends the life of the lightbar and ensures safety Periodically check that the lightbar operates properly and that all mounting hardware is securely fastened to the vehicle Also check the domes and lenses for cracks hairline cracks crazing discoloration and other defects For service support or replacement parts contact the Federal Signal Service Department at 1 800 433 9132 7 to 5 pm Monday through Friday CT QUALIFICAT
32. AL SOURCES Always fuse current voltage sources with a fuse connected near the power source Be sure that the fuse is properly rated to protect the electrical load the wiring and the connectors used in the circuit Failure to follow this notice could result in vehicle or equipment damage FUSE IGNITION ZS eui BuulM BLACK WHITE MAXI FUSE LIGHTBAR 40A SERIAL INTERFACE MODULE PART 8583446 BATTERY CAT5 CABLE BLACK 10 AWG RED 10 AWG 290A5898 Figure 5 2 Wiring block diagram 46 Wiring the Serial Interface Module Wiring the 2 in the Vehicle 5 MODES 1 2 3 To activate mode apply 12 Vdc to mode control wire MODE 3 overrides MODE 2 and MODE 2 overrides MODE 1 You can program one of the 26 flash patterns in the lightbar s library to each mode input STEADY BURN When the lightbar is equipped with one or more STEADY BURN LED modules ap plying 12 Vdc BAT to the STEADY BURN control wire red white turns on the LEDs when any MODE input is selected FRONT CUTOFF When 12 Vdc BAT is applied to the FRONT CUTOFF control wire the select ed MODE operation is deactivated to the front of the lightbar Only the rear LEDs function Additionally with FLASH TAKEDOWN ALLEY active only the ALLEY lights turn on REAR CUTOFF When 12 Vdc BAT is applied
33. D N 42 BLACK WHITE RED z E o p 9 GREEN O n gt Ll GREEN BLACK WHITE 2 IE mp ORANGE GREEN gt MOMENTARY SWITCHES 1 8 E ORANGE LLL BLUE RED 8 L RED GREEN G i L WHITE RED IGNITION JA c WHITE BLACK POWER 12 Vdc MODE 3 MODE 2 MODE 1 STEADY BURN INTERSECTION FLASH TAKEDOWN ALLEY RIGHT ALLEY LEFT ALLEY TAKEDOWNS FRONT CUTOFF ENABLE REAR CUTOFF ENABLE LOW POWER LIGHTBAR TEST J1 CABLE TO SERIAL INTERFACE 1 LEFT MODULE 8 RIGHT IGNITION POWER GROUND 1 BLACK WHITE GROUND 2 IGNITION POWER INCLUDES POWER THE CRANKING POSITION 290A5901 Figure 5 5 SignaLMaster control functions wired to ground for External default control Wiring the Serial Interface Module 51 POWER 12 Vdc 1A BLACK RED MODE 3 1A OO BLUEWHITE MODE 2 1A BLUE ep MODE 1 1A o e REDMHITE STEADY BURN 1A Cy c BLUE BLACK INTERSECTION cy c REDIBLACK FLASH TAKEDOWN ALLEY RIGHT ALLEY M GREENIBLACK LEFT ALLEY c MHITEIBLACK BLUE WHITE SBEENWHITE FRONT CUTOFF ENABLE OO ORANGE BLACK REAR CUTOFF ENABLE 1A RED LEFT J1 CABLE TO GREEN CENTER SERIAL INTERFACE O O MODULE 5 1A GREEN BLACK WHITE RIGHT 5 5 TA ORANGE GREEN WARN 1 Sa O O 1A lt amp WARN 2 o6 L
34. Electrical Hazards e Strobe systems present a shock hazard because they use high voltage to operate Do not handle strobe cables the power supply or bulbs or remove the lens while the equipment is connected Strobe systems can also hold their charge even after they have been turned off After disconnecting power to the unit wait five minutes before handling any parts of the strobe system e light system is a high current system In order for the system to function properly separate negative connection and positive connection must be made nega tive connections should be connected to the negative battery terminal and a suitable fuse should be installed on the positive battery terminal connection as close to the battery as possible Ensure that all wires and fuses are rated correctly to handle the device and system amperage requirements e Never attempt to install aftermarket equipment that connects to the vehicle wiring without reviewing a vehicle wiring diagram available from the vehicle manufacturer Ensure that your installation will not affect vehicle operation or mandated safety func tions or circuits Always check the vehicle for proper operation after installation e lighting system components especially light bulbs strobe tubes LEDs and the outer housing get hot during operation Be sure to disconnect power to the system and allow the system to cool down before handling any components of the system e
35. FEDERAL SIGNAL Safety and Security Systems Advancing security and well being ded null TIS a Lr Installation Operation and Service Manual 2562328E REV E 1008 Printed in U S A Contents Chapter 1 Safety Messages ER E rU Gu UR RR RR a 1 Safety Message to Installers and Service Personnel of Warning Light Equipment l Safety Message to Operators of Warning Light Equipment eicere 4 Chapter 2 An Overview of the RAYDIAN S4 RR aS ROC 7 Product MT 8 NM C OE 8 POTS VES M H 8 Flash Pattern e 9 UM E ir eae 10 Chapter 3 Preparing the RavpiaN S2 for 13 U packins the 13 Bench Testing aud Reprogramming the LigBibat 13 Additional Mainbar Tests and Configurations 22 Chapter 4 Installing the S2 the Vehicle 31 Planning the Ligbtbar Installaatio e 21 Options for Mounties the
36. ILLIPS SCREWS 10 32 PHILLIPS SCREW 290A5904 0 5 Figure 6 2 PCB removed from end dome 6 Servicing the Mainbar ROC Assemblies 57 Cleaning the End Dome Reflectors l Use a mild soap lukewarm water and a soft lint free cloth to gently clean the plastic surfaces To avoid damaging the reflectors do not use heavy pressure or caustic abrasive or petroleum based cleaners Rinse and dry the surfaces with a soft lint free cloth to prevent water spotting Installing an End Dome ROC PCB NOTICE PROPERLY TIGHTEN SCREWS To prevent damage to the lightbar do not overtighten screws 1 Secure two 8 32 Phillips screws retaining ROC to dome bracket and shim Figure 6 2 on page 56 Secure the two 8 32 Phillips screws retaining the bottom plate to the dome bracket Slide the assembly into the dome Before securing the 10 32 Phillips screw in the next step ensure that the holes for the dome s mounting screws are properly aligned from top to bottom Secure the 10 32 Phillips screw in the bottom of the dome Fasten the end dome to the mainbar as described in Installing an End Dome on page 55 Servicing the Mainbar ROC Assemblies The 42 inch 52 RS242 has two mainbar ROC PCB assemblies and the 52 inch model RS252 has three ROC PCB assemblies The PCB assemblies are in the front and rear lightbar lenses Servicing includes removing an assembly for replacement and removing
37. IONS To properly service a light assembly you must have a good understanding of auto motive electrical procedures and systems along with proficiency in the installation and use of safety warning equipment 54 Servicing the End Domes N 77 zZ lt lt ic So gt 2 7 6 Disconnect ALL power to the lightbar before you perform maintenance Failure to do so may result in property damage serious injury or death to you or others BURN HAZARD After prolonged operation the lightbar gets hot and can cause burns Do not touch the lightbar while or shortly after it has been operating Always allow the lightbar to cool before handling NOTICE STATIC SENSITIVE DEVICE The lightbar s circuitry can be damaged by an electrostatic discharge ESD Follow anti static procedures while installing the lightbar Servicing the End Domes Servicing the end domes includes removing them and inspecting their seals and hardware to ensure that the domes remain secure and watertight Inspection also involves check ing the domes for cracks crazing hairline cracks discoloration and other defects For replacement parts see Table 6 1 on page 70 Removing an End Dome 1 Remove the two 1 4 20 Phillips truss head screws retaining the end dome assem bly to the lightbar Figure 6 1 on page 55 2 Remove and inspect the O rings for damage Figure 6 1 Replace
38. OANNOOSIG H3MOd H31SVWTVNDOIS NON 3 18VN3 HH 1H4 SNOLLO3NNOO TVOIdA L xpueddy RAYDIAN SMARTSIREN SOLARIS are registered trademarks of Federal Signal Corporation EPIC is a trademark of microEngineering Labs Inc ToucHMASTER is a trademark of Federal Signal Corporation Ford and Crown Victoria are registered trademarks of Ford Motor Company Maxi Blade Fuse is a trademark of Littelfuse Plexus is a registered trademark of BTI Chemical Company Inc Torx is a registered trademark of Camcar Textron Inc Windows is a registered trademark of Microsoft Corporation in the United States and other countries fe FEDERAL SIGNAL Safety and Security Systems Advancing security and well being 2645 Federal Signal Drive University Park IL 60466 3195 Tel 800 264 3578 Fax 800 682 8022 www fedsig com 2008 Federal Signal Corporation
