Valor™ Lightbar - Federal Signal
Contents
1. 18 Table 3 4 SignalMaster control wires and warning patterns internal Serial Interface Module control 21 Table 4 1 Cross reference for controller leads external Serial Interface Module control 28 Table 5 2 Replacement WIRES eie Ro Re seen ohne EL On ERE ERE DEM 41 Figures Figure 31 Serial Interface Module connections for testing and reprogramming 12 Figure 3 2 Serial Interface Module with Cover 13 Figure 3 3 DIP switch settings in Serial Interface i o den aa ens 14 Figure 3 4 SignalMaster flash sequences internal Serial Interface Module control 21 Figure 4 1 Relay isolating devices with large filter capacitors 25 Fi re4 2 Winne dui uu RT 25 Figure 4 3 SignalMaster 331105 controller external Serial Interface Module control 28 Figure 4 4 SmartSiren SS2000SM Series controller external Serial Interface Module control 29 Figure 4 5 SignalMaster control functions wired to ground for external Serial Interface Module control 30 Figure 4 6 SignalMaster control functions wired to 12 Vdc for internal Serial Interface Module2. SNOILONYLSNI H3d SNOLLO3NNOO SNINIVIA3H HOLIMS A3TW ino iz X H31SVWIVNOIS TOH INOO IWNHALNI SNOLLO3NNOO TVOIdALL YOUMS SSOOPMS suonoeuuoo 2 9 4 SNOILONYLSNI SNOLLO3NNOO SNINIVIA3H 13NVd HOLIMS 45 Valor Lightbar Chapter 6 Wiring Schematics 70095065 HOIVA LHM 3OVJH3LNI TVIH3S 9 5 29290 20 a 1 UZ 5625 1 22 lt LiIm mcH232223 SNOILONHLSNI Wad S SNOI LO3NNOO See Sse Sen 15000255 D 3snd H31SVWIVNSIS Vi 7 JONON 5 t SGOW SGOW 1 13 x18 a38 INSO002SS SNOLLO3NNOO 1VOIdAL NSO00ZSS I9po N UBISWeWS suonoeuuoo 2 n la 46 Chapter 6 Wiring Schematics 89597062 HOIVA LHM FINGOW 39v3H3 LNI TvIH3S 13 NOILINDI a3u ouo 7
3. Valor Lightbar 48 NOTES E FEDERAL SIGNAL Public Safety Systems 2645 Federal Signal Drive University Park IL 60484 3167 Tel 800 264 3578 Fax 800 682 8022 www fedsig com 2011 Federal Signal Corporation
4. FEDERAL SIGNAL Public Safety Systems Valor Lightbar Installation Maintenance and Service Manual 2562549B REV B 1211 Printed in U S A Contents CHAPTER 1 Safety 5 Safety Message to Installers and Service Personnel of Warning Light 5 Safety Message to Operators of Warning Light eene 8 CHAPTER 2 An Overview of the Valor Lightbar ccce ere Lecce rennen e niens ra unnkams 9 LED Lights Colors and Flash Patterns eene enne nennen nennen seni 9 Modular Connector Syster 9 Controller Options 9 A 10 10 Electrical and Temperature eiiis 10 CHAPTER 3 Preparing the Valor for Installation eere eren 11 Unpacking 11 Connecting the Valor for the Lightbar 5 11 Quick Testing the Valor with the Lightbar 5 13 Selecting Internal SignalMaster enne rnnt nns 13 Selecting External SignalMaster 14 Entering Progr m ror rrr rk a ee re ri 15 EXiting Progra
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7. the appropriate alley LEDs turn on The left and right alley lights override the flash takedown alley lights Takedown Lights When 12 Vdc BAT is applied to the Takedown control wire white black the takedown LEDs turn on Takedown overrides Flash Takedown Alley and Front Cutoff Valor Lightbar Chapter 4 Wiring the Valor the Vehicle Scene Light Left and Scene Light Right This function applies only to lightbars with Spectralux Technology Valor and Vision SLR To use this function with the Serial Interface Module place SW 2 Switch 3 in the Module in the down position ON When 12 Vdc is applied to the Scene Light Left control wire blue black the left half of the lightbar lights up When 12 Vdc is applied to the Scene Light Right wire black white red the right half of the lightbar lights up Intersection and Lightbar Test are unavailable with these options Low Power NOTE Low power mode is disabled when the lightbar is in MODE 3 or displaying the Intersection flash pattern AWARNING 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 warning lights Use extreme caution when using this function Ensure that the ambient 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 Failu
8. 14 and Table 3 3 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 BAT maintained OFF up OFF up Tap BAT push on push off ON down OFF up 8 Second Timeout activated by OFF up ON down Valor Lightbar Chapter 3 Preparing the Valor for Installation Front Rear Cutoff or Enable The operational setting for Front Rear Cutoff or Enable must be programmed after Mode and Intersection The default setting is for Cutoff in which the Front or Rear LEDs turn off when 12 BAT is applied to their control wires In contrast Enable turns on these LED modules when BAT is applied to their control wires Both the front and rear LEDs share the same operational setting and are not independent To program this feature 1 Unplug the 24 pin harness from the Serial Interface Module 2 On the Serial Interface Module move Switch 1 on SW 2 to a the down on position for Front Rear Enable b the up off position for Front Rear Cutoff 3 Plug the 24 pin harness into the Serial Interface Module NOTE When set to Enable 12 Vdc must be applied to a 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
9. 16 For a description of the control wires from the Serial Interface Module see Table 3 3 on page 18 For typical installations with common controllers and switch boxes see the wiring schematics in the Chapter 6 on page 43 For wiring the controller s functions to the Serial Interface Module s 24 pin cable harness see Table 4 1 on page 28 and the figures on pages 28 though 31 If additional wire is necessary for the harness except ground 22 AWG wire is adequate The ground wires must be extended with 16 AWG or thicker wire Figure 4 2 Wiring block diagram IGNITION BLACK WHITE BATTERY BLACK 10 AWG RED 10 AW 290 6563 Valor Lightbar 25 26 Chapter 4 Wiring the Valor the Vehicle Priority Modes 1 2 and 3 To activate a priority mode apply 12 Vdc BAT to a mode control wire Mode 3 black red overrides Mode 2 blue white and Mode 2 overrides Mode 1 blue You can program one of the flash patterns in the lightbar to each Mode input Steady Burn HotFoot Only When the lightbar is equipped with one or more Steady Burn LED modules applying 12 BAT to the control wire red white for Steady Burn turns on the LEDs when any Mode input is selected Front Cutoff When 12 Vdc BAT is applied to the Front Cutoff control wire green white the selected Mode operation is deactivated to the front of the lightbar Only the rear LEDs function Additionally w
10. 3 13 38 0 1A WHITE RED FAST S 1A Qc WHITEIBLACK RED LOW POWER or SCENE LIGHT RIGHT with SW 2 Switch 3 1A Q c BLACKIWHITE RED LIGHTBAR TEST down ON in the Serial Interface Module IGNITION 1A WHITE IGNITION POWER po BLACK GROUND 1 BLACK WHITE GROUND 2 IGNITION POWER INCLUDES POWER THE CRANKING POSITION 290A5981D Valor Lightbar 32 Chapter 4 Wiring the Valor the Vehicle Testing the Installation AWARNING SOUND HAZARD AII effective sirens and horns produce loud sounds 120 dB that may cause permanent hearing loss Always minimize your exposure to the sound of the siren and horn and wear hearing protection Do not sound the siren or horn indoors or in enclosed areas where you and others will be exposed to the sound AWARNING LIGHT HAZARD To be an effective warning device an emergency warning system produces bright light that can be hazardous to your eyesight when viewed at a close range Do not stare directly into the lights at a close range or permanent damage to your eyesight may occur After testing the installation test the emergency warning system to ensure that it is operating properly Also test all vehicle functions including horn operation vehicle safety functions and vehicle lighting systems to ensure proper operation Ensure that the installation has not affected the vehicle operation or chang
