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Installation, Operation, and Service Manual

1. Pattern SEE dS CCR Title 13 CCR Title 13 Amber 10045 LGD53 LGD24 LGD45 19053 100245 100455 LGD53SC P1 Y Y Y Y Y Y Y Y Y P2 Y Y Y Y Y 7 Y P3 Y Y Y Y Y Y Y v gt P4 Y Y Y N Y Y E Y Y Y Y Y Y Y Y P6 Y Y Y N Y N Y Y Y P7 Y Y N Y N T 7 Y y 8 N N N N E Y Y gt 5 P9 Y Y Y Y Y 8 alio Y Y Y Y Y Y Y Y Y 9 P11 Y N Y N N T x 53 12 Y N N N N N Y T 55 13 N Y Y E y a 9 P14 N Y Y N N N Y Y Y P15 Y Y Y N N N T v 2 Y Y Y P17 Y Y Y N N N Y Y Y ee i Y Y N N N Y Y Y Y Y Y N N N Y Y Y Y Y N N Y Y Y 21 N N N N N N v 7 P22 Y N N Y N N Y Y Y N N N N Y Y Y P24 Y N N N N N Y Y i i N N N N N Y Y Y ES Y i N N N Y Y Y P27TEST N T Y ONLY 28 N T ONLY b Serially controlled 24 Legend Pattern 27 All LEDs lighthead turns on Pattern 28 Each LED lighthead sequentially turns on for 1 second For amber Title 13 compliant models Selecting the Low Power option makes the flash patterns non compliant It is the user s responsibility to verify the acceptability of Low Power in his or her jurisdiction before using this option 14 Legend Lightbar Preparing the Legend for Installation Taking the preparatory steps in this chapter before mounting and wiring the lightbar to a vehicle will help e
2. for a typical loaded lightbar with all lights flashing at 50 percent duty cycle Halogen takedowns are not available the LGD24 and the Discrete Wired 24 Legend models Serial Interface Module Model 8583446 Length Height Width Shipped with a 24 pin cable harness 17513644 that is 3 feet 6 25 in 2 88 in 1 06 in long The harness connects to the 15 9 cm 7 3 cm 2 7 module s J1 outlet Approvals SAE J845 Light Output select flash patterns Table 2 1 on page 12 Title 13 select flash patterns Table 2 1 1113 41 Part 15 Legend Lightbar 13 aq 5 IE 5 m D m gt 5 lt S Flash Pattern Compliances Flash Pattern Compliances The patterns listed as Yes Y in Table 2 1 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 Flash pattern compliances to standards
3. 58 Schematic Typical connections with SmartSiren controller 59 Schematic A 5 Typical connections with non SignalMaster controller 60 Schematic A 6 Typical connections with PA640 controller 61 Legend Lightbar 5 Legend SmartSiren and Solaris are registered trademarks of Federal Signal Corporation EPIC is a trademark of Microchip Technology Inc Ford and Crown Victoria are registered trademarks of Ford Motor Company Maxi Blade Fuse is a trademark of Littelfuse Plastite is a registered trademark of SFS Unimarket Plexus is a registered trademark of 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 6 Legend Lightbar Safety Messages For your safety read this manual thoroughly before installing operating and servicing the Legend 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 1 800 433 9132 7 am 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 i
4. 54 Figure 6 7 Click the Program icon to clone 55 Figure 6 8 Programming 55 Figure 6 9 Cloning complete click OK tnter terere aana a a aana NaS 55 List of Tables Table 2 1 Flash pattern compliances to standards 14 Table 3 1 Control wires from the Serial Interface Module 17 Table 3 2 SW 2 DIP Switch 20 Table 3 3 Switch settings for INTERSECTION operation 22 Table 3 4 SignalMaster control wires External 25 Table 3 5 SignalMaster control wires and warning patterns Internal operation 25 Table 4 1 Cross reference for controller leads 32 4 Legend Lightbar Table 5 1 Domes and ROC panel assemblies for Legend models 38 Table 5 2 Legend replacement parts exea rette eR 49 Table 5 3 Troubleshooting 5 iier retra e ER cr reete Sen rena 50 List of Schematics Schematic 1 Discrete wired 24 Legend lightbar 56 Schematic A 2 Typical connections with SignalMaster controller External Control 57 Schematic Typical connections with SW400SS Switch Module Internal Control
5. 52 Connecting the Programmen s ues occa 53 Cloning the Serial Interface 54 Appendix Wiring Schematics 56 An Overview of the Discrete Wired 24 Legend 22 2 0 0 56 Legend Lightbar 3 List of Figures Figure 3 1 Electrical connections for testing and 16 Figure 3 2 Serial Interface Module with cover 18 Figure 3 3 DIP switch settings in Serial Interface 19 Figure 3 4 Light options for Legend 23 Figure 3 5 SignalMaster flash sequence six head example 26 Figure 4 1 Relay isolating devices with large filter capacitors 29 Figure 4 2 Wiring block 29 Figure 4 3 SignalMaster 331105 controller External sess 32 Figure 4 4 SmartSiren SS2000SM Series controller External sse 32 Figure 4 5 SignalMaster control functions wired to ground for External default control 33 Figure 4 6 SignalMaster control functions wired to 12 for Internal
6. 9 gt 72 15 46 Legend Lightbar Adjusting the Aim of the HotFoot LED Assemblies Adjusting the Aim of the HotFoot LED Assemblies You can horizontally adjust the aim of the LED assemblies by positioning them straight at 45 degrees or at 90 degrees Each position has 10 degrees of adjustment To adjust the aim Figure 5 10 Adjusting the aim of the LED assembly PHILLIPS SCREW SECURES LED j MOUNTING PLATE TO FOOT TWO PHILLIPS SCREWS SECURE LED ASSEMBLY TO MOUNTING PLATE 290 6122 01 1 Remove the Phillips Plastite screw that secures the LED mounting plate to the foot Figure 5 10 2 Liftand slide the LED assembly off the foot just far enough to invert the assembly 3 Loosen or remove for a major adjustment both Phillips Plastite screws securing the LED assembly to the mounting plate 4 Rotate the LED assembly to the selected position NOTICE DO NOT OVERTIGHTEN SCREWS To avoid damage to the HotFoot assembly do not over tighten the screws Tighten both Phillips Plastite screws securing the LED assembly to the mounting plate Secure the mounting plate to the foot by tightening the Plastite screw Cleaning the Domes Periodically cleaning the domes using proper procedures and compatible cleaners will prolong their service life Unlike the reflectors the domes do not have to be removed from the lightbar for
7. 1 1593 cNHVW LNHVM NH5 5HO LHW T8 NHO H31N39 1487 SNOILONYLSNI 391430 SNOLLO3NNOO SNINIVIN3H HOLIMS SNOLLONYLSNI 39IA3Q SNOLLO3NNOO TANVd HOLIMS YALSVWIVNDIS SNOLLO3NNOO WWOIdAL 1 YOUMS SSOOFMS 2 Hui AA Legend Lightbar 58 Appendix Wiring Schematics 009 062 3957 Wiring Schematics AdALIVE zum 1 1 5 v IHAWXTIS NHO Q3H LHM NH9 Q3H ng 3NON LE 01 6 8 9 9 v 2 o ovoooz EmP232221 SNOLLONYLSNI SNOILOANNOO 115000255 VH 7 18 NH5 SGOW 1 13 INSO00 SS SNOLLO3NNOO TVOIdA Jejjonuoo e suoioeuuoo
8. 34 Figure 4 7 Stop turn tail wiring between lightbar and vehicle harness 35 Figure 4 8 Work light wiring between lightbar and switched 12 0 36 Figure 5 1 Four barrel nuts in passenger side end 38 Figure 5 2 ground 39 Figure 5 3 Controller and standoffs removed from ROC 40 Figure 5 4 Fuses lightbar controller 41 Figure 5 5 Base removed from aluminum 43 Figure 5 6 End gasket in the end base 022442 1 0 44 Figure 5 7 Lip seal on edge Of plastic ve oe at 44 Figure 5 8 Takedown halogen roug tem enun Dae Ee ew meat 45 Figure 5 9 Alley halogen 46 Figure 5 10 Adjusting the aim of the LED 47 Figure 6 1 Programmer Setup Wizard click Next 52 Figure 6 2 EPIC programmer cable 53 Figure 6 3 New Hardware Wizard click 4 53 Figur 6 4 Legend PIC c 54 Figure 6 5 Download progress atte a 54 Figure 6 6 Download complete click
9. oneueuoag 3505 5 5 59 Legend Lightbar Appendix Wiring Schematics S009v06c 5 i 2 AHBLLIVG vor ig 8179 1 13 8 vb 7 Q D 18 LHM 3a0W 1 1 i As AGE CO 881 SNOILONYLSNI 391430 SNOLLO3NNOO HOLIMS 00 SDN H31SVW TVNOIS NON SNOILO3NNOO WOIdAL 4eJ o4 uoo 1ejsejyjeuDig uou 2 Legend Lightbar 60 Appendix Wiring Schematics 0497060 Wiring Schematics HV8 1H9Ir1lQON3931 3OVJH3LNI TVIH3S OF SMV 01 LOH vi 000v9Vd SNOLLO3NNOO TWOIdAL Ada Asna vor OM 81 XNVHO LOH NOLLIND 995995 LHS LSNI 33S SNOLLOQH