39. ODE 1 INTERSECTION MODE 3 1 Apply 12 Vdc 4 BAT to the MODE 3 control wire black red from the Serial Interface Module to display the assigned pattern 2 On the Serial Interface Module press and release the SW 1 push button until the pattern you want appears on the lightbar 3 Remove 12 Vdc from the MODE 3 control wire MODE 2 1 Apply 12 Vdc 4 BAT to MODE 2 control wire blue white from the Serial Interface Module to display the assigned pattern 2 On the Serial Interface Module press and release the SW 1 push button until the pattern you want appears on the lightbar 3 Remove 12 Vdc from the MODE 2 control wire MODE 1 1 Apply 12 Vdc BAT to the MODE 1 control wire blue from the Serial Interface Module to display the assigned pattern 2 On the Serial Interface Module press and release the SW 1 push button until the pattern you want appears on the lightbar 3 Remove 12 Vdc from the MODE 1 control wire Bench Testing Reprogramming Lightbar 21 INTERSECTION The INTERSECTION flash pattern overrides all three priority modes when activated To select a new pattern you must apply 12 Vdc to the control wire for either MODE 1 2 or 3 Table 3 1 on page 16 and the blue black control wire for INTERSECTION NOTE This procedure only programs the INTERSECTION pattern It does not assign the pattern to a MODE 1 Apply 12 Vdc BAT to a control wire for either MODE 1 2 or 3 and th
40. PPLY 12 Vde SIGNAL ACTIVATED 12 Vde N o z lt lt 5 c FUSE AMPERAGE DEPENDS ON AMPERAGE OF DEVICES o gt 29045897 Tt H H N Figure 5 1 Relay isolating devices with large filter capacitors NOTE After installation check the entire system to ensure the lights are flashing properly and all light system functions are operating properly 5 Wiring the Serial Interface Module 45 Wiring the Serial Interface Module For the wiring block diagram see Figure 5 2 below For typical installations with common controllers and switch boxes see the wiring sche matics in the Appendix on pages 79 though 84 For wiring the controller s functions to the Serial Interface Module s 24 pin cable harness see Table 5 1 on page 48 and the figures on pages 49 though 51 If additional wire is nec essary for the harness except ground 22 AWG wire is adequate The ground wires must be extended with 16 AWG or better wire This section is an overview of default settings that are activated when connecting LED and MODE control wires to 12 BAT All programming and changes to default set tings should be done after bench testing the lightbar and before installation Programming is covered in Programming Priority MODES 1 2 3 and INTERSECTION on page 20 For a description of the control wires from the Serial Interface Module see Table 3 1 on page 16 NOTICE FUSE ELECTRIC
41. RTANT Plan all cable routing before completing the installation To maximize aerodynamic efficiency we recommend that the lighting system be mounted as close to the vehicle roof as possible Adjust the mounting feet on the mounting bracket as needed ZS NviaAvH y uo o 38 Installing the Keeper Plate Part Number 8583193 N 42 2 o 2 gt 4 10 Check to ensure the lightbar is level If not adjust the lightbar s position in the mounting bracket slots Tighten all eight 5 16 Torx bolts that fasten the footpad brackets to the mounting feet Figure 4 5 on page 37 Remove the lightbar from the vehicle roof To avoid scratching the domes place the lightbar assembly upside down on soft rags or cardboard Torque the four 3 8 16 hex nuts on each mounting foot to 20 ft lb Press the vinyl caps onto the 3 8 inch hex nuts until they lock Place the lightbar on the vehicle s roof in its original position To fasten the mounting hook and complete the installation see Installing the Keeper Plate Kit Part Number 8583193 in the next section Installing the Keeper Plate Kit Part Number 8583193 The Keeper Plate Kit is used with the separately purchased mounting hook and is required for and included with the Horroor and Low Profile mounting kits Table 4 4 Keeper Plate Kit Qt
42. ack white wire 6 from the 24 pin harness to the negative GND battery lug DRIVER SIDE FRONT PASSENGER SIDE FRONT RAYDIAN 52 RS242 DRIVER SIDE REAR PASSENGER SIDE REAR POWER LINE RED GROUND POWER LINE BLACK CATS COM SERIAL CABLE INTERFACE GRAY dade MODULE VEHICLE BATTERY BLACK WIRE G BLACK WHITE WIRE WHITE WIRE 24 PIN HARNESS 290A5883 v Figure 3 1 Electrical connections for testing and reprogramming 5 5 m os 2 2 D gt ow 5 O 16 Bench Testing Reprogramming the Lightbar Preparing Raypian S2 for Installation 3 Control Wires for Flash Patterns This chapter describes how to display flash patterns during bench testing and pro gramming by applying 12 Vdc to the control wires in the Serial Interface Module s 24 pin harness Table 3 1 shows the control wires and their colors The wire s first color is the predominant color and additional colors are stripes Table 3 1 Control wires from the Serial Interface Module Lightbar Controls Wire Color Description MODE 1 Blue Lowest priority MODE 2 Blue White Overrides MODE 1 MODE 3 Black Red Overrides MODES 1 and 2 STEADY BURN Red White One or more LEDs steadily burn when 12 Vdc is applied to the control wire for a MODE and the control wire for STEADY BURN FRONT CUTOFF Turns OFF the
43. and reapplying the sealant to the dome seal Removing a Mainbar ROC Assembly I Remove the two 1 4 20 Phillips flat head screws retaining the end dome assem bly to the lightbar Figure 6 1 on page 55 Slide the dome assembly away from the lightbar and unplug the electrical con nector Note that there is a latch that must be pressed on the underside of the connector that is most easily accessed by inverting the dome assembly Disconnect both mainbar ROC cables at the controller end Note that there 15 a latch that must be pressed on the underside of each connector ZS NVIGAVY y 9 pue 58 Servicing the Mainbar ROC Assemblies 4 Remove the two 1 4 20 Phillips screws that secure the end bracket and ground wires to the aluminum extrusion Figure 6 3 5 Slide the end bracket dome seal and controller assembly out of the extrusion just far enough to remove the end bracket and dome seal from under the retaining tab on the controller assembly NOTICE PROPERLY TIGHTEN SCREWS To prevent damage to the wiring do not pull on the electrical connector 6 Hold the plastic lens to prevent it from sliding then slide the mainbar ROC as sembly from the lightbar If necessary pull on the reflector or bottom frame RETAINING TAB FOR THE CONTROLLER ASSEMBLY ALUMINUM EXTRUSION ON TOP OF THE END BRACKET REAR ROC ASSEMBLY
44. ater e USB e EPIC M USB programmer with USB cable programming cable and software CD Federal Signal part number ROCPRI sold separately NOTE Cloning only transfers the programmed flash patterns If you have changed de fault jumper and switch settings on the source Interface Module and lightbar controller and want the same settings for each vehicle you must manually set them To change the SiGNALMAsTER Internal External control settings see pages 17 and 18 To configure the STEADY BURN LEDs see page 23 See also Configuring the Flashing of the Mainbar LEFT and RIGHT ALLEY LEDs on page 24 and Configuring the Flashing of the Mainbar TAKEDOWN LEDs on page 25 74 Installing the Programmer Software 9 ES 1 Cs 2 2 5 9 3 HE de de oo gt S E 96 4 Installing the Programmer Software Close all applications on your computer Insert the melabs Programmer CD into your CD ROM drive When the Programmer Setup Wizard appears click Next Figure 7 1 NOTE If the Wizard does not appear double click My Computer then double click the icon for your CD ROM drive Double click the file setup exe Follow the on screen instructions to complete the installation Welcome to the melabs Programmer Setup Wizard Programmer 4 20 on your computer hal you close af other applications before cont
45. de to the left OFF Figure 3 5 on page 24 and Table 3 5 on page 26 Move Switch 2 on SW3 for the RIGHT ALLEY PASS is the passenger s side to the left OFF Reinstall the control in the mainbar Test the setting by applying and removing 12 Vdc to a MODE control wire Table 3 1 on page 16 and Figure 3 6 on page 26 NOTES SW3 does not affect the HorFoor ALLEY lights The HorFoor lights flash only when 12 Vdc is applied to a MODE control wire and the FLASH TAKEDOWN ALLEY control wire SW3 does not affect the operation of the LEFT and RIGHT ALLEY lights by their control wires from the Serial Interface Module Configuring the Flashing of the Mainbar TAKEDOWN LEDs The default setting has the mainbar TAKEDOWN LEDs flash when 12 Vdc BAT is connected to a control wire for MODE 1 2 or 3 and the control wire for the FLASH TAKEDOWN ALLEY LEDs To change the default setting so that the mainbar TAKEDOWN LEDs flash when 12 Vdc is connected only to a MODE control wire 1 Remove controller from mainbar See Removing the Controller for Configuration or Fuse Replacement on page 61 On the controller move the switches SW2 to the left OFF Figure 3 5 on page 24 and Table 3 5 on page 26 Reinstall the controller in the mainbar Test the setting by applying and removing 12 Vdc to a MODE control wire Table 3 1 on page 16 and Figure 3 6 on page 26 NOTES SW2 SWA does not affect the HorFoor TAKEDOWN light