11. Intersection A WARNING 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 emergency 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 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 Valor Lightbar Chapter 3 Preparing the Valor for Installation To dim the LEDs 1 Apply 12 Vdc BAT to the control wire for Mode 1 or 2 Table 3 2 on page 16 2 Apply 12 Vdc 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 from the Low Power control wire and reapply it Testing the SignalMaster LEDs Modules for External Operation If the Serial Interface Module is set to External SignalMaster operation default test the LED modules by applying ground GND to the control wires listed in Table 3 4 on page 21 Testing the SignalMaster LED Modules for Internal Operation If the Serial Interface Module 1 set to Internal SignalMaster operation test the LED modules by applying 12 BAT to the control wires listed in Table 3
12. Serial Interface Module 1 the black wire and the black white wire are connected to ground GND 2 the white wire is connected to 12 Vdc Check the 1 A fuse 3 a MODE wire has 12 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 14 and Table 3 2 on page 16 Check the fuses on the mainbar controller An LED module does not light Swap the LED board with good board to see if the board is bad Check the connections of the cable that goes from the lightbar controller to the LED ROC board a rear module check the SignalMaster connections Half of an LED module does not light Replace the ROC board that the LED is on The lightbar turns off when the Flash Ensure that the vehicle battery is fully charged Takedown Alley lights turn on Check that the lightbar s red power line BAT and black ground power line CGND are properly connected to a good fully charged 12 volt battery Check the red power line BAT and the black ground power line connections in the lightbar and vehicle continued on next page Valor Lightbar 39 40 Chapter 5 Maintaining and Servicing the Valor Table 5 1 Troubleshooting tips cont
13. 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 IMPORTANT Ensure that SW 2 Switch 3 is in the up position for the Lightbar Test The down position is ON for the Scene Light Right option in lightbars with Spectralux Technology Valor and Vision SLR For the scene light control wires see Figure 4 5 on page 30 and Figure 4 6 on page 31 The Lightbar Test does not test the optional Steady Burn LEDs To test and configure these LEDs see Testing the Steady Burn LEDs HotFoot Only on page 19 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 Lightbar Test control wire black white red from the Serial Interface Module 2 The LEDs flash from red to blue to white amber 3 Remove 12 from the Lightbar Test control wire Selecting Internal SignalMaster Control The Interface Module SignalMaster control leads are defined in Table 3 2 on page 16 The SignalMaster can be configured for internal operation Power BAT applied to the specified control lead activates the lightbar s internal SignalMaster controller The Internal SignalMaster setting controls the flash pattern rather than driving each Signal
14. control 31 Figure 5 1 Locations of the barrel nuts in lens numbers indicate tightening 34 Figure 5 2 Locations of ROC PCRS ncaccsssssncesudssncesesasoantosndosabessdosscessinansessddasaesssosesnansanstuseautspbioeeinalameencdbucbboed 35 Figure 5 3 Locations of watertight 36 Figure 5 4 Secondary lock mechanism in the plug and receptacle 37 Figure 6 1 Typical connections with a SignalMaster controller external 44 Figure 6 2 Typical connections with SW400SS Switch Module internal control 45 Figure 6 3 Typical connections with a SmartSiren Model SS2000SM 46 Figure 6 4 Typical connections with a non SignalMaster controller esee 47 Figure 6 5 Typical connections with PA640 controller 48 Valor Lightbar 1 Safety Messages For your safety read and understand this manual thoroughly before installing operating and servicing the Valor lightbar The safety messages presented in this chapter and throughout 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
15. 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 Valor Lightbar Chapter 1 Safety Messages Electrical Hazards 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 A light system is a high current system In order for the system to function properly a separate negative connection and positive connection must be made All negative 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 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 functions or circuits Always check the vehicle fo
16. lightbar The lightbar is shaped to provide maximum intersection warning the most dangerous situation in moving traffic LED Lights Colors and Flash Patterns The lightbar s internal microprocessor supplies three priority operational modes and a library of 27 flash patterns To increase the safety of officers pedestrians and motorists the lightbar has standard front and rear cutoff dimming and intersection warning Bright white LED takedown and alley lights that are horizontally adjustable are also available with the HotFoot configured option Multi color heads are available with up to three different colored LEDs eliminating the loss of primary warning colors in takedown alley and directional warning positions Individual Valor lightheads can flash between red blue amber or white Modular Connector System The Valor Lightbar has a waterproof IP67 external connector system for power and communication to allow removal of the lightbar from the vehicle without opening the lightbar or the vehicle hood The Valor is protected against reversed polarity damage The Valor Lightbar may be installed in any vehicle with a 12 volt negative ground electrical system Controller Options Flash patterns are controlled through the lightbar s CAT5 communication cable The cable connects to the Serial Interface Module Part Number 8583446 the Federal Signal Six Button Serial Controller Part Number 8623133 the Three Button Serial Control
17. 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 Exiting Program Mode When you are finished programming patterns switch the Serial Interface 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 SW 2 Switch 6 to the up OFF position 3 Plug the 24 pin harness into the Serial Interface Module Additional Main Bar 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 ensure they function properly The test procedures are described in the next sections Testing the Steady Burn LEDs HotFoot Only The Steady Burn LEDs are factory configured per the customer order for one of these options e No Steady Burn the LEDs flash with the pattern Driver s side Steady Burn e Driver s and passenger s side Steady Burn Valor Lightbar 19 20 Chapter 3 Preparing the Valor for Installation 1 Apply 12 BAT to the red white control wire for the Steady Burn LEDs and a control wire for Mode 1 2 or 3 Table 3 2 on page 16 The LEDs light and stay on default setting 2 Remove 12 Vdc from the Mode and Steady Burn control wires Testing the Flash Takedown Alley Lights 1 Apply 12 Vdc BA