10. Legend Lightbar 19 19 5 7 m D 5 0 5 9 5 5 D aq 5 20 Testing and Reprogramming the Lightbar SW 2 DIP Switch Settings in the Serial Interface Module For the location of SW 2 see Figure 3 3 on page 19 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 SW 2 Switch Setting Switch Up Down Number OFF ON Function 1 4 FRONT REAR LEDs cut off turn off when 12 Vdc is applied their control wires Table 3 1 on page 17 1 J FRONT REAR LEDs enable turn on when 12 Vdc is applied to their control wires 2 4 Keep in OFF position 3 Keep in OFF position 4 A SignalMaster External controller 4 4 SignalMaster Internal controller 5 Cycle forward through the selection of flash patterns 5 Cycle backward through the selection of flash patterns 6 Operation Mode 6 J Program Mode 7 Switch for INTERSECTION operational settings Table 3 3 on page 22 8 Switch for INTERSECTION operational settings Table 3 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 operates in one of these modes the SignalMaster modules keep sequence with the flash pattern You can change defa
11. y WHITE IGNITION POWER BLACK GROUND 1 BLACK WHITE GROUND 2 IGNITION POWER INCLUDES POWER IN THE CRANKING POSITION 290A5980 Legend Lightbar 33 Wiring the Serial Interface Module Figure 4 6 SignalMaster control functions wired to 12 Vdc for Internal control POWER 12 Vdc 1A c BLACK RED MODE 3 1A BLUENHITE MODE 2 1A BLUE igre MODE 1 1A o STEADY BURN 1 00 BLUEIBLACK INTERSECTION 1A RED BLACK FLASH TAKEDOWN ALLEY cy RIGHT ALLEY 1 GBEENIBLACK LEFT ALLEY 1A OO WHITEIBLACK TAKEDOWN o o GREENWHITE FRONT CUTOFF ENABLE 5 REAR CUTOFF ENABLE 2m 1A 0270 LEFT J1 CABLE TO 1 GREEN DENTEB SERIAL INTERFACE o MODULE GREEN BLACK WHITE RIGHT 1A ORANGE GREEN WARN 1 WARN 2 BLUE RED WARN 3 RED GREEN WARN 4 1A WHITE RED FAST vo 5 Q c WHITEIBLACKIRED LOW POWER 1A Q c BLACKWHITEIRED LIGHTBAR TEST IGNITION WHITE IGNITION POWER BLACK GROUND 1 BLACK WHITE GROUND 2 IGNITION POWER INCLUDES POWER IN THE CRANKING POSITION 290A5981B 34 Legend Lightbar Wiring the Stop Turn Tail Lights Wiring the Stop Turn Tail Lights The lightbars stop turn tail lights are a factory configured option The lightbar is shipped with the option s three conductor cable ready for splicing into the vehicle harne
12. 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 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 EN m KS 5 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 ensure they function properly The test procedures are described in the next sections 22 Legend Lightbar Additional Mainbar Tests and Configurations 23 Figure 3 4 Light options for Legend lightbars LGD24 SERIALLY CONTROLLED DRIVER SIDE PAS
13. One Center Passenger Side Two Intermediate LGD61 Two Center Center 2 Two Intermediate Passenger Side Driver Side Center 1 Two End LGD70 Center 2 Three Center Center 3 Two Intermediate Passenger Side Removing and Inspecting the Domes 1 Remove the 1 4 20 Phillips head barrel nuts securing the dome then carefully remove the dome to avoid damaging the lip seal Figure 5 1 2 Verify that an O ring is under the head of each barrel nut and not stuck to the dome Use a wooden plastic pick to carefully remove the O rings from the dome to prevent damaging them 3 Inspect the O rings and the lip seal for deformation brittleness cuts or tears To maintain watertightness replace a questionable O ring or seal 4 nspectthe dome for cracks crazing hairline cracks discoloration and other defects Replace defective domes For replacement parts see Table 5 2 on page 49 Figure 5 1 Four barrel nuts in passenger side end dome 290A5984 38 Legend Lightbar Replacing ROC Panel Assemblies Reinstalling the Domes 1 Place the domes over the ROC panel ensuring that it is properly seated in the lip seal NOTICE PROPERLY TIGHTEN NUTS To prevent damage to the lightbar do not overtighten the nuts 2 prevent cross threading turn the barrel nuts counterclockwise until you hear a click then tighten them Replacing the ROC Panel Assemblies 1 Remove the dome over the pan
14. all models except LGD24 3 9 A Bi pin halogen Polished reflector Offset compound curve LED Takedown Lights 1 0 Bright white LEDs polished spot beam reflector Offset compound curve LED 1 0 Bright white LEDs polished spot beam available on LGD24 only reflector Alley Light 35 W 2 7 Bi pin halogen Faceted SIX GEN high Offset compound curve Agars LED Malabar 195 brightness LEDs polished reflector 5 5 Amperage per pair with flashing takedown and alley lights gt Amperage STEADY BURN mode o 2 7 Lightbar Dimensions SIE 5 g Mainbar Model Length Height Width Weight 24 25 in 2 5 11 2 16 6 Ib DEDE 61 6 cm 6 4 cm 28 4 cm 7 5 kg 44 5 in 2 5 11 2 20 4 Ib 133 0 6 4 28 4 9 3 52 7 2 5 11 2 24 2 Ib 133 9 cm 6 4 cm 28 4 cm 11 0 kg 60 9 2 5 in 11 2 in 28 0 Ib 154 7 6 4 28 4 12 7 kg 69 1 2 5 in 11 2 in 31 81 Ib 175 5 6 4 28 4 14 4 kg With standard mounting feet 12 Legend Lightbar Approvals Technical Specifications Ses withHalogen wiih gD OPES Takedowns Takedowns LGD45 12 8 14 5 11 5 en 42 LGD53 12 8 16 5 13 5 ES n pue a LGD61 12 8 Vdc 18 5 A 15 5 hen 2 10070 12 8 20 5 17 5 es
15. before installation Programming is covered in Programming Priority MODES 1 2 3 INTERSECTION on page 20 For a description of the control wires from the Serial Interface Module see Table 3 1 on page 17 MODES 1 2 and 3 To activate a mode apply 12 Vdc BAT to a 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 applying 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 selected 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 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 independent The default setting is for 12 Vdc 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 ENABLE or CUTOFF on page 22 INTERSECTION When 12 is ap
16. cleaning CRAZING CHEMICALS Crazed cracked or faded domes or reflectors reduce the light output and the effectiveness of the lighting system Tops or reflectors 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 domes and reflectors o 2 E m 5 2 95 5 Legend Lightbar 47 Cleaning the Reflectors Failure to follow this warning can damage the domes and reflectors and may result in bodily injury or death to you or others 15 Rinse the 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 The most effective product you can use for cleaning protecting and polishing clear and colored plastics is Plexus Over time exposure to heat sunlight and smog causes plastic to fa
17. connect this system to the vehicle battery until ALL other electrical connections are made mount ing 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 recali brated for proper airbag deployment 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 compart ment 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 all 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 pac
18. default 1 Unplug the 24 pin harness from the Serial Interface Module 2 On the 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 3 Serial Interface Module PCB move JP 1 from INT to EXT Figure 3 3 Figure 3 3 DIP switch settings in Serial Interface Module BACK OF SERIAL INTERFACE MODULE PUSH 12345678 SERIAL INTERFACE MODULE PCB 2222 SWITCHES 1 THROUGH 8 ON SW 2 PX 4 N a c N 2 N X ux N ia a2 4 Reinstall the cover on the Interface Module 5 Move Switch 4 on SW 2 to the up OFF position 6 Plug the 24 pin harness into the Serial Interface Module 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 Onthe Serial Interface Module move Switch 6 SW 2 to the down ON position Figure 3 3 3 Plug the 24 pin harness into the Serial Interface Module NOTE 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 ON up position on SW 2
19. o lt OTE FOLLOW THE ONTROLLER S INSTALLATION ISTRUCTIONS FOR POWER ROUND AND OTHER OSSIBLE FUNCTIONS WHITE RED o zm gt TO J1 ON 290A5978B INTERFACE MODULE Figure 4 4 SmartSiren SS2000SM Series controller External RED WHT 1 Bis SS GREEN BRN 2 a GRN BLK WHT 1 GRN 3 ORN 4 ORANGE PRP 5 RED GREEN WHITE RED TO J1 ON INTERFACE MODULE 32 Legend Lightbar Wiring the Serial Interface Module Figure 4 5 SignalMaster control functions wired to ground for External default control POWER 12 Vdc 1 c BLACK RED MODE 3 1A MODE 2 BLUEWHITE o 1A BLUE MODE 1 oo 2 1A PEDMHITE STEADY BURN 1A c BLUEIBLACK INTERSECTION Q c PED BLACK FLASH TAKEDOWN ALLEY cy ORANGE RED RIGHT ALLEY 1A cy c GREEN BLACK LEFT ALLEY 1A OO WHITEIBLACK TAKEDOWNS 1A OO SREENWHITE FRONT CUTOFF ENABLE REAR CUTOFF ENABLE O o E WHITE BLACK RED LOW POWER 3 O 1A BLACK WHITE RED LIGHTBAR TEST gt F J1 CABLE TO hz RED ien SERIAL INTERFACE So MODULE pu 5 5 L GREEN 2 O a GREEN BLACK WHITE 3 O L ORANGE GREEN 4 MOMENTARY SWITCHES 1 8 L ORANGE 5 O BLUE RED 6 L RED GREEN 7 O 7 L 8 RIGHT IGNITION T