46. dule Wiring the Serial Interface Module The lightbar is completely wired at the factory and does not need any additional internal wiring For typical installations with common control systems see the wiring schematics in the Appendix on pages 79 though 84 Wiring the Lightbar in the Vehicle NOTE The basic light functions of the lightbar must be controlled by a user supplied control panel AIR BAG DEPLOYMENT Do not install equipment or route wiring in the deployment path of an air bag Failure to observe this warning will reduce the effectiveness of the air bag or poten tially dislodge the equipment causing serious injury to you or others LIGHT HAZARDS To be an effective warning device this product produces bright light that can be hazardous to your eyesight when viewed at close range Do not stare directly into this lighting product at a close range or permanent damage to your eyesight may occur 41 42 Mounting Serial Interface Module N 42 2 lt 5 lt 53 PA c Sc 5 NOTICE MOUNT LIGHTBAR BEFORE WIRING To avoid damage to the lightbar and its wiring ensure that the lightbar has been properly installed on the vehicle s roof before wiring the lightbar in the vehicle NOTICE AVOID PINCHING OR PENETRATING WIRES To prevent a short circuit or broken wire dress the wires or cable to avoid pinch ing between the base plate and mounting surface Also do not allow the
47. dule from Operation Mode to Program Mode Unplug 24 pin harness from Serial Interface Module 2 On the Serial Interface Module move SW 2 Switch 6 to the up OFF position 3 Plug the 24 pin harness into the Serial Interface Module Additional Mainbar Tests and Configurations After programming and testing the MODES 1 2 and 3 and the INTERSECTION flash pattern test the STEADY BURN LEDs and FLASH TAKEDOWN ALLEY lights to en sure they function properly Testing the STEADY BURN LEDs Apply 12 Vdc BAT to red white control wire for the STEADY BURN LEDs and a control wire for MODE 1 2 or 3 Table 3 1 on page 16 The LEDs light and stay on default setting Figure 3 4 on page 23 Remove 12 Vdc from the MODE and STEADY BURN control wires Additional Mainbar Tests and Configurations 23 Configuring the STEADY BURN LEDs The STEADY BURN LEDs are factory configured per the customer order for one of these three options No STEADY BURN the LEDs flash with the pattern Driver s side STEADY BURN Driver s and passenger s side STEADY BURN To change the settings 1 Remove the controller from the mainbar See Removing the Controller for Configuration or Fuse Replacement on page 61 2 Switch SW 1 controls the STEADY BURN LEDs Figure 3 5 on page 24 For STEADY BURN move the switch to ON right For FLASH move the switch to OFF left DVR is the driver s side PASS is the passenger
48. e control wire for INTERSECTION from the Serial Interface Module 2 the Serial Interface Module press and release SW 1 push button until the pattern you want appears on the lightbar 3 Remove 12 Vdc from the MODE and INTERSECTION control wires INTERSECTION Operational Settings You can select one of three options to turn on the INTERSECTION pattern e HIGH with power maintained default the lightbar displays the INTERSECTION pattern until power is removed push on push off the INTERSECTION flash pattern is turned on and off by pressing a momentary contact switch such as a horn button Momentary 12 Vdc turns on the pattern a second momentary 12 Vdc signal turns it off e 8 SECOND TIMEOUT activated by momentary12 Vdc turns on the INTERSECTION flash pattern for eight seconds To change from HIGH to TAP II or 8 SECOND TIMEOUT 1 Unplug the 24 pin harness from the Serial Interface Module 2 On the Serial Interface Module set Switch 7 and Switch 8 on SW 2 to select a method of operation Figure 3 3 on page 18 and Table 3 3 below Each setting is independent of the other 3 Plug the 24 pin harness into the Serial Interface Module Table 3 3 Switch settings for INTERSECTION operation SW 2 Operational Settings SW7 SW8 HIGH maintained OFF up OFF up BAT push on push off ON down OFF up 8 SECOND TIMEOUT activated by OFF
49. e properly mated with the recesses in the lens and aluminum extrusions Slide the end bracket into the dome seal and tighten the screws On the driver s side install the dome seal and end bracket under the retaining tab for the controller assembly Ensure that all the projecting ribs on the dome seal are properly mated with corresponding recesses in the extrusions Slide the end bracket into the dome seal ensuring cables and ground leads are properly routed through the cutouts in the dome seal and end bracket Ensure that the cables are properly connected Secure the two 1 4 20 Phillips screws that fasten the end bracket and ground wires to the aluminum extrusion Figure 6 1 on page 55 Install the end dome a Reconnect the electrical connector to the board and slide the dome onto the lightbar Use care to avoid pinching the cables Use 1 4 inch drift punch or the 1 4 inch shank of a 2 Phillips screwdriver to align the holes in the dome end bracket and ROC assembly While keeping slight pressure inward on the dome align both holes leaving the drift in the second hole while starting the screw in the first hole To prevent cross threading the screws use care when starting the screws Start both 1 4 20 Phillips flat head screws before tightening them Cleaning Lenses End Domes 67 Cleaning the Lenses and End Domes Periodically cleaning the lenses and domes using proper procedures and compatible clean
50. ections NOTICE REVERSE POLARITY MISWIRING Reverse polarity or incorrect voltage may damage the lightbar To avoid damage to the lightbar ensure that the battery voltage is the same as the voltage rating of the lightbar and that the lightbar s red and black power lines are connected to the battery lugs in the correct polarity The 52 does not require any internal wiring Two 10 AWG power conduc tors red and black and a CATS cable exit the lightbar The lightbar s basic light functions are communicated through the CATS cable which connects to the Serial Interface Module To make the electrical connections for bench testing and reprogramming the lightbar see Figure 3 1 on page 15 and follow these steps 1 To supply power to the lightbar use a fully charged 12 volt automotive battery with terminal lugs 2 Place the lightbar on a sturdy flat surface 3 Plug the CATS communication cable 1 from the lightbar into the Serial Inter face Module J1 Bench Testing Reprogramming Lightbar 15 Plug the 24 pin harness 2 into the Serial Interface Module Attach the lightbar s black ground power line 3 to the negative GND ground battery lug Attach the lightbar s red power line 4 to the positive BAT battery lug The lightbar is now powered and ready for testing Attach the white wire 5 from the 24 pin harness to the positive BAT battery lug Attach the black wire and the bl
51. ectrical con nector Note that there is a latch that must be pressed on the underside of the connector that is most easily accessed by inverting the dome assembly Disconnect both mainbar ROC cables at the controller end Note that there is a latch that must be pressed on the underside of each connector Remove the two 1 4 20 Phillips screws that secure the end bracket and ground wires to the aluminum extrusion Figure 6 3 on page 58 Slide the end bracket dome seal and controller assembly out of the extrusion just far enough to remove the end bracket and dome seal from under the retaining tab in the controller assembly Slide the controller assembly until it clears the extrusion then flip it backwards on top of the extrusion Figure 6 6 Do not twist the wires 290A5908 Figure 6 6 Controller upside down on the aluminum extrusion 42 lt o 5 gt 5 5 y 2 gt 9 5 gt 2 62 Servicing the Lightbar Controller 77 lt lt So 2 6 Replacing Fuses the Lightbar Controller The lightbar controller has six fuses ranging from 5 A to 20 A To check if a fuse is bad inspect the horseshoe shaped wire on its side to see if it has burned through and broken the circuit Figure 6 7 To replace a fuse 1 Pull the fuse straight out to avoid damaging the connector 2 Gently press a new fu
52. eping slight pressure inward dome align both holes leaving drift punch in the second hole while starting the screw in the first hole 2 0 4 To prevent cross threading the screws use care when starting the screws Start both 1 4 20 Phillips truss head screws before tightening them 7 S gt 8 56 Servicing the ROC PCBs the End Domes Servicing the ROC PCBs in the End Domes Servicing the ROC PCBs in the end domes includes removing and disassembling the domes to replace the PCBs and cleaning the end dome reflectors Removing a ROC PCB from an End Dome 1 Remove the two 1 4 20 Phillips flat head screws retaining the end dome assem bly to the lightbar Figure 6 1 on page 55 2 Slide the dome assembly away from the lightbar and unplug the electrical con nector Note that there is a latch that must be pressed on the underside of the connector that is most easily accessed by inverting the dome assembly 3 Remove the 10 32 Phillips screw from the bottom of the dome Figure 6 2 4 Slide the ROC assembly from the dome 5 Remove the two 8 32 Phillips screws securing the bottom plate to the dome bracket 6 Remove the two 8 32 Phillips screws securing the ROC PCB to the dome bracket and shim ROC PCB DOME LENS REFLECTOR N 8 32 PHILLIPS SCREWS lt gt lt lt 8 8 os 8 So c gt 8 32 PH