18. prepared with the following information e Your Federal Signal customer or account number e purchase order number under which the items were purchased e The shipping method e The model or part number of the product being returned e The quantity of products being returned e Drop ship information as needed e estimate required Valor Lightbar 41 42 Chapter 5 Maintaining and Servicing the Valor When you receive your RMA Number e Write the RMA number on the outside of the box of returned items e Reference the RMA number on your paperwork inside of the box e Write the RMA number down so that you can easily check on status of the returned equipment Send all material with the issued RMA Number to Federal Signal Corporation Public Safety Systems 2645 Federal Signal Drive University Park IL 60484 3167 Attn Service Department RMA www fedsig com Valor Lightbar 6 Wiring Schematics This chapter has schematics showing the Valor lightbar with typical connections to these controllers e SignalMaster controller external control SWA00SS Switch Module internal control e SmartSiren Model SS2000SM Non SignalMaster e PA640 Valor Lightbar 43 Chapter 6 Wiring Schematics S9S9V06E HOIA Ad3illv8 199 2 29 ga 29390583 mz rduJmurm
19. sequence with the flash pattern You can change default Mode flash patterns by programming each mode with one of patterns in the lightbar s library A typical setup would be Mode 1 Rear LEDs Mode 2 Front Rear LEDs Modes 1 and 2 Front Rear Cutoff Mode 3 Siren SmartSiren or Federal Signal compatible and Front Rear LEDs and Flash Takedown Alley LEDs on the main bar NOTE If the lightbar needs to be programmed after you connect a progressive slide switch the programming sequence must be Mode 3 Mode 2 Mode 1 Intersection Table 3 2 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 Steady Burn HotFoot only Black Red Red White Overrides Modes 1 and 2 One or more LEDs steadily burn when 12 is applied to the control wire for a Mode and the control wire for Steady Burn Front Cutoff Front Enable Green White Turns off the front of the lightbar Turns on the front of the lightbar Rear Cutoff Rear Enable Low Power Orange Black White Black Red Turns off the rear of the lightbar Turns on the rear of the lightbar 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 Int
20. 3 2 on page 17 NOTE With the flexibility of the SmartSiren Platinum System both the Intersection and the Scene Light Left option are available in Vision SLR and Valor lightbars without the need to choose one or the other 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 the control wire for Intersection from the Serial Interface Module 2 On the Serial Interface Module press and release the SW 1 pushbutton until the pattern you want appears on the lightbar 3 Remove 12 Vdc from the Mode and Intersection control wires Intersection Operational Settings Select one of three options to turn on the Intersection pattern e HIGH with BAT power maintained default the lightbar displays the Intersection pattern until power is removed e 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 BAT momentary 12 Vdc turns on the Intersection flash pattern for eight seconds To change from High to Tap 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
21. 4 3 page 28 and Figure 4 4 on page 29 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 4 1 on page 28 Valor Lightbar 27 Chapter 4 Wiring the Valor the Vehicle Internal SignalMaster 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 Internal SignalMaster Control on page 13 To activate the lightbar s internal SignalMaster controller apply 12 BAT to the SignalMaster control wires Table 4 1 Cross reference for controller leads external Serial Interface Module control 24 Harness from the SignaLMaster Wire 2000 Wire Serial Interface Module Figure 4 3 Figure 4 4 Red White White 1 Green Brown 2 Green Black White Green 3 Orange Green Orange 4 Orange Purple 5 Blue Red Gray 6 Red Green Yellow 7 White Red Blue 8 Wire colors as described in the controller s installation instructions Figure 4 3 SignalMaster 331105 controller external Serial Interface Module control SIGNALMASTER C
22. 4 on page 21 Table 3 4 SignalMaster control wires and warning patterns internal Serial Interface Module control Warning Pattern 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 Orange Two outer LEDs alternate Blue Red Right four LEDs alternate with left four LEDs Red Green Two outer LEDs flash then the four LEDs between the inner and outer LEDs flash Control Wires Description White Red Operates the selected pattern 50 percent faster Figure 3 4 SignalMaster flash sequences internal Serial Interface Module control LEFT WARN 1 1 2 WARN 2 1 1 2 2 2 1 1 2 4 RIGHT WARN 3 Valor Lightbar 21 22 4 Wiring the Valor in the Vehicle Before proceeding ensure that the lightbar has been installed on the vehicle roof in accordance with the instructions included with the mounting kit Depending on the type of vehicle and mounting system feature there are two options available for installing the lightbar to the roof of the vehicle hook on mounting or permanent mounting WARNING INSTALLATION PRECAUTIONS The w
23. 800 433 9132 7 a m to 5 p m Monday through Friday CT Safety Message to Installers and Service Personnel of Warning Light Equipment AWARNING People s lives depend on your proper installation and servicing of Federal Signal products It is important to read and follow all instructions shipped with this product In addition listed below are some other important safety instructions and precautions you should follow Before Installation or Service Qualifications 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 vehicle service manuals when performing equipment installations on a vehicle Light Hazards 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 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 safely operate the vehicle Federal Signal power supplies and lightheads are designed to work together as a system Combining lightheads and a power supply from
24. BLE REAR CUTOFF ENABLE LOW POWER or SCENE LIGHT RIGHT with SW 2 Switch 3 LIGHTBAR TEST down in the Serial Interface Module 1 LEFT mE GREEN BLACK WHITE 3 L ORANGE GREEN ORANSEGREEN ANY SIGNALMASTER CONTROLLER ORANGE L BLUE RED lt RED GREEN NES WHITE RED 1 AA N WHITE O BLACK 5 8 RIGHT IGNITION POWER GROUND 1 BLACK WHITE GROUND 2 IGNITION POWER INCLUDES POWER THE CRANKING POSITION Valor Lightbar Chapter 4 Wiring the Valor the Vehicle Figure 4 6 SignalMaster control functions wired to 12 Vdc for internal Serial Interface Module control POWER 12 Vdc J1 CABLE TO SERIAL INTERFACE 1A BLACK RED MODE 3 MODULE 1 OO BLUEMHITE MODE 2 BLUE MODE 1 1 5 RED WHITE STEADY BURN or SCENE LIGHT LEFT with SW 2 Switch 3 1A O BLUE BLACK INTERSECTION down ON in the Serial Interface Module 1A RED BLACK FLASH TAKEDOWN ALLEY cy c ORANGE RED RIGHT ALLEY GREENIBLACK LEFT ALLEY 18 WHITE BLACK TAKEDOWN id Q o GREENWHITE FRONT CUTOFF ENABLE TA REAR CUTOFF ENABLE fea REARCUTOFT ENABIE 1A RED LEFT 1A 5 GREEN CENTER oE OT 1A A GREEN BLACK WHITE RIGHT A ORANGE GREEN WARN 1 Oooo 1A WARN 2 1 5 BLUE RED WARN 3 RED GREEN WARN 4 Oo a