20. operation 6 Head SicNALMasrER Control Wires Description Controls 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 3 Blue Red Outer LEDs and two inner LEDs alternate WARN 4 Red Green Outer LEDs and two inner LEDs flash then the LEDs between the inner and outer LEDs FAST White Red Operates the selected pattern 50 percent faster Legend Lightbar 25 5 2 D 5 o 5 5 D aq 5 26 Additional Mainbar Tests and Configurations Figure 3 5 SignalMaster flash sequence six head example LGD45 DRIVER SIDE PASSENGER SIDE WARN 1 1 2 WARN 2 1 1 22 2 WARN 3 1 A 2 1 WARN 4 290A6060 6 26 Legend Lightbar 4 Wiring the Legend in the Vehicle Before wiring the lightbar in the vehicle mount the lightbar according to the instructions included with the mounting kit The lightbar is completely wired at the factory and doe
21. 4 on page 23 2 Remove 12 Vdc from the MODE and STEADY BURN control wires Testing the FLASH TAKEDOWN ALLEY Lights 1 Apply 12 Vdc to the control wire for MODE 1 2 or Table 3 1 on page 17 2 Apply 12 Vdc 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 1 on page 17 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 Vdc to the white black control wire to turn on the TAKEDOWN lights 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 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 The LOW POWER function dims the mainbar LEDs approximately 50 percent to prevent blinding approaching drivers NOTE The LOW POWER function o
22. 5991 4 Insert the new lamp and ensure that it is properly seated the socket NOTICE PROPERLY TIGHTEN NUTS To prevent damage to the lightbar do not overtighten the nuts 5 Reconnect the ground wire and tighten the ground nut 6 Invert the PCB and reinstall the dome as described in Reinstalling the Domes on page 39 Legend Lightbar 45 o s 55 5 55 95 Replacing the Halogen Lamps Replacing the Halogen Alley Lamps 1 Remove the dome as described in Removing and Inspecting the Domes on page 38 2 Toaccess the lamp remove the PCB ground nut and invert the PCB 3 Use 1 16 inch hex key to remove the screws and clamps retaining the lamp Figure 5 9 Figure 5 9 Alley halogen lamp 290A5992 NOTE To remove the lamp it may be necessary to unplug the connector to get enough slack in the lamp leads 4 Slide the lamp and socket from the housing just far enough to grasp the socket 5 Hold the socket firmly and unplug lamp NOTICE PROPERLY TIGHTEN NUTS To prevent damage to the lightbar do not overtighten the screws 6 Insertthe new lamp and install the clamps Do not overtighten the screws If necessary plug in the connector 7 Invert the PCB and reconnect the ground wire Do not overtighten the ground nut 8 Reinstall the dome as described in Reinstalling the Domes page 39
23. EY 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 Dims the lights approximately 50 percent to Red prevent blinding approaching drivers LOW POWER is only available in MODES 1 and 2 andis disabled when switched to another flash pattern including MODE 3 and INTERSECTION LIGHTBAR TEST Black White Flashes the LEDs sequentially and then flashes PATTERN Red the 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 18 Be sure to reattach the cover when you are finished Legend Lightbar 17 5 m D 5 0 9 5 5 r D aq 5 EN KS 5 18 Testing Reprogramming the Lightbar Figure 3 2 Serial Interface Module with cover attached 8 32 x 1 4 HEX HEAD SCREWS 4 290A5958 Quick Testing usi
24. F877A for the Legend Figure 6 4 Legend PIC file AES HIIRI BER Eile view Program Options Help 9 BEREA READ ICON 3 Todownload the file from the source Serial Interface Module click the Read icon 4 During downloading the EPICWin software displays a Reading progress bar Figure 6 5 Download progress Reading PITTI TTT TTT TT 5 When downloading is finished click OK and disconnect the programming cable from the source Interface Module Figure 6 6 Download complete click OK PONN 4 ReadjVerify complete 6 On the Serial 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 7 Connect the programming cable to the target Serial Interface Module Figure 6 2 on page 53 54 Legend Lightbar Cloning the Serial Interface Module 8 Tostart cloning click the Program icon Figure 6 7 Click the Program icon to clone WARDS HIJI File View Program Options SH Avo 29 3 3 5 a 5 0 lt 0 oz 50 5 o PROGRAM ICON 9 During cloning the EPICWin software displays a Programming progress bar Figure 6 8 Programming progress EH IG EET Bro rund 10 When cloning is finished click OK and disconnect the programming cable from the target Interface Module Figure 6 9 Cloning complete clic
25. FEDERAL SIGNAL Public Safety Systems 125127423 Installation Operation and Service Manual 2562365D REV D 211 Printed in U S A Contents Chapter 1 Safety Messages ien nien 7 Safety Message to Installers and Service Personnel of Warning Light 7 Safety Message to Operators of Warning Light 2 2 2 2000 4 9 Chapter 2 Overview of the Legend 11 11 yero TEE 11 Product Specifications 12 peo ce 13 Flash Pattern Compliances E 14 Chapter 3 Preparing the Legend for Installation 15 DERE 15 Testing Reprogramming the 15 Additional Mainbar Tests and eene nennen ennt nnns 22 Chapter 4 Wiring the Legend in the 27 Wiring the Lightbar in the Vehicle ciini coz ka cen 27 Mounting the Serial Interface Module 27 Wiring the Serial Interface Module ne ef
26. GROUND e BRACKET NUT a INTERMEDIATE PCB ASSEMBLY PCB CONNECTOR END PCB ASSEMBLY ALUMINUM EXTRUSION BASE VENT PLUG gt GROUND P did BRACKET BOLT e CARRIAGE BOLT 290A5988B n 5 gt 5 3 Legend Lightbar 43 Replacing an End Gasket Replacing an End Gasket The end gaskets cushion the aluminum extrusion against the end of the end bases for a snug fit Check the end gaskets for cracks tears or brittleness To replace the gasket 1 Remove the old gasket from inside the end base 2 Peel the paper backing from the new gasket 3 Center the gasket in the end of the cavity in the end base 4 Press the gasket along its length so that it adheres evenly Figure 5 6 End gasket in the end base cavity END GASKET TZ 290A5989C Replacing a Lip Seal Check the lip seals for cracks tears or brittleness To replace the seal 1 Remove the lightbars domes as described in Removing and Inspecting the Domes on page 39 2 Note the joint position of the seal then remove the old lip seal 3 Install the seal with the fins angled downward as shown in Figure 5 7 positioning the joint in the same posi tion as original slightly off center along the straight surface where the bases mate The edge of the seal should be flush with the top surface Figure 5 7 Lip seal on edge of p
27. LISNI 391430 SNOLLO3NNOO 5NINIVIA3H 000029 X18 SMV rwy NH9 SMV v08 3504 H3H9IH 3HInO3H 5 NOLLVTIVLSNI NMOHS voe v Oc ccu 255 220 a Ber 0 4 Mx T 0 9 5 2 o 8 540 1 61 Legend Lightbar sili 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 2010 Federal Signal Corporation
28. Module For the wiring block diagram see Figure 4 2 E 2 gt 2 9 5 Figure 4 2 Wiring block diagram IGNITION BLACK WHITE MAXI FUSE 40A SERIAL INTERFACE MODULE PART 8583446 BATTERY 5 CABLE BLACK 10 AWG RED 10 AWG 290A5977 NOTICE 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 Legend Lightbar 29 e 0 5 55 m gt gt Wiring the Serial Interface Module For typical installations with common controllers and switch boxes see the wiring schematics in the Appendix starting on page 56 For wiring the controllers functions to the Serial Interface Module s 24 pin cable harness see Table 4 1 on page 32 and the figures on pages 32 though 34 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 better wire This section is an overview of default settings that are activated when connecting LED and MODE control wires to 12 Vdc programming and changes to default settings should be done after bench testing the lightbar and