53. erly connected to a good fully charged 12 volt battery Check the red power line BAT and the black ground power line NEG connections in the lightbar and vehicle cS NviaAvH y pue 72 Troubleshooting the Lightbar 2 2 lt lt Sc So gt 6 Corrective Action The lightbar has a de Ensure the connections on the Serial Interface Module layed response to are kept separate from strobe supplies i hut off 59 Check all the ground connections especially on the Serial In terface Module A FLASH TAKEDOWN Ensure there is no voltage on the corresponding control wire ALLEY light stays on with TUE ignition power applied Tosee if the ROC board is bad swap it with a similar board Swap the cables on the lightbar controller outputs with a known good output If the problem moves to another light send the lightbar controller to Federal Signal for repair TAKEDOWN and AL Y Ensure that 12 Vdc is applied to the TAKEDOWN and ALLEY LEY lights work but the red black control wire Ed TAE Check the 12 power and negative ground connections to ALLEY lights do not work the lightbar to ensure there is enough current Only one TAKEDOWN Check the connections from the lightbar controller to the ROC light turns on boards and the HorFoor a
54. ers will prolong their service life Unlike the reflectors the lenses and domes do not have to be removed from the lightbar for cleaning CRAZING CHEMICALS Crazed cracked or faded domes or reflectors reduce the light output and the effec tiveness of the lighting system Domes or lenses showing this type of aging must be replaced Failure to follow this warning may result in bodily injury or death to you or others CRAZING CLEANING SOLUTIONS The use of cleaning solutions such as strong detergents solvents and petroleum products can cause crazing cracking of the plastic domes and lenses Failure to follow this warning can damage the domes and reflectors and may result in bodily injury or death to you or others 1 Rinse the lenses and domes with lukewarm water to loosen dirt and debris 2 Use a mild soap lukewarm water and a soft cloth to gently clean the plastic surfaces To avoid damaging the reflectors do not use heavy pressure or caustic abrasive or petroleum based cleaners 3 Rinse and dry the plastic surfaces with a soft cloth to prevent water spotting To remove fine scratches and haze use a specialty plastic cleaner polish such as Plexus and a soft cloth You can also use a high quality automotive paste cleaner wax that is non abrasive ZS NVIGAVY 9 pue 68 Servicing the Mounting Brackets 2 lt lt
55. ffs Figure 6 8 c Gently and evenly press the controller onto the standoffs until all five tabs lock d Secure the 10 32 Phillips ground screw e Reconnect the wires and harnesses w f Flip the controller component side down and slide controller part of the lt way into the aluminum extrusion 5 g Apply new RTV to the dome seal as shown in Figure 6 4 on page 59 2 Install end dome y 2 gt 3 Install dome seal and end bracket under retaining tab for control 5 5 ler assembly Ensure that all projecting ribs dome seal gt erly mated with corresponding recesses in the extrusions ep 2 b Slide end bracket into dome seal ensuring that cables and ground wire are properly routed through the cutouts in the dome seal and end bracket 64 Servicing the Lenses 7 2 lt lt Sc So S gt 2 6 Ensure that cables are properly connected Secure the two 1 4 20 Phillips screws that fasten the end bracket and ground wires to the aluminum extrusion Figure 6 1 on page 55 Reinstall the driver s side end dome as described in Installing an End Dome on page 55 Servicing the Mainbar Lenses Proper servicing of the mainbar lenses includes inspecting them for watertightness cracks crazing and other damage and replacing them In addit
56. g lights Use extreme caution when using this function Ensure that the ambi ent light conditions are low enough that you are seen and that the reduction of glare from the lightbar is safer than full light output in the situation Failure to heed this warning may result in serious injury or death to you or others in your vicinity NOTE Low power mode is disabled when the lightbar is in MODE 3 or displaying the INTERSECTION flash pattern When 12 Vdc BAT is applied to the LOW POWER control wire the LEDs are dimmed to approximately 50 percent of their full brightness LOW POWER is only functional in MODE 1 or MODE 2 LOW POWER is disabled when switching to another flash pattern including INTERSECTION To use LOW POWER again dis connect 12 Vdc from the LOW POWER control wire and reapply 12 Vdc to the LOW POWER control wire after a change in flash pattern occurs IGNITION Connect the white wire from the supplied J1 cable harness on the Interface Module to a l ampere fuse Connect the fuse end as close as possible to switched ignition power Power should also be present in the cranking position Connect the black and black white wire from the 24 pin cable harness on J1 from the Serial Interface Module to battery ground Use 16 AWG wire to extend the cable length SicNALMAsrTER Connections NOTE The 42 inch model RAvpiAN S2 has six SIGNALMASTER LED heads The 52 inch model has eight heads Be certain to use the controller that
57. ge of the roof as possible Roof damage can occur if the hook adjustment bolts are over tightened Tighten ad justment bolts 10 to 11 ft lb to prevent the lightbar from sliding front to back when pulling on the mounting bracket 3 9 4 Safety Message to Operators of Warning Light Equipment e Locate the light system controls so the VEHICLE and CONTROLS be operated safely under all driving conditions After Installation or Service e After installation test the light system to ensure that it is operating properly Test all vehicle functions including horn operation vehicle safety functions and ve hicle light systems to ensure proper operation Ensure that the installation has not affected the vehicle operation or changed any vehicle safety function or circuit e Scratched or dull reflectors mirrors or lenses will reduce the effectiveness of the lighting system Avoid heavy pressure and use of caustic or petroleum based products when cleaning the lighting system Replace any optical components that may have been scratched or crazed during system installation 1 Safety Messages Do not attempt to activate or de activate the light system control while driving in a hazardous situation e You should frequently inspect the light system to ensure that it is operating properly and that it is securely attached to the vehicle e After installation and testing are complete provide a c
58. gure 6 11 4 Slide the assembly off the pivot 5 Unplug the connector to the LED assembly 8 32 SCREW 8 32 TOOTH LOCKWASHER REMOVE 8 32 SCREW AND LOCK WASHER SLIDE THE LED ASSEMBLY OFF THE PIVOT IN THIS DIRECTION 290A5916B Figure 6 11 Top left and side view of a Horroor LED assembly Installing LED Assembly 1 Plug the connector into the LED assembly D lt 2 Slide the assembly onto the pivot 9 5 PROPERLY TIGHTEN SCREWS S To prevent damage to lightbar do not overtighten screws gt lt 3 Replace lockwasher and tighten 8 32 screw retaining LED assembly 2 m Figure 6 12 4 Place plastic dome over the LED assembly 70 Raydian 52 Replacement Parts 5 Place hold down tab in the tab holder Figure 6 10 on page 68 6 Tighten the three Torx 10 32 screws securing the dome Cleaning the Horroor Domes To clean the Horroor domes use the same procedure described in Cleaning the Lenses and End Domes on page 67 RavpiaN S2 Replacement Parts This section contains a partial list of replacement parts To order replacement parts from the factory call the Federal Signal Service Department at 800 433 9132 7 AM to 5 PM Monday through Friday CT or contact your nearest distributor Table 6 1 Lightbar replacement parts
59. htbar Installation To prevent damage to the lightbar and vehicle and ensure that all equipment operates properly carefully plan where to mount and wire the lightbar and controlling equipment 1 Verify that the lightbar and mounting hardware fit the vehicle 2 Determine where to mount the lightbar on the vehicle 3 Determine where to mount the controlling equipment a trunk or remote location b console 4 Decide where to route wiring around airbag areas 5 Decide where to route the lightbar s power and ground wires to their connection points 6 To make wiring easier remove the seats spare tire and pull down the headliner where needed 7 Separate all electronic equipment wiring from two way radio equipment wiring 8 avoid interference keep two way radio antennas a minimum of 18 in 45 7 away from warning equipment 32 Options for Mounting the Lightbar N 42 2 o 2 gt 4 9 Whenever possible run wire lengths DO NOT splice wires 10 Do not coil excess wire Leave a drain loop for servicing 11 After drilling holes for wires deburr them smooth sharp edges and insert grommets to protect the wires from chafing 12 When you frame ground the equipment use the manufacturer supplied ground loca tions in the vehicle Options for Mounting the Lightbar Depending on the type of vehicle and mounting system feature