25. Master head 1 Unplug the 24 pin harness from the Serial Interface Module 2 Usea 1 4 inch driver to remove the four 8 32 x 1 4 hex head screws on the Serial Interface Module and remove the cover Figure 3 2 Figure 3 2 Serial Interface Module with cover attached 8 32 x 1 4 HEX HEAD SCREWS 4 290A6560 3 On the Interface Module PCB move JP 1 from EXT to INT Figure 3 3 on page 14 Valor Lightbar 13 Chapter 3 Preparing the Valor for Installation 4 Reinstall the cover on the Interface Module 5 Move Switch 4 on SW 2 to the down position ON 6 Plug the 24 pin harness into the Serial Interface Module Selecting External SignalMaster Control The Interface Module comes factory preset for the external SignalMaster option The Interface Module drives each SignalMaster head independently via an external Federal Signal SignalMaster controller or the SS2000SM Series Siren Either device will provide an independent ground signal to illuminate each head 1 Unplug the 24 pin harness from the Serial Interface Module 2 Onthe Serial Interface Module 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 position OFF Table 3 1 on page 15 Plug the 24 pin harness into the Serial Interface Module Fi
26. ON on SW 2 Table 3 1 SW 2 DIP switch settings in Serial Interface Module SW 2 Switch Setting Switch Up Down Number OFF ON Function Front Rear LEDs cut off turn off when 12 Vdc is applied their control wires Table 3 2 on page 16 Front Rear LEDs enable turn on when 12 Vdc is applied to their control wires Keep in OFF position Intersection when 12 Vdc is applied to blue black wire Lightbar Test when 12 Vdc is applied to black white red wire Left scene light turns on when 12 Vdc is applied to blue black wire Right scene light turns on when 12 Vdc is applied to black white red wire Intersection and Lightbar Test are unavailable This function applies only to lightbars with Spectralux technology Valor and Vision SLR SignalMaster External controller SignalMaster Internal controller Cycle forward through the selection of flash patterns Cycle backward through the selection of flash patterns Operation Mode Program Mode Switch for Intersection operational settings Table 3 3 on page 18 Switch for Intersection operational settings Table 3 3 Valor Lightbar 15 Chapter Preparing the Valor for Installation 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 operates in one of these modes the SignalMaster modules keep
27. ONTROLLER 331105 SHOWN GREEN BLACK WHITE ORANGE ORANGE GREEN VIOLET ORANGE GRAY 1 BLUE RED YELLOW RED GREEN BLUE WHITE RED 1 TO J1 ON INTERFACE MODULE NOTE FOLLOW THE CONTROLLER S INSTALLATION INSTRUCTIONS FOR POWER GROUND AND OTHER POSSIBLE FUNCTIONS 28 Valor Lightbar Chapter 4 Wiring the Valor the Vehicle Figure 4 4 SmartSiren SS2000SM Series controller external Serial Interface Module control RED WHT 1 GREEN 1 BRN 2 gt gt ORN 4 5 BLUE RED RED GREEN WHITE RED TO J1 ON FUSE INTERFACE MODULE Valor Lightbar 29 30 Chapter 4 Wiring the Valor the Vehicle Figure 4 5 SignalMaster control functions wired to ground for external Serial Interface Module control 1A Q c BLACK RED 1A o o BLUEWHITE 1A BLUE BLY 1 RED WHITE 7 BLUE BLACK 1 OO REDIBLACK 1 ORANGE RED O oO 1A c GREENIBLACK 1A WHITE BLACK oO BLAC 1A GREENWHITE 1A RANGE BLACK c ORANGE BLAC 1 WHITE BLACK RED Oo 1 BLACK WHITE RED L RED O 1 _ GREEN POWER 12 J1 CABLE TO SERIAL INTERFACE MODE 3 MODULE MODE 2 MODE 1 STEADY BURN or SCENE LIGHT LEFT with SW 2 Switch 3 INTERSECTION down ON in the Serial Interface Module FLASH TAKEDOWN ALLEY RIGHT ALLEY LEFT ALLEY TAKEDOWNS FRONT CUTOFF ENA
28. T to the control wire for Mode 1 2 or 3 Table 3 2 on page 16 2 Apply 12 BAT to the red black control wire for the Flash Takedown Alley lights to flash the them 3 Remove 12 Vdc from the Mode and Flash Takedown Alley control wires Testing the Left and Right Alley Lights 1 Apply 12 Vdc to the control wire for either the left or right alley LED Table 3 2 on page 16 to turn it on 2 Remove 12 Vdc from the control wire 3 Repeat steps 1 and 2 for the other alley light Testing the Takedown Lights Apply 12 BAT to the white black control wire to turn on the takedown lights Testing the Left and Right Scene Lights This function applies only to lightbars with Spectralux Technology Valor and Vision SLR Place SW 2 Switch 3 in the Serial Interface Module in the down position ON to activate this option then cycle power to the lightbar Intersection and the Lightbar Test are unavailable Applying 12 Vdc to the Scene Light Left wire white black red turns on the left half of the lightbar Applying 12 Vdc to the Scene Light Right wire black right red turns on right half of the lightbar Testing the Low Power Function The Low Power function dims the main bar LEDs approximately 50 percent to prevent blinding approaching drivers NOTE The Low Power function only operates in Mode 1 or Mode 2 It is disabled when the lightbar is turned off or switched to another flash pattern including Mode 3 or
29. arks at the selected mounting location Mounting centers are 2 00 in x 5 95 in 5 08 cm x 15 11 A WARNING DO NOT DRILL INTO SERIAL INTERFACE MODULE DO NOT drill holes into ANY part of the Serial Interface Module Damage to the unit serious injury or death may result A WARNING DRILLING PRECAUTIONS Before drilling holes check the area into which you plan to drill to ensure you do not damage vehicle components drilled 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 drill position marks sized for the recommended user supplied 8 mounting hardware 3 Secure the Serial Interface Module to the mounting surface with installer supplied 78 hardware 4 Install the CATS serial cable from the lightbar to the J3 output jack of the Serial Interface Module 5 Install the three foot long 24 conductor cable from the lightbar to the J1 input connector of the Serial Interface Module 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 example 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 Fig
30. arning system and or two way radio system may operate improperly if a two way radio antenna installed on or within 18 inches of the lightbar Before permanently installing the lightbar or a two way radio antenna test the warning system and two way radio system DO NOT install a two way radio antenna on the lightbar Some installations may require the relocation of the two way radio antenna to a trunk or fender location DO NOT drill holes in the lightbar or install auxiliary devices on the lightbar or the warning system may fail Planning the Electrical Installation The lightbar is completely wired at the factory and does not require any additional internal wiring All the conductors necessary for control of any and all basic and optional functions are contained in the CATS cable The basic light functions of the Valor must be controlled by a installer supplied control head 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 WARNING LOCATING OPERATOR CONTROLS The controls for the light system must be located so that the VEHICLE and CONTROLS can be operated safely under all driving conditions 4 WARNING UNIT REQUIRES SHELTER FROM WEATHER The Serial Interfa
31. ce Module is NOT waterproof It must be mounted a location that is sheltered from rain snow standing water etc 3 Determine where to mount the controlling equipment a Trunk or remote location b Console Valor Lightbar Chapter 4 Wiring the Valor the Vehicle AWARNING AIRBAG DEPLOYMENT Do not install equipment or route wiring in the deployment path of an airbag Failure to observe this warning will reduce the effectiveness of the airbag or potentially dislodge the equipment causing serious injury or death 4 Decide where to route wiring around airbag areas AWARNING BATTERY EXPLOSION To avoid a battery explosion always disconnect the negative battery cable first and reconnect it last Avoid causing a spark when connecting near or to the battery The gases produced by a battery can cause a battery explosion that could result in vehicle damage and serious injury 5 Decide where to route the lightbar s power and ground wires AWARNING SEAT REMOVAL PRECAUTION If a vehicle seat is temporarily removed verify with the vehicle manufacturer if the seat needs to be recalibrated for proper airbag deployment Failure to follow this warning cause serious injury or death 6 To make wiring easier remove the seats spare tire and pull down the headliner where needed 8 Separate all electronic equipment wiring from two way radio equipment wiring 7 To avo