29. OUGH 13A ISASA 290A5987B To remove a fuse pull it straight out to avoid damaging the connector Gently press a new fuse of the same type and amperage into the connector Ensure that all pins are prop erly seated Reinstalling the Controller 1 2 3 10 Insert the four standoffs into the controller Gently push the controller s standoffs into their holes on the ROC panel until they lock Reconnect all wires and harnesses Turn the PCB over and place it on the two standoffs with the holes in the PCB centered over the holes in the standoffs Ensure that the ground wire is not caught between the edges of the PCBs Gently push on the PCB until it clicks into place NOTICE PROPERLY TIGHTEN NUTS SCREWS To prevent damage to the lightbar do not overtighten nuts and screws Reconnect the ground wire and tighten the nut Figure 5 2 on page 39 Place the dome over the PCB ensuring that it is properly seated in the lip seal To prevent cross threading turn the barrel nuts counterclockwise until you hear a click then tighten them Figure 5 1 on page 38 Test the lightbar to ensure that it operates properly Legend Lightbar 41 is 9 gt 72 Replacing Lightbar Base Replacing
30. OWER LINE BLACK ES SERIAL CABLE 57 GRAY MODULE 5 VEHICLE R 19 2 BLACK WIRE L BLACK WHITE WIRE WHITE WIRE 24 PIN HARNESS 290A5957B 16 Legend Lightbar Testing Reprogramming the Lightbar Control Wires for Flash Patterns This chapter describes how to display flash patterns during bench testing and programming 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 FRONT of the lightbar Green White FRONT ENABLE 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 Red Black Flashes the ALLEY and TAKEDOWN lights in TAKEDOWN MODES 1 2 or 3 ALLEY LEFT ALL
31. SENGER SIDE LGD70 290A5960C TAKEDOWN WK WORK LIGHT SB STEADY BURN L L1 ALLEY LIGHT ST STOP TURN TAIL 5 SicNALMAsTER LED POSITIONS 5 o 6 HEAD 8 HEAD aZ LGD45 10 15 LGD53 12 19 WITHOUT STOP TURN TAIL LIGHTS aa LGD53 13 18 WITH STOP TURN TAIL LIGHTS IN 12 AND 19 LGD61 15 22 WITHOUT WORK LIGHTS 2 8 19061 16 21 WITH WORK LIGHTS IN 15 AND 22 LGD70 18 25 WITH WORKLIGHTS IN 17 AND 26 5 16070 19 24 EE NOTE LED WARNING LIGHTS OF ANY COLOR FUNCTION AS SIGNALMASTER DIRECTIONAL WARNING LIGHTS EXCEPT STOP TURN TAIL LEDS AND WORK LIGHTS Legend Lightbar 23 o EN gt m KS amp 24 Additional Mainbar Tests and Configurations Testing the STEADY BURN LEDs The STEADY BURN LEDs are factory configured per the customer order for one of these options No STEADY BURN the LEDs flash with the pattern Driver s side STEADY BURN Driver s and passenger s side STEADY BURN 1 Apply 12 Vdc to the red white control wire for the STEADY BURN LEDs and a control wire for MODE 1 2 or 3 Table 3 1 on page 17 The LEDs light and stay on default setting Figure 3
32. 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 1 control wire Intersection The INTERSECTION flash pattern overrides all three priority modes when activated To select a new pat tern you must apply 12 Vdc to the control wire for either MODE 1 2 or 3 Table 3 1 on page 17 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 the control wire for INTERSEC TION from the Serial Interface Module On the Serial Interface Module press and release the SW 1 pushbutton until the pattern you want appears on the lightbar Remove 12 Vdc from the MODE and INTERSECTION control wires Intersection Operational Settings Select one of three options to turn on the INTERSECTION pattern 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 8 SECOND TIMEOUT activated by momentary 12 turns on the INTERSECTION flash pattern for eight seconds To change from HIGH
33. Serial Interface Module to the mounting surface with user supplied 8 mounting hardware 4 Install the lightbars CAT5 serial cable to the J3 output jack of the Serial Interface Module 5 Install the three foot long 24 conductor cable to the J1 input connector of the Serial Interface Module 28 Legend Lightbar Wiring the Serial Interface Module 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 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 Figure 4 1 All components wires are user supplied Figure 4 1 Relay isolating devices with large filter capacitors RELAY CONTROL LEAD STROBE SUPPLY 12 Vdc SIGNAL ACTIVATED 12 FUSE AMPERAGE DEPENDS FUSE ON AMPERAGE OF DEVICES 290A5976 NOTE After installation check the entire system to ensure the lights are flashing properly and all light system functions are operating properly Wiring the Serial Interface
34. a Lightbar Base The lightbar s bases secure and protect the LED circuit boards and controller Regularly inspect them for loose hardware cracks and weather tightness For replacement parts see Table 5 2 on page 49 To replace a base 1 Remove the domes and ground connection a b d e Remove the lightbar s domes as described in Removing and Inspecting the Domes on page 38 Remove the PCB ground nut Figure 5 2 on page 39 disconnect the ground wire and invert the PCB Note and record the connections then disconnect the wires and harnesses Remove the ground bracket nut ground bracket star washer and ground bracket bolt Remove the base retainer screw and the cable clamp on the cable entry side 2 Remove the base a b If the lightbar is on the vehicle Slide the base from the aluminum extrusion catching the carriage bolts as they are freed from the channels If the lightbar is off the vehicle Invert the lightbar on soft rags or cardboard to protect the domes then slide the base from the aluminum extrusion The carriage bolts can then be removed from base Remove the vent plugs and or grommets from base 3 Reinstall the new base NOTICE PROPERLY TIGHTEN NUTS SCREWS To prevent damage to the lightbar do not overtighten nuts and screws a Be sure the new base has a new end gasket and lip seal See Replacing an End Gasket and Replac ing a Lip Seal on page 44 If the lightba
35. age 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 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 s ground GND terminal 3 Route and connect the lightbar s red lead through the supplied 40 A Maxi fuse holder at the source which is the positive battery terminal Legend Lightbar 27 55 m o Mounting the Serial Interface Module Mounting the Serial Interface Module The Serial Interface Module communicates between a user supplied lightbar siren controller a SignalMaster controller or a switch box and the Legend To minimize the 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 17 The information is converted to a digital format and communicated to the lightbar through the CAT5 serial communication cable The Discrete Wired 24 Legend does not connect to the Serial Interface Module LOCATION OF LIGHT SYSTEM CONTROLS Light system controls must be located so that VEHICLE and CONTROLS can be operated safely under all driving conditions NOTE If you a
36. and 70 inches Model LGD70 Also available is the Discrete Wired 24 Model Legend which has one flash pattern and does not connect to the Serial Interface Module Product Features Additional features include Design provides superior 360 degree intersection warning Bright white LED takedowns long life and significantly reduce power consumption Lightbar housing is wind tunnel tested to ensure durability at high speeds and maximum fuel efficiency Available LED colors include amber blue red green and white Built in SignalMaster directional warning capability is standard on all Legend models except LGD24 and the Discrete Wired 24 Legend SignalMaster flash patterns can be activated with switched 12 Vdc a SignalMaster controller or 6 button controller Five year warranty on LEDs Easily 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 Legend Lightbar 11 Product Specifications Product Specifications Operating and technical specifications for the Legend are listed in this section by lighting option and model Warning Lights Current Lamp Lighting Option Draw Technology Reflector Style Takedown Work Lights 50 W
37. are properly connected to a good fully charged 12 volt battery 9 gt 72 is IE lights turn on Check the red power line BAT and the black ground power line CGND con nections in the lightbar and vehicle continued on next page 50 Legend Lightbar Troubleshooting the Lightbar T ble 5 3 Troubleshooting tips continued from previous page Problem Corrective Action The lightbar has a Ensure that the connections on the Serial Interface Module are kept separate delayed response to from strobe supplies Beng enut on Check all the ground connections especially on the Serial Interface Module A FLASH Ensure there is no voltage on the corresponding control wire TAKEDOWN ALLEY E TT light stays on with To see if the ROC board is bad swap it with a similar board ignition power applied 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 Fed eral Signal for repair TAKEDOWN AL 4 Ensure that 12 Vdc is applied to the TAKEDOWN and ALLEY red black control LEY lights work but wire iod TAKEDOWN the 12 Vdc power and negative ground connections to the lightbar to en ALLEY lights do not sure there is enough current work Only one Check the connections from the