60. ightness LEDs spot beam reflector Three GEN high Offset compound curve polished Alley Light brightness LEDs spot beam reflector Three Gen II high efector with wide angle spreader brightness LEDs lans gle sp Flashing LED 0 5 A Amperage in STEADY BURN mode Product Specifications 11 Lightbar Dimensions Mainbar Model Length Height Width Weight 42 2 in 25 14 7 21 8 Ib Desde 107 2 cm 6 3 cm 87 3 cm 9 89 kg 52 3 in 2 5 in 14 7 in 26 8 Ib 132 8 6 3 37 3 12 16 kg 8 8 Ib 3 99 kg for Low Profile mounting foot option add 10 5 Ib 4 76 kg for mounting option Technical Specifications Model EFC Current Draw Operating Potential Temperature 22 F to 149 F RS242 12 8 Vdc 11 5A 30 to 65 C 22 F to 149 F RS252 12 8 13 5 30 C to 65 C for a typical loaded lightbar with all lights flashing at 50 percent duty cycle Serial Interface Module y JO cS NVIGAVY Model 8583446 Length Height Width Shipped with a 24 pin cable har ness 1751364 that is 3 feet long 6 25 in 2 88 in 1 06 in The harness connects to the mod 15 9 cm 7 3 cm 2 7 cm ule s J1 outlet 12 Product Specifications cS NviaAVH JO G
61. ily repaired and reconfigured without taking the lightbar off the vehicle Applications Police Fire and EMS Vehicles Heavy Duty Towing and Recovery Vehicles Parking enforcement and community service vehicles Private security vehicles Approvals SAE 1845 Light Output select flash patterns Table 2 1 on page 9 CCR Title 13 select flash patterns Table 2 1 SAE 1113 41 RFI FCC Part 15 9 Flash Pattern Compliances The patterns in Table 2 1 listed as Yes Y comply with the flash requirements and light output requirements of the lighting standard in the table header Patterns listed as No N do not comply with either the flash requirements or the light output of the standard You should use a non compliant pattern only after the people you are trying to warn have been trained to recognize the pattern as a warning signal End users are responsible for choosing the light patterns that meet their jurisdiction s requirements Table 2 1 Raypian S2 flash patterns compliances to standards Flash Pattern Number SAE J845 CCR Title 13 Y Y 9 10 Default MODE 1 11 12 13 14 15 16 17 Default MODE 2 18 19 20 21 22 Default INTERSECTION 23 24 25 26 Default MODE 3 27 For testing only N A N A 28 For testing N A N A Pattern 27 all LEDs turn on Pattern 28 each LED sequentially
62. inuing to Continue o Cancel to Setup Figure 7 1 Programmer Setup Wizard click Next Connecting the Programmer I Connect the EPIC programmer to a USB port on your computer with the USB A B cable Figure 7 2 on page 75 The first time you connect the programmer the New Hardware Wizard appears Click Next to install the device driver Figure 7 3 on page 75 IMPORTANT When the programmer is ready its LED glows green Do not discon nect the programmer when the LED glows red which indicates that the programmer is connecting or cloning Connecting Programmer 75 SERIAL INTERFACE MODULE TO COMPUTER USB PORT EPIC PROGRAMMER INNER PINS es ss 3 5 2 5 9 usejJ Buiuo 2 Figure 7 2 EPIC programmer cable connections Connect the EPIC SIDE of the programming cable to the five inner pins on the pro grammer Figure 7 2 On the Serial Interface Module to be downloaded source use a 1 4 inch driver to remove the four 8 32 x 1 4 hex head screws and remove the cover Figure 3 2 on page 17 Connect the programming cable to the source Interface Module Founda Hardware Wizard Welcome to the Found New Hardware Wizard This wizard helps you install software for USB Human Interface Device 6 If your hardware came with an installation CD gt or floppy disk insert it now What do you want the w
63. ion periodically cleaning the lenses and domes will extend their service life Removing the Lenses 1 Remove both end domes a Remove the end domes by removing the two 1 4 20 Phillips flat head screws retaining the end dome assembly to the lightbar Figure 6 1 on page 55 Slide the dome assembly away from the lightbar and unplug the electrical connector Note that there is a latch that must be pressed on the underside of the connector that is most easily accessed by inverting the dome assembly Remove the ROC assembly from the lens a Disconnect both mainbar ROC cables at the controller end Note that there is a latch that must be pressed on the underside of each connector Remove the two 1 4 20 Phillips screws that secure the end bracket and ground wires to the aluminum extrusion Figure 6 3 on page 58 Slide the end bracket dome seal and controller assembly out of the extru sion just far enough to remove the end bracket and dome seal from under the retaining tab in the controller assembly Remove the two 1 4 20 Phillips screws end bracket and dome seal from the passenger side Remove the lens a b Slide the lens and the ROC assembly off the aluminum extrusion Figure 6 1 on page 55 NOTICE WIRE DAMAGE To prevent damage to the wiring do not push or pull on the electrical connector Push the mainbar ROC assembly from the lens Servicing the Mainbar Lenses 65 c Remove the two vent plug
64. izard to do Click Next to continue Figure 7 3 New Hardware Wizard click Next 76 Cloning Serial Interface Module o 2 rm 2 o Q TES Do gt 55 O 7 Cloning the Serial Interface Module 1 Click Start gt Programs gt melabs Programmer gt melabs Programmer 2 Inthe drop down list select PIC16F877A Bile Run Configuration Options Help READ ICON Figure 7 4 PIC file to download 3 To download the file from the source Interface Module click the Read icon 4 During downloading the EPICWin software displays a Reading progress bar BACWin Readings Figure 7 5 Download progress 5 When downloading is finished click OK and disconnect the programming cable from the source Interface Module 1 Read Verify complete Figure 7 6 Download complete click OK 6 On the Interface Module to be cloned target use a 1 4 inch driver to remove the four 8 32 x 1 4 hex head screws and remove the cover Cloning the Serial Interface Module 77 7 Connect the programming cable to the target Interface Module Figure 7 2 on page 75 8 start cloning click Program icon 55 5 Erud zT File Program Options 9 gt P 2 70 5 5 0 Figure 7 7 Click the Program icon to clone O
65. kept clean dry and free of foreign par ticles that prevent good surface contact Ensure that mounting surface is flat A magnet mounting system should not be used on vehicles with vinyl tops prevent sliding of light assembly on mounting surface quick acceleration and hard stops should be avoided Failure to follow these precautions may result in property damage serious injury or death to you to passengers and to others RETAIN AND REFER TO THIS MESSAGE 6 Safety Message to Operators of Warning Light Equipment 1 Safety Messages Overview of Raypian S2 Topics covered Product Features Applications Approvals Flash Pattern Compliances Product Specifications The 52 is a single level all LED lightbar with ROC Reliable On Board Cir cuitry and SoLaris LED technologies and lighted mounting feet for additional warn ing protection ROC eliminates approximately 85 percent of potential failure points by incorporating a printed circuit board PCB in one assembly to substantially reduce the number of electrical connections SoLARIS LED modules use offset complex reflector surfaces for accurate beam shaping and the highest optical efficiency The modules over lapping 360 degree lighting eliminates weak spots and provides off axis warning around the lightbar The lightbar s internal microprocessor supplies three priority operational modes and a library of 26 flash patterns
66. n change the default settings for the optional STEADY BURN LEDs and the TAKEDOWN and ALLEY lights by setting switches on the mainbar controller For more information see Configuring the STEADY BURN LEDs on page 23 Bench Testing Reprogramming Lightbar 17 See also Configuring the Flashing of the Mainbar LEFT and RIGHT ALLEY LEDs on page 24 and Configuring the Flashing of the Mainbar TAKEDOWN LEDs on page 25 8 32 x 1 4 HEX HEAD SCREWS 290A5884 Figure 3 2 Serial Interface Module with cover attached Quick Testing using the LIGHTBAR TEST 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 NOTE The LIGHTBAR TEST does not test the optional STEADY BURN LEDs To test and configure these LEDs see Testing the STEADY BURN LEDs on page 22 Before programming and testing flash patterns perform the LIGHTBAR TEST to ensure that all LEDs light properly by following these steps 1 Apply 12 Vdc BAT to the LIGHTBAR TEST control wire black white red from the Serial Interface Module 79 2 After all LEDs flash in sequence the TAKEDOWN and ALLEY lights flash UO 3 Remove 12 Vdc from the LIGHTBAR TEST control wire cm Selecting Internal SignaLMaster Control s gt