32. e turns on right half of the lightbar Lightbar Test down position Pattern is unavailable Mode 3 1 Apply 12 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 pushbutton 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 BAT to the 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 pushbutton 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 pushbutton until the pattern you want appears on the lightbar 3 Remove 12 Vdc from the Mode control wire Valor Lightbar 17 Chapter Preparing the Valor for Installation 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 2 on page 18 and the blue black control wire for Intersection SW 2 Switch 3 in the Serial Interface Module must be in the up position for this function See Table
33. ed any vehicle safety functions or circuits After testing is complete provide a copy of these instructions to the instructional staff and all operating personnel Do not test the sound and light system of the vehicle while driving Operating the vehicle warning systems may pose a hazard to the operator and other drivers if the systems do not function as expected Test the vehicle only in a controlled environment Valor Lightbar 5 Maintaining and Servicing the Valor This chapter describe how to maintain and service the Valor lightbar Establishing a regular maintenance and inspection schedule extends the life of the lightbar and ensures safety For service support or replacement parts contact the Federal Signal Service Department at 1 800 433 9132 7 a m to 5 p m Monday through Friday CT See Table 5 2 on page 41 for replacement parts and part numbers SHOCK HAZARD Disconnect ALL power to the lightbar before any maintenance is WARNING performed Failure to do so may result in property damage serious injury or death A CAUTION BURN HAZARD After prolonged operation the unit gets hot and can cause burns Do not touch the unit while or shortly after it has been operating Always allow the unit to cool before handling it Cleaning the Lightbar Lens WARNING CRAZING CLEANING SOLUTIONS The use of cleaning solutions such as strong detergents solvents and pe
34. er and CATS at Lightbar on page 36 Use a T27 Torx driver to remove the 1 4 20 Torx head barrel nuts securing the lens Figure 5 1 Carefully remove the lens and gasket as a unit Avoid damaging the lip seal Verify that an O ring is under the head of each barrel nut and not stuck to the lens Use a wooden or plastic pick to carefully remove the O rings from the lens to prevent damaging them Inspect the O rings and the lip seal for deformation brittleness cuts or tears To maintain watertightness replace a questionable O ring or seal Inspect the lens for cracks crazing hairline cracks and other defects Figure 5 1 Locations of the barrel nuts in lens numbers indicate tightening sequence 7 6 10 MODEL VALR44 290A6556 Valor Lightbar Chapter 5 Maintaining and Servicing the Valor Reinstalling the Lens To reinstall the lens 1 Reinstall the gasket and lens To prevent cross threading the barrel nuts back them counterclockwise until you hear the click of the threads engaging 2 Tighten the barrel nuts to 16 24 in Ib in the sequence shown in Figure 5 1 on page 34 Replacing a PCB The Valor lightbar has two front two rear and two end ROC PCBs as well as a controller PCB Figure 5 2 They are configured at the factory per the customer order STATIC SENSITIVE DEVICE This lightbar s circuit
35. ersection Flash Takedown Alley Red Black Flashes the alley and takedown lights in 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 continued on next page Valor Lightbar Chapter 3 Preparing the Valor for Installation Table 3 2 Control wires from the Serial Interface Module continued Lightbar Controls Wire Color Description Intersection Blue Black Dims the lights approximately 50 percent to SW 2 Switch 3 in the prevent blinding approaching drivers Low up position Power is only available in Modes 1 and 2 and is disabled when switched to another flash pattern including Mode 3 and Intersection Scene Light Left is unavailable Scene Light Left Applying 12 Vdc to the Scene Light Left wire SW 2 Switch 3 in the turns on the left half of the lightbar only for Valor down position and Vision SLR Intersection is unavailable Lightbar Test Pattern Black White Red Flashes the LEDs sequentially and then flashes SW 2 Switch 3 in the the takedown and alley lights Scene Light Right up position is unavailable Scene Light Right Applying 12 Vdc to the Scene Light Right wire SW 2 Switch 3 in th
36. fting techniques when removing replacing this product Failure to follow this warning may cause personal injury REVERSE POLARITY MISWIRING Reverse polarity or incorrect voltage Ee 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 Valor does not require any internal wiring Two 10 AWG power conductors red and black and a 5 cable exit the lightbar The lightbar s basic light functions are communicated through the CATS cable which connects to the Serial Interface Module SmartSiren Platinum or other Federal Signal controllers The electrical connections in this section enable you to perform a quick test of the lightbar with the Serial Interface Module The Serial Interface Module communicates between an installer supplied lightbar siren controller a SignalMaster controller or a switch box and the lightbar To minimize the number of discrete wires to the lightbar control head functions are wired to the Module through a 3 foot long 24 conductor cable harness Table 3 3 on page 19 The information is converted to a digital format and communicated through the CATS serial communication cable Valor Lightbar 11 Chapter 3 Preparing the Valor for Installation The numbers in the steps belo
37. ghts flashing at 50 percent duty cycle Valor Lightbar 3 Preparing the Valor for Installation 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 instructions for quick testing the lightbar this chapter has instructions for changing default settings and flash patterns with the Serial Interface Module The number of available flash patterns vary between the Serial Interface Module and the SmartSiren Platinum System If you are using the SmartSiren Platinum System refer to the Smart Siren Platinum Installation Maintenance and Service Manual Doc No 2562502 and to the Smart Siren Platinum Control Pad Configuration Software Manual Doc No 2562418 programming instructions 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 a m to 5 p m Monday through Friday CT Connecting the Valor for the Lightbar Test AWARNING HEAVY OBJECT Use lifting aids and proper li