38. ber 1 sold separately NOTE Cloning only transfers the programmed flash patterns If you have changed default 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 18 and 19 Installing the Programmer Software 1 Close all applications on your computer 2 Insert the melabs Programmer CD into your CD ROM drive 3 When the Programmer Setup Wizard appears click Next Figure 6 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 4 Follow the on screen instructions to complete the installation Figure 6 1 Programmer Setup Wizard click Next Serup melas Programme Welcome to the melabs Programmer Setup Wizard This will install melabs Programmer 4 20 on your computer It is recommended that you close all other applications before continuing Click Next to continue or Cancel to exit Setup 52 Legend Lightbar Connecting the Programmer Connecting the Programmer 1 Connect the EPIC programmer to a USB port on your computer with the USB A B cable Figure 6 2 2 The first time you connect the programmer the New Hardware Wizard appears Click Next to install the device driver Figure 6 3 IMPORTANT When the programmer is rea
39. burns Do not touch the lightbar while or shortly after it has been operating Always allow the lightbar to cool before handling Servicing the Lightbar Domes Servicing the lightbar domes includes removing them and inspecting their seals and hardware to ensure that the domes remain secure and watertight Inspection also involves checking the domes for cracks crazing hairline cracks and other defects For replacement parts see Table 5 2 on page 49 CRAZING CHEMICALS Crazed cracked or faded domes or reflectors reduce the light output and the effectiveness of the lighting system Domes or reflectors showing this type of aging must be replaced Failure to follow this warning may result in bodily injury or death to you or others NOTICE STATIC SENSITIVE DEVICE The lightbar s circuitry can be damaged by an electrostatic discharge ESD Follow anti static procedures while installing the lightbar NOTICE PROPERLY TIGHTEN SCREWS NUTS To prevent damage to the lightbar do not overtighten the screws or nuts Legend Lightbar 37 S 7 9 gt 72 Servicing the Lightbar Domes Table 5 1 Domes and ROC panel assemblies for Legend models Model Domes ROC Panels LGD24 and Discrete Ep Side Two End Wired 24 9 Driver Side Two End Passenger Side Two Intermediate Driver Side Two End LGD53 Center
40. d 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 gases produced by a battery can caused a battery explosion that could result in vehicle damage and serious injury DO NOT
41. de discolor scratch or become brittle Plexus seals the pores of the plastic making the domes easier to clean improving scratch resistance and increasing product longevity Cleaning the Reflectors Use a damp cloth to gently clean the plastic surfaces To avoid damaging the reflectors do not use heavy pressure or caustic abrasive or petroleum based cleaners 7 fe 9 gt 72 is 48 Legend Lightbar Replacement Parts 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 am to 5 pm Monday through Friday Central Time or contact your nearest distributor Table 5 2 Legend replacement parts Description Part Number PCB Assembly End Configured Contact Federal Signal PCB Assembly Intermediate Configured Contact Federal Signal PCB Assembly Center Configured Contact Federal Signal PCB Assembly Controller Configured Contact Federal Signal PCB Assembly Controller Steady Burn Red Driver Side CA Contact Federal Signal PCB Assembly Controller Steady Burn Red Driver and Passenger Side CA Contact Federal Signal Lamp Halogen Alley 35 W MR 11 8107241 Lamp Halogen Takedown 50 W GH 8 Bi Pin 8107169 Fuse M
42. dy its LED glows green Do not disconnect the programmer when the LED glows red which indicates that the programmer is connecting or cloning T 3 3 5 a 5 95 V lt 9 oz 50 5 o 3 Connect the EPIC SIDE of the programming cable to the five inner pins on the programmer 4 Onthe 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 18 5 the programming cable to the source Serial Interface Module Figure 6 2 EPIC programmer cable connections a TO COMPUTER USB PORT 2 SERIAL EPIC MODULE INNER PINS Figure 6 3 New Hardware Wizard click Next Found New Wizard Welcome to the Found New Hardware Wizard This wizard helps you install software for USB Human Interface Device If your hardware came with an installation CD floppy disk insert it now What do you want the wizard to do Install from a list or specific location Advanced Click Next to continue Legend Lightbar 53 ES 2 TEMP 2 55 Oo Cloning the Serial Interface Module Cloning the Serial Interface Module 1 2 Click Start Programs melabs Programmer melabs Programmer In the drop down list select PIC16
43. e es bn 29 Wiring the Stop rtt 35 the Work P 36 Chapter 5 Maintaining and Servicing the 37 Servicing the Lightbar 37 Replacing the ROC Panel 2 0 1 00000000 eene enne nnne nennen nnns 39 Servicing the Lightbar 40 Replacing eie e titt i ete 42 Replacing an End Gasket intei eiit basi cien eee 44 Replacing a Lip Seal ctrca eee cer inrer un 44 Replacing the Halogen 5 45 Adjusting the Aim of the HotFoot LED Assemblies 47 Cleaning the DOImes etd oe it tantu is etu tula decre 47 Cleaning the Reflectors 48 aE A 49 50 Chapter 6 Cloning Flash Patterns from Vehicle to Vehicle 52 Installing the Programmer 2
44. el as described in Removing and Inspecting the Domes above 2 Remove the panel s 7 16 inch ground nut and disconnect the ground wire 3 Invert the ROC panel note and record the connections then disconnect the wires and harnesses 4 If required remove the controller as described in Removing the Controller in the next section 5 On the replacement ROC panel connect the wires and harnesses NOTICE PROPERLY TIGHTEN NUTS To prevent damage to the lightbar do not overtighten the nuts 6 Turn the ROC panel over connect the ground wire and tighten the ground nut 7 Reinstall the controller if necessary as described in Reinstalling the Controller on page 41 8 Reattach the dome as described in Reinstalling the Domes above Figure 5 2 PCB ground nut ADJUSTING SCREW LOCK NUT o Em 5 2 95 5 Legend Lightbar 39 Servicing the Lightbar Controller Servicing the Lightbar Controller The controller generates and receives the signals that control the lightbars 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 NOTICE STATIC SENSITIVE DEVICE The lightbar s circuitry can be damaged by an electrostatic discharge ESD Follow anti static procedures while installing the li
45. ether and meets federal state and local standards or guidelines 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 light system is high current system In order for the system to function properly a separate negative connection and positive connection must be made 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 Legend Lightbar 7 6 2 4 o Warning Light Equipment Never attempt to install aftermarket equipment that connects to the vehicle wiring without reviewing a ve hicle wiring diagram available from the vehicle manufacturer Ensure that your installation will not affect ve hicle operation or mandated safety functions or circuits Always check the vehicle for proper operation after installation The lighting system components especially light bulbs strobe tubes LEDs an
46. ghtbar Removing the Controller 1 Remove the passenger side end dome as described in Removing and Inspecting the Domes on page 38 2 Remove the 7 16 inch ground nut from the end panel and disconnect the ground wire 3 Invert the panel to expose the controller noting ground lead placement on ground bracket 4 Note and record connections then disconnect the wires and harnesses 5 Compress the lock tab on the nylon standoffs and remove controller with its standoffs from ROC panel 6 Compress the secondary lock tabs and remove the standoffs from controller Figure 5 3 Controller and standoffs removed from ROC panel NYLON STANDOFFS CRM 4 CONTROLLER N 2 D 3 PASSENGER SIDE Lm gt 7 9 gt 7 72 S 290A5986 40 Legend Lightbar Replacing the Controller Fuses 1 The lightbar controller has four 15 fuses and one 5A fuse To see 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 5 4 For replacement fuses see Table 5 2 on page 49 Figure 5 4 Fuses on lightbar controller PCB GOOD FUSE 15A 15A WIRE INTACT 20055738 5 Bs sw BAD FUSE WIRE BURNED THR