67. nd ensure they in the proper locations Mainbar TAKEDOWN Check that the TAKEDOWN and ALLEY switches are set in the ALLEY lights flash with ON position on the lightbar controller see Figure 3 5 on page MODE independent of 24 FLASH TAKEDOWN ALLEY input TAKEDOWN comes on Check the connections from the lightbar controller to the Hor instead of ALLEY Foot and ensure they are connected to the proper locations MasteR LEDs Check the jumper and switch settings the Serial Interface not light Module Ensure they are both set for the correct operation See Figure 3 3 on page 18 and Table 3 2 on page 19 Ensure that Switch 4 SW 2 is in the correct position for the selected operation on the Serial Interface Module and ignition power was removed and reapplied Check the connections at the SianaLMastTer controller If the controller is model 5520005 ensure that the connector has power and the ground is connected to Pins 10 and 11 on the plug 73 Cloning Flash Patterns from Vehicle to Vehicle Topics covered W Installing the Programmer Software W Connecting the Programmer Cloning the Serial Interface Module The 52 and RS485 system make it fast and easy to copy and upload clone flash patterns to other RAvpiAN S2 equipped vehicles through the Serial Interface Module Cloning requires e laptop or desktop computer with Windows 98 or l
68. nection Ground Circuit Breaker Normally Open Momentary Switch 9 NO Switch 80 Appendix Wiring Schematics 926SV06E JOAJUOD 42 041u02 1 5 1021441 20 GATIONLNOO 711935 919 co 1 INGON vi XNVHO LOH SMV 0 X18 OL 3509 vor 1vIH3S OL S IVNSIS S3diAOHd 3091 H31SVWTVNOSIS Nu9 LHM NYS OIA AWD HA ma XVIN 001 H3H9IH NOLLYTTVLSNI NMOHS uod v 06 NI LOH xnv d Nuo 9 ANP vus X 9 13A 9 a3u x18 N 2 X mia 5939 1 9 aSNA YL SNOLLO3NNOO TWOIdAL xpueddy 611299 LHS 15 336 H3TIOHINOO
69. ng MODE 3 or INTERSECTION To dim the LEDs Apply 12 Vdc BAT to the control wire for MODE 1 2 Table 3 1 on page 16 2 Apply 12 Vdc BAT to the white black red control wire for the LOW POWER function 3 Remove 12 Vdc from the MODE and LOW POWER control wires To apply LOW POWER again after you program a flash pattern disconnect 12 Vdc BAT from the LOW POWER control wire and reapply it ZS NviaAvH 10 O 28 Additional Mainbar Tests and Configurations Testing the SicnaLMasterR LED Modules for External Operation With the lightbar in External SiGNALMASTER control default Figure 3 3 on page 18 apply ground to the control wires listed in Table 3 6 to test the LEDs Figure 3 7 on page 29 Table 3 6 SigNaLMaster control wires External operation RS242 Lightbar 6 Head RS252 Lightbar 8 Head Red Green Green Green Black White Green Black White Orange Green Orange Green Orange Orange Blue Red Blue Red Red Green Red Green White Red Testing the SicnaLMaster LED Modules for Internal Operation If the Serial Interface Module is set to Internal SignalMaster operation test the LEDs Figure 3 7 on page 29 by applying 12 Vdc to the control wires listed in Table 3 7 Table 3 7 directional control wires and warning patterns Internal operation
70. nicated to the lightbar through the CATS serial communication cable LOCATION OF LIGHT SYSTEM CONTROLS Light system controls must be located so that VEHICLE and CONTROLS can be operated safely under all driving conditions Mounting the Serial Interface Module 43 NOTE If you are using the INTERNAL SiGNALMASTER option you must configure the Se rial Interface Module before installation as described in Selecting Internal SIGNALMASTEr Control on page 17 NOTICE UNIT REQUIRES SHELTER FROM WEATHER The Serial Interface Module is NOT waterproof It must be mounted in a location that is sheltered from rain snow standing water etc NOTICE UNIT REQUIRES VENTILATION The Serial Interface Module needs to radiate heat Do not install it in an area where it cannot dissipate heat into the air Do not mount it near a heater duct IMPORTANT The Serial Interface Module must be installed within 36 in 91 cm of the lightbar controller 1 Use the Serial Interface Module as a template and scribe four drill positioning marks at your selected mounting location Mounting centers are 2 in x 5 95 in 5 08 cm x 15 11 DRILLING PRECAUTIONS DO NOT drill holes in ANY part of the Serial Interface Module Damage to the unit serious injury or death to you or others may result NOTICE 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 d
71. oduces 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 e Itis important that you fully understand how to safely operate this warning system before use e You should only operate your vehicle and its light sound system in accordance with your department s Standard Operating Procedures 9 sobessoy e selected function does not perform properly or if any of lamps remain illumi nated when the control is off disconnect the power connector from the control unit and contact the nearest service center e start of your shift you should ensure that the entire warning light system and the siren system is securely attached and operating properly e Suction cup mounting is for temporary applications only The unit should be re moved from the window and stored securely when not in use Temperature changes and sunlight can cause suction cups to lose holding power Periodically check the unit to be sure the suction cups have a firm grip on the mounting surface An improp erly secured light could fall off of the vehicle causing injury and damage Holding power of magnetic mounting systems is dependent upon surface finish surface flatness and thickness of the steel mounting surface Therefore to promote proper magnetic mounting Mounting surface and magnets must be
72. opy of these instructions to instructional staff and all operating personnel e File these instructions in a safe place and refer to them when maintaining and or re installing the product Failure to follow all safety precautions and instructions may result in property dam age serious injury or death to you or others RETAIN AND REFER TO THIS MESSAGE Safety Message to Operators of Warning Light Equipment People s lives depend on your safe use of our products Listed below are some impor tant safety instructions and precautions you should follow Do not attempt to activate or de activate the light system control while driving in a hazardous situation e Although your warning system is operating properly it may not be completely effec tive People may not see or heed your warning signal You must recognize this fact and continue driving cautiously e Also situations may occur which obstruct your warning signal when natural and man made objects are between your vehicle and others such as raising your hood or trunk lid If these situations occur be especially careful Safety Message to Operators of Warning Light Equipment 5 e effective sirens and horns produce loud sounds which may cause in certain situ ations permanent hearing loss You and your passengers should consider taking ap propriate safety precautions such as wearing hearing protection e Inorder to be an effective warning device this product pr
73. or route wiring or the plug in cord in the deployment path of an air bag Before mounting any components check the manual to be sure that the component you are installing is suitable for use in that area of the vehicle Many components are not suitable for use in the engine compartment or other extreme environmental expo sure areas Service life of light bulbs and strobes tubes will be shortened if the glass portion is touched during installation Use gloves when handling these components If the glass portion has been touched clean the glass carefully with isopropyl alcohol When drilling into a vehicle structure be sure that both sides of the surface are clear of anything that could be damaged Remove all burrs from drilled holes To prevent electrical shorts grommet all drilled holes through which wiring passes Also en sure that the mounting screws do not cause electrical or mechanical damage to the vehicle Refer to the manual packed with the lighting system for proper electrical connec tions additional precautions and information Because vehicle roof construction and driving conditions vary do not drive a vehicle with a magnetically mounted warning light installed The light could fly off the ve hicle causing injury or damage Repair of damage incurred because of ignoring this warning shall be the sole responsibility of the user To avoid denting the roof of the vehicle place the lightbar mounting feet as close to outer ed
74. oving the PCBs from the aluminum frames for replacement and cleaning the reflectors Removing a Mainbar ROC PCB 1 Remove the mainbar ROC assemblies as described in Removing a Mainbar ROC Assembly on page 57 Remove the four 8 32 Phillips screws that secure the bottom frame and ROC PCB to the top frame then remove the bottom frame Figure 6 5 on page 60 Carefully separate the PCBs at the board to board connectors using care to pre vent damage to the connector Depending on the length of the lightbar there may be more than one connector 42 lt o 5 5 y 2 22 565 gt 2 nos 60 Servicing the ROC PCBs 8 32 PHILLIPS SCREWS PCB pe SS v R 55 0 Py 290A5907 Figure 6 5 ROC PCBs removed from one side of the mainbar Cleaning the Mainbar Reflectors 1 Use a mild soap lukewarm water and a soft lint free cloth to gently clean the plastic surfaces To avoid damaging the reflectors do not use heavy pressure or caustic abrasive or petroleum based cleaners 2 Rinse and dry the surfaces with a soft lint free cloth to prevent water spotting Installing a Mainbar ROC PCB NOTICE DO NOT OVERTIGHTEN NUTS To prevent damage to the lightbar do not overtighten screws 1 Carefully connect the PCBs at the board to board connector using care