38. gure 3 3 DIP switch settings in Serial Interface Module BACK OF SERIAL INTERFACE MODULE uL PUSH BUTTON SW 1 SERIAL INTERFACE MODULE PCB MTM SWITCHES 1 Syn THROUGH 8 ON SW 2 N N p SW NN Pd a P d N rom x m Z ur N 7 N INTERNAL SIGNALMASTER EXTERNAL SIGNALMASTER CONFIGURATION CONFIGURATION 29046561 14 Valor Lightbar Chapter 3 Preparing the Valor for Installation Entering Program Mode To switch the module from Operation Mode to Program Mode 1 2 Unplug the 24 pin harness from the Serial Interface Module On the Serial Interface Module move Switch 6 on SW 2 to the down position ON Figure 3 3 on page 14 Plug the 24 pin harness into the Serial Interface Module SW 2 DIP Switch Settings in the Serial Interface Module For the location of SW 2 see Figure 3 3 on page 14 Table 3 1 lists the DIP switch settings in the Serial Interface Module for programming flash patterns Selecting a Flash Pattern When you press and release the SW 1 pushbutton 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 up position
39. hem counterclockwise until you hear the click of the threads engaging then tighten them to 16 24 in Ib in the sequence shown in Figure 5 1 on page 34 3 Reconnect power to the lightbar Disconnecting Connecting Power and CAT5 at the Lightbar A detachable weather proof connector at the bottom of the lightbar on the passenger side enables you to quickly disconnect both power and ground together without removing the cables from the battery Figure 5 3 The smaller waterproof connector is for the 5 communication cable The connectors each joining internal two foot cables leading to the lightbar controller are secured with a secondary lock that prevents disconnection unless the lock is fully disengaged For instructions on mating and unmating the connectors see the following pages Figure 5 3 Locations of watertight connectors POWER AND GROUND PLUG CAT5 PLUG 290A6570 36 Valor Lightbar Chapter 5 Maintaining and Servicing the Valor Figure 5 4 Secondary lock mechanism in the plug and receptacle position assurance Locking Ramp Locking Latch Receptacle Plug Disconnecting a Cable at the Lightbar To disconnect the power or 5 cable 1 Pull back the CPA on the receptacle 2 Fully depress the locking latch To allow the connectors to be separated the locking latch must be fully depressed to release the locking ramp on the plug Locking
40. id interference keep two way radio antennas a minimum of 18 in 45 7 cm away from warning equipment 8 Whenever possible run full wire lengths DO NOT splice the wires 9 Do not coil excess wire Leave a drain loop for servicing 10 After drilling holes for wires deburr them smooth sharp edges and insert grommets to protect the wires from chafing 11 When you frame ground the equipment use the manufacturer supplied ground locations in the vehicle IMPORTANT After the installation frequently inspect the lightbar and mounting feet to ensure that all fasteners and brackets are tight Connecting Power to the Lightbar NOTE Plan the location of the wire routing hole in the vehicle roof so that the power and communication cables do not have tight bends and have some slack to allow disconnection on removal A WARNING BATTERY EXPLOSION To avoid a battery explosion always disconnect the negative cable first and reconnect it last Avoid causing a spark when connecting near or to the battery The gases produced by a battery can cause an electrical explosion that could result in vehicle damage and serious injury A WARNING 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 cigarette lighter plug o
41. ied Check the connections at the SignalMaster controller If the controller is a model SS2000SM ensure that the connector has power and the ground is connected to pins 10 and 11 on the SignalMaster plug Valor Lightbar Chapter 5 Maintaining and Servicing the Valor Replacement Parts This section contains a partial list of replacement parts To order replacement parts call the Federal Signal Service Department at 800 433 9132 7 a m to 5 p m Monday through Friday Central Time or contact your nearest distributor Table 5 2 Replacement parts Description Part Number PCB Assembly End Configured Contact Factory PCB Assembly Front Configured Contact Factory PCB Assembly Rear Configured Contact Factory PCB Assembly Controller Configured Contact Factory Nut 1 4 20 Barrel 7065071 Seal Lip Lens 8651116 O Ring Lens Nut 7067016 Gasket Lens 8651125 Lens Clear 44 8651101 Lens Clear 51 8651103 Getting Technical Support and Service For technical support and service please contact Federal Signal Corporation Service Department Public Safety Systems Phone 1 800 433 9132 Fax 1 800 343 9706 Email empserviceinfo fedsig com Returning a Product to Federal Signal Before returning a product to Federal Signal call 800 264 3578 800 433 9132 or 800 824 0254 to obtain a Returned Merchandise Authorization number RMA number To expedite the process please be
42. inued Problem Corrective Action The lightbar has a delayed response to being shut off v Ensure that the connections the Serial Interface Module are separate from strobe supplies Check all the ground connections especially on the Serial Interface Module A Flash Takedown Alley light stays on with ignition power applied Ensure there is no voltage on the corresponding control wire To see 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 halogen light send the lightbar controller to Federal Signal for repair Takedown alley lights work but Flash Takedown Alley lights do not work Ensure that 12 Vdc is applied to the takedown and alley red black control wire Check the 12 Vdc power and negative ground connections to the lightbar to ensure there is enough current Only one takedown light turns on Check the connections from the lightbar controller to the ROC boards and ensure they are in the proper locations SignalMaster LEDs do not light Check the jumper and switch settings on the Serial Interface Module Ensure they are both set for the correct operation See Figure 3 3 on page 14 and Table 3 1 on page 15 Ensure that Switch 4 on SW 2 is in the correct position for the selected operation on the Serial Interface Module and ignition power was removed and reappl
43. ith Flash Takedown Alley red black active only the alley lights turn on Rear Cut Off When 12 Vdc BAT is applied to the Rear Cutoff control wire orange black the selected Mode operation is deactivated to the rear of the lightbar Only the front LEDs flash NOTE The operational settings for Front Cutoff and Rear Cutoff are not independent The default setting is for 12 BAT to be applied for the lightbar s front and rear lightheads 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 19 Intersection When 12 Vdc BAT is applied to the Intersection control wire blue black and a Mode control wire it turns on the Intersection pattern When 12 Vdc is removed the lightbar returns to its previous state SW 2 Switch 3 must be in the up ON position in the Serial Interface Module See Scene Light Left Right on page 27 NOTE With the flexibility of the SmartSiren Platinum System both the Intersection and the Scene Light Left option are available in Vision SLR and Valor lightbars without the need to choose one or the other Flash Takedown Alley When 12 Vdc BAT is applied to the Flash Takedown Alley control wire red black 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 green black or Right Alley control wire orange red