47. good Check that the CAT5 cable is connected to the Serial Interface Module J1 and there are no damaged pins in the sockets Try a new CAT5 cable Check the connections on the 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 3 aMODE wire has 12 Vdc 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 Fig ure 3 3 on page 19 and Table 3 2 on page 20 Check the fuses on the mainbar controller Figure 5 4 on page 41 An LED module does Swap the LED board with good board to see if the board is bad RE Check the connections of the cable that goes from the lightbar controller to the LED ROC board 4 Ensure that STEADY BURN switches on the lightbar controller SW3 PSR for the passenger side and SW3 DSR on the driver side are set correctly Figure 5 4 on page 41 rear module check the SignalMaster connections Half of an LED mod Replace the ROC board that the LED is ule does not light The lightbar turns Ensure that the vehicle battery is fully charged ff when the FLASH Sada iet Check that the lightbar s red power line BAT and black ground power line
48. he vehicle s stop turn tail lights Figure 4 7 Stop turn tail wiring between lightbar and vehicle harness FROM LIGHTBAR TYPICAL CAR WIRING RED YELLOW BLACK LEFTBRAKELIGHT BROWN TAIL LIGHT GREEN A FO RIGHT BRAKE LIGHT 290A5982 Legend Lightbar 35 5 5 lt Q 5 m 5 aq 5 xe e a 55 m o c gt Wiring the Work Lights Wiring the Work Lights The lightbar s work lights are a factory configured option The lightbar is shipped with the option s three conductor cable ready for splicing into the vehicle harness For the location of the lights see Figure 3 4 on page 23 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 injuries Disconnect the vehicle battery s negative ground cable then the positive cable 2 Locate the three conductor cable exiting the lightbar with red black and green wires 3 Connect the wires to switched 12 Vdc positive signals to activate Figure 4 8 NOTE High Power Mode overrides the Low Power Mode i e if both lines are activated the work lights come on in High Power Mode Low Power Mode dims the lightbar to 50 percent of fu
49. ics 2009 062 YVELHOM 39 7 e e e e e e HB 940 aad NHu9 d3H OIA 13 414 034 o E 2 o 2 m 5 2 E m E s SNOLLO3NNOO 9 8 5 SNINIVINSH H3TTOH INOO 8 TES e 3 918 6 LHM gt gt vt 3 CD CL i NO SNOLLO3NNOO ONINIVIN3H HOLIMS im w 291 YALSVWIVNDIS TVNH3 X3 SNOLLO3NNOO WOIdAL JOMUOD 9 1ejsejqjeuDiS e 82Id Z y oneueuog 57 Legend Lightbar Appendix Wiring Schematics 009v06c HvalH9S rTON3931 c Oe 3OVHH3LNI 1VIH3S NOILISOd NMOG OL 7504 HOLIMS did ZMS 3AOW OL 13 414 034 71 9 a1 18 1HM GOW 1
50. ighting 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 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 lights and halogen takedown and alley lights are available in the lightbar Flash patterns are controlled through the lightbar s CAT5 serial communication cable The cable connects to the Federal Signal Serial Interface Module Model Number 85834496 or the Federal Signal Six Button Serial Controller Model Number 8623133 or the Federal Signal Three Button Serial Controller Model Number 8623141 With the Serial Interface Module the Legend can be activated by Federal Signal lightbar controllers SignalMaster directional light controllers or by individual low current switch boxes SignalMaster directional warning lights are not available with the Model LGD24 The programmable Six Button Serial Controller has six illuminated pushbuttons and a three position slide switch with LED indicators for operating the lightbar The programmable Three Button Serial Controller has three illuminated pushbuttons and LED indicators for operating the lightbar The Legend is available in five lengths 24 inches Model LGD24 45 inches Model LGD45 53 inches Model LGD53 61 inches Model LGD61
51. ing 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 hear ing loss You and your passengers should consider taking appropriate safety precautions such as wearing hearing protection Legend Lightbar 9 o lt g Q 6 2 4 o Safety Message to Operators Warning Light Equipment In order 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 It is important that you fully understand how to safely operate this warning system before use You should only operate your vehicle and its light sound system in accordance with your department s Standard Operating Procedures If a 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 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 windo
52. ini Controller 32 V 15 A 148181 06 Fuse Holder Maxi 143137 Fuse Mini 15 A 1148181 06 Fuse Maxi 20 A 148182 02 Fuse Maxi 40 148182 01 Gasket End 8653110 Seal Lip Clear 5 5 ft per end section 3 5 ft per center section 8583020 01 O Ring Top Nut 5 16 7067016 Standoff Nylon 230315 Base End 8653100 Top End Clear 8653101 Top End Amber 8653101 02 Top End Blue 8653101 03 Top End Red 8653101 04 Base Center Clear 8653102 Top Center Clear 8653103 Top Center Black 8653103 01 Top Center Amber 8653103 02 5 3 Top Center Blue 8653103 03 5 Top Center Red 8653103 04 5 zi Top End 12 Clear 24 Legend 653176 Top End 12 Amber 8653176 02 9 12 8653176 03 cc Top End 12 Red 8653176 04 Legend Lightbar 49 Troubleshooting the Lightbar 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 CT Table 5 3 Troubleshooting tips Problem Corrective Action The lightbar does not Check that the lightbar s red power line and the black ground power line light are properly connected to a good fully charged 12 volt battery Ensure that the ground connection from the lightbar controller to the aluminum extrusion is
53. k OK 1 Program Verify complete 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 reinstall 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 am to 5 pm Monday through Friday CT Legend Lightbar 55 Appendix Wiring Schematics This chapter has schematics showing the Legend lightbar with typical connections to these controllers SignalMaster controller external control SW400SS Switch Module internal control SmartSiren Model 5520005 Non SignalMaster PA640 An Overview of the Discrete Wired 24 Legend Lightbar The Discrete Wired 24 Legend is a special model that is designed to flash only one flash pattern as long as power is supplied to the lightbar Because the lightbar does not connect to the Serial Interface Module it has no CAT5 cable the 10 AWG red and black cables are the only connections An installer supplied switch is required Figure A 1 Schematic A 1 Discrete wired 24 Legend lightbar N 7 20 INSTALLER SUPPLIED SWITCH 12 BATTERY LEGEND LIGHTBAR 290A6306 56 Legend Lightbar iring Schematics ix Append Wiring Schemat
54. ked with the lighting system for proper electrical connections additional precau tions and information Legend Lightbar Safety Message to Operators of Warning Light Equipment 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 dam age 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 torque each hook adjustment bolt 10 ft lb to 11 ft lb On all other lightbars torque each hook adjustment bolt 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 Test all vehicle functions including horn operation vehicle safety functions and vehicle light systems to ensure proper operation Ensure that the installation has not affected the vehicle operation or changed any vehicle safety function or circuit Scratched or dull reflectors mirrors or lenses will reduce the effectiveness of the lighting system Avoid heavy pressure and