75. questionable O rings 3 Slide the dome assembly away from the lightbar and unplug the electrical con nector Note that there is a latch that must be pressed on the underside of the connector that is most easily accessed by inverting the dome assembly Inspecting an End Dome 1 Inspect the dome seal for deformation brittleness cuts or tears To maintain watertightness replace a questionable seal 2 Inspect the self clinching nuts in the bottom plate to ensure they are not loose in the plate and the threads are undamaged If the nuts are loose or their threads are damaged replace the bottom plate assembly 3 Inspect each dome for cracks crazing hairline cracks discoloration and other defects If a dome is defective replace it Servicing End Domes 55 1 4 20 SCREW 2 CONNECTOR END DOME 3 290A5903B Figure 6 1 End dome removed from mainbar Installing an End Dome NOTICE PROPERLY TIGHTEN SCREWS To prevent damage to the lightbar do not overtighten screws NOTE Because the dome seal is slightly compressed to provide a good seal you must apply pressure to the dome as you install it 1 careful not to pinch cables or wires Reconnect the electrical connector to the board then slide the dome onto the lightbar 2 Use a 1 4 inch drift punch or the 1 4 inch shank of a 2 Phillips screwdriver to align the holes in the dome s end bracket and the ROC assembly 3 While ke
76. rilled holes should be de burred and all sharp edges should be smoothed wires going through drilled holes should be protected by a grommet or convolute split loom tubing 2 Drill four mounting holes at the position marks sized for the recommended user supplied 48 mounting hardware 3 Secure the Serial Interface Module to the mounting surface with user supplied 8 mounting hardware 4 Install the lightbar s CATS serial cable to J3 output jack of the Serial Interface Module 5 Install the 3 foot long 24 conductor cable to J1 input connector of the Serial Interface Module ZS NVIGAVY eui BuulM 44 Wiring the Rayoian S2 in the Vehicle NOTE Powering multiple devices with a common control wire may cause one or more devices to briefly remain functional after signal power is removed For ex ample due to the high input filter capacitance a strobe supply can briefly supply the current required to signal a lightbar function to remain ON If necessary use a relay to isolate devices with large filter capacitors Figure 5 1 All components wires are user supplied SHOCK HAZARD Strobe and HID light systems generate high voltages Disconnect power from the system and wait at least 5 minutes before opening the unit Do not apply power to the unit while the unit is open Failure to follow this warning could result in serious injury or death RELAY CONTROL LEAD STROBE SU
77. s The HotFoot lights flash only when 12 Vdc is applied to a MODE control wire and the FLASH TAKEDOWN ALLEY control wire SW2 SWA does not affect the operation of the TAKEDOWN lights through their control wires from the Serial Interface Module ZS 4 10 O 26 Additional Mainbar Tests and Configurations Preparing Raypian S2 for Installation 3 Table 3 5 ALLEY and TAKEDOWN LED positions and controller switches RS242 Mainbar RS252 Mainbar Mainbar Controller ALLEY Positions ALLEY Positions SW3 Switch 1 2 1 2 DVR 15 16 17 18 55 RS242 Mainbar TAKEDOWN Positions RS252 Mainbar TAKEDOWN Positions Mainbar Controller SW2 SW4 Switch 7 7 DFB 8 8 DFA 9 11 PFD 10 12 PFC FRONT MODEL RS242 WORK LIGHT 22 WORK LIGHT 23 WORK LIGHT 24 MODEL RS252 WORK WORK LIGHT LIGHT WORK WORK LIGHT LIGHT NOTE THE TYPICAL HOTFOOT CONFIGURATION HAS THE TAKEDOWN LIGHTS IN THE FRONT LF RF AND THE ALLEY LIGHTS IN THE REAR LR RR 290A5888B Figure 3 6 ALLEY and TAKEDOWN LED positions on the mainbar Testing the LEFT and RIGHT ALLEY Lights 1 Remove 12 Vdc from the control wire Repeat steps 1 and 2 for the other alley lights Testing the TAKEDOWN Lights Apply 12 Vdc BAT to
78. s from the lens by reaching into each lens with a screwdriver to press the locking tabs on the vent plugs while pulling down on the plugs Figure 6 9 VENT PLUGS a 8 290A5911 Figure 6 9 Plastic lens partially removed from aluminum extrusion Installing the Lenses NOTICE PROPERLY TIGHTEN SCREWS To prevent damage to lightbar do not overtighten screws 1 Prepare the mating surfaces and lens a Clean the mating surfaces on the aluminum extrusion and remove the old RTV sealant b Insert the two vent plugs in the lens 2 Install the lens NOTICE WIRE DAMAGE To prevent damage to the wiring do not push or pull on the electrical con nector a Slidethe mainbar ROC assembly into the plastic lens ensuring that the cable connector is on the driver s end Center the ROC assembly in the lens b Slide the lens assembly onto the aluminum extrusion The end of the lens should be flush with the aluminum extrusion 3 Install the dome seals and the end brackets a Apply RTV sealant to the dome seal as shown in Figure 6 4 on page 59 7 lt ga 5 E 5 A lt 9 gt 2 o N pue 66 Servicing the Lenses N o 2 lt lt oz 2 6 Place the passenger s side dome seal against the end of the plastic lens and the aluminum extrusion Ensure that all the projecting ribs on the dome seal ar
79. s side Table 3 4 and Figure 3 4 below 3 Reinstall the controller in the mainbar 4 Testthe STEADY BURN LEDs by applying and removing 12 Vdc as de scribed on page 22 Table 3 4 STEADY BUHN LED positions and controller switches RS242 STEADY BURN RS252 STEADY BURN Mainbar Controller Positions Positions SW1 Switch 6 6 DVR 11 13 PASS MODEL RS242 MODEL RS252 ZS NviaAvH Buuedoug uonejeisu 10 Figure 3 4 Location of the STEADY BURN LEDs O 24 Additional Mainbar Tests and Configurations 77 2 lt lt c 5 D S o gt SW1 DEFAULT SETTINGS FOR STEADY BURN OPTION SWITCH 1 DRIVER AND Is SWITCH 2 PASS TURNED ON PER THE SW2 DEFAULT SETTINGS FOR TAKEDOWN CUSTOMER ORDER SEE TABLE 3 4 AND STEADY LIGHTS IF EQUIPPED AND DEPENDENT ON THE FIGURE 3 4 ON PAGE 23 RED POSITION OF MAINBAR TAKEDOWNS SWITCHES PFD PFC DFB OR DFA ARE TURNED ON SEE TABLE 3 5 AND FIGURE 3 6 ON PAGE 26 we PFD N T in FA 1 m FB DFC DFA sw ALLEYS sw3 DEFAULT SETTINGS FOR MAINBAR DVR ETE LEFT RIGHT ALLEY LEDS IF EQUIPPED SWITCH 1 PASS VR LEFT AND SWITCH 2 PASS RIGHT SW3
80. se of the same type and amperage into the connector En sure that all pins are properly seated For fuse part numbers see Table 6 1 on page 70 GOOD FUSE WIRE INTACT 20A bs TAKEDOWNS ALLEYS an LED FEET HAL 7686 sw ser 7 5A ALLEY EEG swt zu mi or zs BAD FUSE WIRE BURNED THROUGH 29045909 Figure 6 7 Fuses lightbar controller PCB Removing the Controller from the Lightbar 1 Remove the controller from the aluminum extrusion See Removing the Lightbar Controller for Fuse Replacement on page 61 2 Note and record connections then disconnect the wires and harnesses 3 Remove the 10 32 Phillips ground screw next to the power connector Figure 6 8 on page 63 4 To release the controller from the spacer squeeze the lock tabs on the five nylon standoffs Servicing the Lightbar Controller 63 STANDOFFS w SPACER 290A5910 Figure 6 8 Controller PCB removed from lightbar Installing the Controller NOTICE PROPERLY TIGHTEN SCREWS To prevent damage to the lightbar do not overtighten the ground screw 1 Prepare the dome seal and install the controller a Remove the old RTV sealant from the dome seal and the end of the lightbar b Center the holes in the controller over the five stando
81. talled on forward track of lightbar 36 Installing the Low Profile Mounting Kit Installing the Low Profile Mounting Kit N z Before installing the Low Profile Mounting Kit install the gutter hooks described in In B stalling the Hook On Mounting Kit Gutter Hooks on page 33 tc Table 4 3 Low Profile mounting kit Qty Description Part Number gt 8 Screw Head Torx 5 16 18 x 5 8 7000434 10 5 8 Lock Washer Split 5 16 7074A020 01 5 8 Washer Flat 5 16 7072234 4 Nuts Hex 3 8 16 7057A032 4 Pad Mounting Rubber 8572029 4 Bracket Assembly Foot Pad 8654157 1 Kit Keeper Plate 8583193 8 Plug Cap Vinyl 231214 Attaching the Low Profile Mounting Feet to the Lightbar 1 Turn the lightbar over so that the bottom of the lightbar faces up To avoid scratch ing the domes place the lightbar on soft rags or cardboard 2 Use the 5 16 18 x 5 8 Torx bolts 5 16 flat washers and 5 16 lock washers to attach a foot pad bracket on the mounting foot Figure 4 4 3 Position the 5 16 18 x 5 8 Torx bolts in the foot pad bracket at the bottom of the slots Figure 4 5 on page 37 Tighten the bolts only enough to hold the mounting foot in place 5 16 5 16 18 x 5 8 FLATWASHER HEAD BOLT MOUNTING PAD lod VINYL MOUNTING FOOT 290A5893 Figure