44. l drilled holes through which wiring passes Also ensure 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 connections 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 vehicle 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 the outer edge of the roof as possible Roof damage can occur if the hook adjustment bolts are over tightened On Arjent and Vista lightbars tighten the hook adjustment bolts 10 ft lb to 11 ft lb On all other lightbars tighten the adjustment bolts 6 ft lb to 7 ft lb Locate the light system controls so the VEHICLE and CONTROLS can be operated safely under all driving conditions After Installation or Service After installation test the light system to ensure that it is operating properly To ensure proper operation test all vehicle functions including horn operation vehicle safety functions and vehicle light systems Ensure that the installation has not affected the vehicle operation or changed any vehicle safety function or circuit Scratched or dull reflectors mirrors or lense
45. latch in down position Locking latch is fully connectors cannot be unmated depressed latch releases locking ramp 3 Pull the connectors apart Valor Lightbar 38 Chapter 5 Maintaining and Servicing the Valor Reconnecting a Cable at the Lightbar To reconnect the power or CATS cable 1 Firmly push the connectors together until you feel them snap together and you hear a click This tactile and audible confirmation ensures that the connectors are properly and fully mated 2 Press the CPA towards the plug to engage the secondary lock Valor Lightbar Chapter 5 Maintaining and Servicing the Valor 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 a m to 5 p m Monday through Friday CT Table 5 1 Troubleshooting tips Problem Corrective Action The lightbar does not light Check that the lightbar s red power line BAT and the black ground power line GND are properly connected to a good fully charged 12 volt battery Check the 40 A fuse Ensure that the ground connection from the lightbar controller to the aluminum extrusion 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 Check the connections the
46. ler Part Number 8623141 or the SmartSiren Series Platinum System or the System control head only With the Serial Interface Module the Valor Lightbar can be activated by Federal Signal lightbar controllers SignalMaster directional light controllers or by individual low current switch boxes Valor Lightbar Chapter 2 An Overview the Valor Lightbar Other advanced features of the Valor Lightbar include Ahigh degree of reliability through the use of advanced microprocessors and other integrated circuits piece seamless construction that eliminates leaking bulkhead gaskets High output long life LEDs with no bulbs to change Dimensions Model Length Height Width Weight VALR44 43 7 in 111 0 cm 1 96 in 5 0 cm 19 8 in 50 4 cm 39 3 Ib 17 8 kg VALR51 51 3 in 130 3 1 96 in 5 0 cm 19 8 in 50 4 cm 43 2 Ib 19 6 kg With standard mounting feet Light Specifications Lighting Option Current Draw Lamp Technology Reflector Style LED all heads High brightness LED Offset compound curve polished reflector Amperage in Steady Burn Mode Electrical and Temperature Modei _ Electrical Potential Operating Temperature VALR44 12 8 12 0A 40 F to 149 F 40 C to 65 C 14 0 A with HotFoot VALR51 12 8 14 0A 40 F to 149 F 40 C to 65 C 16 0 A with HotFoot Amperage for a typically loaded lightbar with all li
47. m Mode 19 Additional Main Bar Tests and Configurations esses eene eene ern eene 19 CHAPTER 4 Wiring the Valor in the Vehicle 22 Planning the Electrical 22 Connecting Power to the Lightbar 23 Installing the Serial Interface Module 24 Wiring the Serial Interface Module 25 Testing the Installation e 32 CHAPTER 5 Maintaining and Servicing the Valor 33 Cleaning the 33 Removing and Reinstalling the Lightbar Lenses 24 Replacine a eee i i 35 Disconnecting Connecting Power and CATS at the 36 Troubleshooting the Lightbar 39 Replacement Parts eee 41 Getting Technical Support Service 41 Returning a Product to Federal 51 41 Valor Lightbar Contents Wiring petu t ES ERR ED Im EE oh d teeters 43 Tables Table 3 1 5 W 2 DIP switch settings in Serial Interface 15 Table 3 2 Control wires from the Serial Interface Module abra iab ts kodak onda sa Fa d dada aedi 16 Table 3 3 Switch settings for Intersection operation
48. r 12 V outlet connect the positive wire to the center terminal and connect the negative wire to the outer terminal Valor Lightbar 23 24 Chapter 4 Wiring the Valor the Vehicle 1 Ensure that the lines are adequately fused as shown in the wiring schematics in Chapter 6 on page 41 2 From the lightbar route the CATS control cable into the vehicle cab or trunk near the eventual location of the Serial Interface Module An input cable is also provided with the Interface Module 3 Route and connect the black lead from the lightbar to the vehicle battery s ground GND terminal 4 Route and connect the red lead from the lightbar through the supplied 40 A Maxi fuse holder at the source which is the positive battery terminal BAT Installing the Serial Interface Module AWARNING 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 AWARNING 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 IMPORTANT The Serial Interface Module must be installed within 36 in 91 cm of the lightbar controller To mount the Serial Interface Module and make the power connections 1 Usethe Serial Interface Module as a template and scribe four drill position m
49. r proper operation after installation The 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 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 Do not mount a radio antenna within 18 inches 45 7 cm of the lighting system Placing 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 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 To avoid a battery explosion always disconnect the negative battery cable first and reconnect it last Avoid causing a spark when connecting near or to the battery The gase
50. re to heed this warning may result in serious injury or death to you or others in your vicinity 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 disconnect 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 71 cable harness on the Interface Module to a 1 A 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 GND Use 16 AWG wire to extend the cable length SignalMaster Connections 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 External SignalMaster 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 SS2000SM series siren Figure
51. ry can be damaged by electrostatic discharge ESD Follow anti static procedures when servicing this lightbar NOTICE Tool required T27 Torx driver Removing a PCB To remove a PCB 1 Disconnect all power to the lightbar at the battery or at the lightbar see Disconnecting Connecting Power and CATS at the Lightbar on page 36 2 Use a T27 Torx driver to remove the 1 4 20 Torx head barrel nuts securing the lens Figure 5 1 and on page 34 Carefully remove the lens and gasket as a unit Avoid damaging the lip seal 3 Verify that an O ring is under the head of each barrel nut and not stuck to the lens Use a wooden or plastic pick to carefully remove the O rings from the lens to prevent damaging them Figure 5 2 Locations of ROC PCBs REAR PCB REAR PCB 290 6564 Valor Lightbar 35 Chapter 5 Maintaining and Servicing the Valor 4 Inspect the O rings and the lip seal for deformation brittleness cuts or tears To maintain watertightness replace a questionable O ring or seal 5 Note and record the connection to the PCB Figure 5 2 on page 35 then lift it and disconnect the harnesses 6 Remove the PCB from the lightbar Reinstalling a ROC PCB To resinstall a PCB 1 Place the new PCB in the same position as the old PCB and reconnect the harnesses 2 Reinstall the gasket and lens To prevent cross threading the barrel nuts back t