55. lastic dome 7 9 gt 72 S 290A5990B 44 Legend Lightbar Replacing the Halogen Lamps Replacing the Halogen Lamps To replace the takedown and alley halogen lamps follow the instructions in the next two sections and replace the defective lamps with an exact replacement only For replacement lamps see Table 5 2 on page 49 HANDLE STROBE AND HALOGEN LAMPS CAREFULLY Strobe and halogen lamps get hot enough to burn you Always allow the lamps to cool before handling these devices Halogen and strobe lamps are also pressurized and if broken can result in flying glass Always wear gloves and eye protection when handling these devices Failure to follow this caution may result in personal injury NOTICE DO NOT TOUCH LAMP WITH BARE HANDS deposits on the glass potion of a strobe or halogen lamp can cause the glass to fracture during use If you are unsure whether the glass portion has been touched without gloves clean the glass using a soft cloth and isopropyl alcohol before installing the lamp Replacing the Takedown Lamps 1 Remove the dome as described in Removing and Inspecting the Domes on page 38 2 Toaccess the lamp remove the PCB ground nut and wire and invert the PCB Figure 5 2 on page 39 3 Gently grasp the lamp and pull it from the socket Figure 5 8 Figure 5 8 Takedown halogen lamp 290A
56. lightbar controller to the ROC boards and ensure TAKEDOWN light they are in the proper locations turns on HotFoot TAKEDOWN Check that the TAKEDOWN and ALLEY switches SW3 FA and FT are set in the ALLEY lights flash ON position on the lightbar controller Figure 5 4 on page 41 with MODE inde pendent of FLASH TAKEDOWN ALLEY input SignalMaster LEDs Check the jumper and switch settings on the Serial Interface Module Ensure they do not light are both set for the correct operation See Figure 3 3 on page 19 and Table 3 2 on page 20 4 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 SignalMaster controller If the controller is a model 5520005 ensure that the connector has power and the ground is connected to Pins 10 and 11 on the SignalMaster plug Legend Lightbar 51 o E m 5 2 95 5 6 Cloning Flash Patterns from Vehicle to Vehicle The Legend and RS485 system make it fast and easy to copy and upload clone flash patterns to other Legend equipped vehicles through the Serial Interface Module Cloning requires laptop or desktop computer with Windows 98 or later one free USB EPIC USB programmer with USB cable programming cable and software CD Federal Signal num
57. ll brightness 4 Reconnect the battery s positive terminal then the negative terminal 5 Testthe lightbar to verify that it operates properly Figure 4 8 Work light wiring between lightbar and switched 12 RED p HIGH POWER WORK LIGHT 45 BLACK LOW POWER WORK LIGHT 12 vac 290A5983 36 Legend Lightbar Maintaining and Servicing the Legend A WARNING QUALIFICATIONS To properly service a light assembly you must have a good understanding of automotive electrical procedures and systems along with proficiency in the installation and use of safety warning equipment Establishing a regular maintenance schedule for the Legend 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 inspect the domes and lenses for cracks crazing hairline cracks discoloration and other defects For service support or replacement parts contact the Federal Signal Service Department at 1 800 433 9132 7 AM to 5 PM Monday through Friday CT 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 BURN HAZARD After prolonged operation the lightbar gets hot and can cause
58. ng 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 24 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 to the LIGHTBAR TEST control wire black white red from the Serial Interface Module 2 After all LEDs flash in sequence the TAKEDOWN and ALLEY lights flash 3 Remove 12 Vdc from the LIGHTBAR TEST control wire Selecting Internal SignalMaster Control 1 Unplug the 24 pin harness from the Serial Interface Module 2 On the Interface Module use a 1 4 inch driver to remove the four 8 32 x 1 4 hex head screws and remove the cover 3 Interface Module PCB move 1 from EXT to INT see Figure 3 3 page 19 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 18 Legend Lightbar Testing and Reprogramming the Lightbar Selecting External SignalMaster Control To return to External SignalMaster control factory
59. nly 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 INTERSECTION To dim the LEDs 1 Apply 12 Vdc to the control wire for MODE 1 or 2 Table 3 1 on page 17 2 Apply 12 Vdc BAT to the white black red control wire for the LOW POWER function 24 Legend Lightbar Additional Mainbar Tests and Configurations 25 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 for External Operation With the lightbar in External SignalMaster control default Figure 3 3 on page 19 apply ground GND to the control wires listed in Table 3 4 to test the LEDs Figure 3 4 on page 23 Table 3 4 SignalMaster control wires External operation 6 Head SianaLtMaster 8 SicNALMAsTER Red Green Green Black White Green Black White Green Orange Green Orange Green Orange Orange Blue Red Blue Red Red Green Red Green White Red Testing the SignalMaster LED Modules for Internal Operation If the Serial Interface Module is set to Internal SignalMaster operation test the LEDs Figure 3 4 on page 23 by applying 12 Vdc to the control wires listed in Table 3 5 Table 3 5 SignalMaster control wires and warning patterns Internal
60. nstallation 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 To properly install or service this equipment you must have a good understanding of automotive mechani cal 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 To be an effective warning device this product produces bright light that 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 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 tog
61. nsure that your installation is fast easy and error free In addition to bench testing this chapter has instructions for changing default settings and flash patterns 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 Testing and Reprogramming the Lightbar 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 default settings and flash patterns before installation Before you begin decide if you want to change these default settings SignalMaster Operation External default or Internal You can change the setting from External to Internal Internal operation uses the lightbars on board 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 internal SignalMa
62. ontrol 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 J1 cable harness on the Interface Module to 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 SiexaL MasrER operation is not activated by a control head or external controller the 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 Fed eral Signal SignalMaster controller or SS2000SM series siren Figures 4 3 and 4 4 on page 32 Either device provides an independent ground signal to turn on each head To cross reference external SignalMas
63. plied 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 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 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 30 Legend Lightbar Wiring the Serial Interface Module 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 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 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 is applied to the LOW POWER c
64. r is on the vehicle Start the base onto extrusion insert the first two long carriage bolts into their wells then hold the bolts up while sliding the base further onto the extrusion The top barrel nuts may be temporarily installed to hold the bolts in position Repeat the procedure with the short carriage bolt that attaches the ground bracket sliding the base on just far enough to trap the bolt then repeat with the two remaining long carriage bolts If the lightbar is off the vehicle With the lightbar inverted start the base onto extrusion then drop the carriage bolts into each of their wells The ground bracket bolt is the short one Figure 5 5 on page 43 4 Slide the base onto the extrusion For a flush fit between the bases apply pressure to the ends of the outer bases and tighten the base retainer screw 5 Reinstall the PCBs a b Reconnect the cable clamp on the cable entry side Reinstall the ground bracket Ensure that a star washer is on the ground bracket bolt Do not over tighten the ground bracket nut 42 Legend Lightbar Replacing a Lightbar Base c Reconnect the wires and harnesses and invert the PCB on the plastic standoffs Ensure that the ground wire is not caught between the edges of the PCBs d Reconnect the ground wire and tighten the nut Do not overtighten 6 Reinstall the domes as described in Reinstalling the Domes on page 39 Figure 5 5 Base removed from aluminum extrusion