82. the lightbar mounting system or the ve hicle s roof Also ensure that the mounting kit is correct for the vehicle and only use the supplied mounting kit hardware If the mounting bracket is improperly assembled the lightbar assembly could fly off the vehicle Evenly snug both adjustment bolts Check to ensure the lightbar that the lightbar re mains centered left to right Torque both hook adjustment bolts to 10 to 11 ft Ib NOTE To properly secure the 10 thread forming screws and keeper plates orient the hex head of the hook adjustment bolt as shown in Figure 4 7 KEEPER SCREWS 10 x 1 2 PLATE 2 THD FRM PHILLIPS PAN HEAD 4 NOTE THE HEX HEAD ORIENTATION OF THE 5 16 18 HOOK ADJUSTMENT BOLT 290A5896 Figure 4 7 Mounting bracket attached to three hole hook 40 Installing Keeper Plate Kit Part Number 8583193 N 42 2 o 2 gt 4 After hook adjustment bolts are properly torqued locate holes next to adjustment bolt on the mounting hook Install the 10 pan head thread forming screws and keeper plates to prevent the hook adjustment bolt from rotating Frequently inspect the lightbar and mounting feet to ensure that all fasteners and brackets are tight Wiring the RavpiaN S2 Vehicle Topics covered Wiring the Lightbar in the Vehicle Mounting the Serial Interface Mo
83. there are two options available for installing the lightbar to the roof of the vehicle e HorFoor lighted mounting brackets that hook onto the vehicle e Low Profile mounting feet that hook onto the vehicle The next sections provide directions for installing each mounting option ROOF SUPPORT STRUCTURE There is a roof support structure that spans the distance between the driver s and passenger s side DO NOT DRILL THROUGH THIS structure Adjust any hole locations until the holes can be drilled without going through this support Failure to follow this warning will weaken the roof of the vehicle and may lead to an increased chance of bodily injury or death in a roll over accident NOTICE AVOID PINCHING OR PENETRATING WIRES To prevent a short circuit or broken wire dress the wires or cable to avoid pinch ing between the base plate and mounting surface Also do not allow the mounting screws to pierce the wires or cables NOTICE DRILLING PRECAUTIONS Before drilling holes check the area into which you plan to drill to ensure you do not damage vehicle components while drilling drilled holes should be deburred and all sharp edges should be smoothed wires going through drilled holes should be protected by a grommet or convolute split loom tubing Installing Hook On Mounting Kit Gutter Hooks 33 Installing the Hook On Mounting Kit Gutter Hooks The kit is used to attach Horroor Lighted Moun
84. ting Brackets and Low Profile Mounting Feet to vehicle The hook is designed for a specific make and model of vehicle es Table 4 1 Parts included in Hook On Mount kit J Qty Description Part Number 2 Hook Varies ES 6 6 Screw 10 Type A Thread Forming 7011196 08 9 190 2 Mounting 7000469 56 1 Place the lightbar assembly on vehicle roof at selected location Usually lightbar should be centered on the center door post B pillar NOTICE WATER LEAKAGE Water may leak into the vehicle interior if the hook is improperly posi tioned Ensure that the hook is positioned above or near the center door post B pillar 2 Determine where the hook will attach to the vehicle EQUAL SPACE ON EACH N SIDE OF LIGHT ASSEMBLY LIGHT ASSEMBLY 5 16 18 HEX EAD ADJUSTMEN OLT ode 2 VEHICLE ROOF 9 MOUNTING HOOK 2 10 HOOK MOUNTING SCREW 6 uu 7 Door 290A5890 Figure 4 1 Lightbar attached to vehicle with hook kit Place the hook in position on the roof sheet metal as shown in Figure 4 1 Use the hook as a template to mark the three hole locations With a 29 drill bit drill three 0 136 inch diameter holes at the marked locations o p Apply a silicone sealant around holes before attaching the hook 34 Installing the HotFoot Lighted Mounting Brackets N 42 za
85. to pre vent damage to the connectors Figure 6 5 NOTE Depending on the length of the lightbar there may be more than one connector 2 Place the assembled PCBs on the inverted top frame and position the board to board connector over the rectangular cutout in the top frame N o z lt lt tc o Ld 2 gt o 5 D Lond 3 Ensure that tabs on the bottom frame and PCB ground pads clean 4 Position the top frame on the ROC PCB ground pads Servicing the Lightbar Controller 61 To prevent stripping the threads in the top frame slightly turn the 8 32 Phillips screws counter clockwise until you hear a click as the threads mate Tighten the screws Reinstall the mainbar ROC assembly as described in Installing a Mainbar ROC Assembly on page 58 Servicing the Lightbar Controller The controller generates and receives the signals that control the lightbar s flash patterns If the lightbar fails the problem may be one or more blown fuses To replace a fuse you can remove the controller from the aluminum extrusion without completely disconnecting it Removing the Controller for Configuration or Fuse Replacement 1 Remove driver s side end dome by removing two 1 4 20 Phillips flat head screws retaining the end dome assembly to the lightbar Figure 6 1 on page 55 Slide the dome assembly away from the lightbar and unplug the el
86. ty instructions and pre cautions you should follow Before Installation or Service Qualifications e To properly install or service this equipment you must have a good understanding of automotive mechanical and electrical procedures and systems along with proficiency in the installation and service of safety warning equipment Always refer to the ve hicle s service manuals when performing equipment installations on a vehicle 2 Safety Message to Installers and Service Personnel of Warning Light Equipment Light Hazards e To be an effective warning device this product produces bright light that can be haz ardous 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 e Do not install the light system in an area that would block impair or blind the driver s vision Ensure that the light system is mounted in a position that is outside of the driver s field of vision so the driver can maintain safe vehicle operation e Federal Signal power supplies and light heads are designed to work together as system Combining light heads and a power supply from different manufacturers may reduce the warning effectiveness of the lighting system and may damage the components You should verify or test your combination to ensure the system works together and meets federal state and local standards or guidelines 1 Safety Messages
87. usion is good Check that the CAT5 cable is connected to the Serial Interface Module J1 and there are no damaged pins in the sockets new 5 cable V Check the connections on the Serial Interface Module 1 the black wire and the black white wire are connected to ground NEG 2 the white wire is connected to 12 Vdc 3 a MODE wire has 12 Vdc V Check the position of Switch 1 on SW 2 in the Serial Interface Module If Switch 1 is down ON ensure that the ENABLE control wires green white and orange black have 12 Vdc applied Check the positions of the DIP switches in the Serial Interface Module See Figure 3 3 on page 18 and Table 3 2 on page 19 V Check the fuses on the mainbar controller Figure 6 7 on page 62 An LED module does not light V Swap the LED board with good board to see if the board is bad V Check the connections of the cable that goes from the lightbar controller to the LED ROC board Ensure that the lightbar controller is not set for STEADY BURN see Configuring the STEADY BURN LEDs on page 23 V fitisa rear module check the SieNALMAsTER connections Half of an LED mod ule does not light Replace the ROC board that the LED is The lightbar turns off when the FLASH TAKEDOWN ALLEY lights turn on V Ensure that the vehicle battery is fully charged V Check that the lightbar s red power line and black ground power line CNEG are prop
88. y Description Part Number 2 Bolt Hex Head 5 16 18 x 1 3 4 7000469 28 2 Bolt Hex Head 5 16 18 x 2 1 2 7000469 40 2 Bolt Hex Head 5 16 18 x 3 1 2 7000469 56 4 Plate Bolt Keeper 8583188 4 Screw 10 x 1 2 inch Thread Forming 7011196 08 Phil Stainless Steel Waxed NOTE Mounting hooks with the three hole hook hardware kit pattern are required Fig ure 4 6 on page 39 For a list of hook kits by vehicle model see the mounting kit refer ence guide in the Federal Signal catalog or online at www fedsig com To install the hardware Fasten gutter hook to the mounting foot using 5 16 18 x 1 3 4 inch 2 1 2 inch or 3 1 2 inch hook adjustment bolt Figure 4 7 on page 39 Finger tighten the bolt for now Repeat step 1 on the other side of the lightbar assembly NOTE If you need bolts of a different size when installing the hook set on vans trucks etc order Federal Signal Model No HK BOLT Use the length that best fits your vehicle Installing the Keeper Plate Kit Part Number 8583193 39 5 7 3 HOLE PATTERN gt 5 gt lt gt 52 HOOK 290A5895 n Figure 4 6 Three hole hook o SECURE MOUNTING Ensure that the mounting bolt keeper plates are securely installed and that the hook kit bolts are torqued from 10 to 11 ft Ib Excessive tightening of the hook adjustment bolts can cause damage to

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