52. s produced by a battery can caused a battery explosion that could result in vehicle damage and serious injury DO NOT connect this system to the vehicle battery until ALL other electrical connections 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 or route wiring or the plug in cord in the deployment path of an airbag If a vehicle seat is temporarily removed verify with the vehicle manufacturer if the seat needs to be recalibrated for proper airbag deployment Valor Lightbar Chapter 1 Safety Messages 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 exposure areas The 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 al
53. s to lose holding power Periodically check the unit to be sure the suction cups have a firm grip on the mounting surface An improperly 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 V Mounting surface and magnets must be kept clean dry and free of foreign particles that prevent good surface contact Ensure that mounting surface is flat A magnet mounting system should not be used on vehicles with vinyl tops V 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 Valor Lightbar 2 An Overview the Valor Lightbar The Valor Lightbar is a single level LED lightbar with ROC Reliable On Board Circuitry and Solaris LED technologies 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 S2 LED modules use offset complex reflector surfaces for accurate beam shaping and the highest optical efficiency The reflectors overlapping 360 degree lighting eliminates weak spots and provides off axis warning around the
54. s 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 Do not attempt to activate or de activate the light system control while driving in a hazardous situation You should frequently inspect the light system to ensure that it is operating properly and that it is securely attached to the vehicle After installation and testing are complete provide a copy of these instructions to instructional staff and all operating personnel File these instructions in a safe place and refer to them when maintaining and or re installing the product Failure to follow these precautions may result in property damage serious injury or death Valor Lightbar Chapter 1 Safety Messages Safety Message to Operators of Warning Light Equipment 4 WARNING People s lives depend on your safe use of our products Listed below are some important 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 Although your warning system is operating properly it may be completely effective People may not see or heed your warning signal You must recognize this fact and continue driving cautiously Also situations may occur which ob
55. struct 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 All effective sirens and horns produce loud sounds that may cause in certain situations permanent hearing loss You and your passengers should consider taking appropriate safety precautions such as wearing hearing protection norder 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 tis 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 e Ifa selected function does not perform properly or if any of the lamps remain illuminated when the control is off disconnect the power connector from the control unit and contact the nearest service center e At the start of your shift you should ensure that the entire warning light system and the siren system is securely attached and operating properly Suction cup mounting is for temporary applications only The unit should be removed from the window and stored securely when not in use Temperature changes and sunlight can cause suction cup
56. troleum products can cause crazing cracking of the lightbar lens and reflectors To clean the reflectors use a soft damp cloth To clean the lens use a soft cloth and a solution of water and a mild detergent 4 WARNING CRAZING CHEMICALS Crazed cracked or faded lenses or reflectors reduce the light output and the effectiveness of the lighting system A lens or reflectors showing this type of aging must be replaced Failure to follow this warning may result in bodily injury or death To clean the lightbar lens 1 Rinse the lens with lukewarm water to loosen dirt and debris 2 Use a mild detergent lukewarm water and a soft cloth to gently clean the lens To avoid damaging the finish do not use heavy pressure or caustic abrasive or petroleum based cleaners 3 Rinse and dry the lens with a soft cloth to prevent water spotting 4 remove fine scratches and haze use a soft cloth and a high quality automotive paste cleaner wax that Is non abrasive Valor Lightbar 33 34 Chapter 5 Maintaining and Servicing the Valor Removing and Reinstalling the Lightbar Lens The lightbar lens which is the top half of the Valor housing covers the ROC Reliable Onboard Circuitry PCBs and controller PCB Tool required T27 Torx driver Removing the Lens To remove the lens 1 Disconnect all power to the lightbar either at the battery or at the lightbar see Disconnecting Connecting Pow
57. ure 4 1 on page 25 All components wires are user supplied Valor Lightbar Chapter 4 Wiring the Valor the Vehicle SHOCK HAZARD Strobe and HID light systems generate high voltages Disconnect A WARNING 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 Figure 4 1 Relay isolating devices with large filter capacitors RELAY CONTROL LEAD STROBE SUPPLY 12 Vde SIGNAL ACTIVATED 12 Vde 290A6562 FUSE AMPERAGE DEPENDS ON AMPERAGE OF DEVICES Wiring the Serial Interface Module FUSE ELECTRICAL 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 This section is an overview of default settings that are activated when connecting LED and Mode control wires to 12 Vdc The basic light functions of the lightbar must be controlled by an installer supplied control head All programming and changes to default settings should be done after quick testing the lightbar and before installation Programming is covered in Programming Priority Modes 1 2 3 and Intersection on page
58. w refer to the wires in Figure 3 1 To connect the Valor to the battery and Serial Interface Module 1 2 supply power to the lightbar use fully charged 12 volt automotive battery with terminal lugs Place the lightbar on a sturdy flat surface Plug the CATS communication cable 1 from the lightbar into the Serial Interface Module J1 Plug the 24 pin harness 2 into the Serial Interface Module Attach the lightbar s black ground power line 3 to the negative battery GND lug Attach the lightbar s red power line 4 through a 40 A Maxi fuse to the positive battery BAT lug Attach the white wire 5 from the 24 pin harness through a 1 A fuse to the positive battery BAT lug Attach the black wire and the black white wire 6 from the 24 pin harness to the negative battery GND lug The lightbar is now ready for testing Figure 3 1 Serial Interface Module connections for testing and reprogramming ID In 9 9 S 9 e f Pin 3 9 9 FUSE 40 A MAXI POWER LINE RED GROUND POWER LINE BLACK 5 SERIAL CABLE INTERFACE GRAY 12 MODULE VEHICLE BATTERY BLACK WIRE BLACK WHITE WIRE 290A6559 WHITE WIRE 24 PIN HARNESS Valor Lightbar Chapter 3 Preparing the Valor for Installation Quick Testing the Valor with the Lightbar Test AWARNING LIGHT HAZARDS
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