65. re using the Internal SignalMaster option you must configure the Serial Interface Module before installation as described in Selecting Internal SignalMaster Control on page 18 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 position marks at the selected mount ing location Mounting centers are 2 in x 5 95 in 5 08 cm x 15 11 cm DRILLING PRECAUTIONS DO NOT drill holes in ANY part of the Serial Interface Module Damage to the unit serious injury or death 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 drilled holes should be de burred and all sharp edges should be smoothed All wires going through drilled holes should be protected by a grommet or convolute split loom tubing 2 Drill four mounting holes at the drill position marks sized for the recommended user supplied 8 mounting hardware 3 Secure the
66. require any internal wiring Two 10 AWG power conductors red and black and a CAT5 cable exit the lightbar The lightbar s basic light functions are communicated through the CAT5 cable which connects to the Serial Interface Module The Discrete Wired 24 Legend does not connect to the Serial Interface Module and has no CAT5 cable For wiring schematics see the Appendix starting on page 56 To make the electrical connections for bench testing and reprogramming the lightbar 1 Tosupply power to the lightbar use a fully charged 12 volt automotive battery with terminal lugs 2 Placethe lightbar on a sturdy flat surface 3 Plugthe CAT5 communication cable 1 from the lightbar into the Serial Interface Module J1 Figure 3 1 4 Plug the 24 pin harness 2 into the Serial Interface Module 5 Attach the lightbar s black ground power line 3 to the negative battery GND lug 6 Attach the lightbars red power line 4 through a 40 A Maxi fuse to the positive battery BAT lug 7 Attach the white wire 5 from the 24 pin harness through a 1 A fuse to the positive battery lug 8 Attach the black wire and the black white wire from the 24 pin harness to the negative battery GND lug Figure 3 1 Electrical connections for testing and reprogramming DRIVER PASSENGER SIDE SIDE 45 LEGEND LGD45 MS D 2 FUSE POWER LINE RED 90 GROUND P
67. s not need any additional internal wiring For typical installations with common control systems see the wiring schematics in the Appendix starting on page 56 The basic light functions of the lightbar must be controlled by a user supplied control panel Wiring the Lightbar in the Vehicle 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 to you or others 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 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 1 Ensure that the lines are adequately fused as shown in the wiring schematics in the Appendix starting on page 56 From the lightbar route the CAT5 control cable into the vehicle s cab or trunk near the eventual location of the Serial Interface Module An input cable is also provided with the Interface Module NOTICE REVERSE POLARITY MISWIRING Reverse polarity or incorrect volt
68. ss For the location of the lights see Figure 3 4 on page 21 QUALIFICATIONS To properly connect a stop tail turn light 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 s service manuals when performing equipment installations on a vehicle After mounting and wiring the lightbar to the vehicle follow these steps to wire the lightbar s stop turn tail lights 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 injuries 1 Disconnect the vehicle battery s negative ground cable then the positive cable 2 Locate the three conductor cable exiting the lightbar with red black and green wires NOTE If installing the option in a vehicle that has its turn signal lights separate from its brake lights you must purchase a tail light converter 3 Splice the appropriate cables into the vehicle s wiring Figure 4 7 The input leads require a positive 12 signal to activate 4 the battery s positive terminal then the negative terminal 5 Test to verify that the lightbar s stop turn tail lights turn on and off with t
69. ster controller MODE 1 2 3 and INTERSECTION MODES 1 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 pattern for each mode from the lightbars 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 INTERSECTION 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 MODE and INTERSECTION 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 Legend Lightbar 15 16 Testing Reprogramming the Lightbar Making Initial Electrical Connections 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 Legend does not
70. ter wiring to a Federal Signal controller or the SM2000SM series siren see Table 4 1 on page 32 Internal SiaNaLMAsTER Internal operation uses the lightbar s built in 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 lightbar s internal SignalMaster controller For the jumper setting in the Serial Interface Module see Selecting Internal SignalMaster Control on page 18 To activate the lightbar s internal SignalMaster controller apply 12 Vdc BAT to the SignalMaster control wires Legend Lightbar 31 5 5 Q 5 m 5 aq 5 Wiring the Serial Interface Module Table 4 1 Cross reference for controller leads 24 Pin Harness from SicnaLMaster Wire SS2000SM Wire the Serial Interface Figure 4 3 Figure 4 4 Module 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 Figure 4 3 SignalMaster 331105 controller External SIGNALMASTER CONTROLLER 331105 SHOWN RED GREEN GREEN BLACK WHITE ORANGE GREEN ee 55 m
71. to TAP II or 8 SECOND TIMEOUT 1 Unplug the 24 pin harness from the Serial Interface Module Legend Lightbar 21 21 5 D 3 0 9 5 5 D aq 5 22 Additional Mainbar Tests and Configurations 2 On the Serial Interface Module set Switch 7 and Switch 8 SW 2 to select a method of opera tion Figure 3 3 on page 19 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 down OFF up 8 SECOND TIMEOUT activated by BAT OFF up ON down FRONT REAR ENABLE or CUTOFF The operational setting for FRONT REAR ENABLE or CUTOFF must be programmed after MODE and IN TERSECTION The default setting is for CUTOFF in which the FRONT or REAR LEDs turn off when 12 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 or CUTOFF 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
72. ult MODE flash patterns by programming each mode with one of 26 patterns in the lightbar s library A typical setup would be MODE 1 REAR LEDs MODE 2 FRONT REAR LEDs MODE 3 Siren SmartSiren or Federal Signal compatible and FRONT REAR LEDs and FLASH TAKEDOWN ALLEY LEDs on the mainbar MODES 1 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 MODE 1 INTERSECTION EN 2 Mode 3 1 Apply 12 Vdc BAT to the MODE 3 control wire black red from the Serial Interface Module to dis play the assigned pattern 20 Legend Lightbar Testing and Reprogramming the Lightbar 2 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 dis play the assigned pattern 2 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 the
73. use of caustic or petroleum based products when cleaning the lighting system Re place 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 all safety precautions and instructions may result in property damage serious injury or death 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 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 not be completely effective People may not see or heed your warning signal You must recognize this fact and continue driving cautiously Also situations may occur which obstruct your warning signal when natural and man made objects are between your vehicle and others such as rais
74. w 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 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 thick ness of the steel mounting surface Therefore to promote proper magnetic mounting 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 To 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 RETAIN AND REFER TO THIS MESSAGE Legend Lightbar The Legend 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 l

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