Federal Signal Corporation Integrity44 Handbuch

25500063

REV. B0 0215

Printed in U.S.A.

Installation, Maintenance,

and Service Manual

INTEGRITYTM Lightbar

blank page

Integrity Lightbar

Contents

Chapter 1 Safety Messages .......................................................................................................... 6

Safety Message to Installers and Service Personnel of Warning Lights........................................................6

Safety Messages to Operators of Federal Signal Sound/Light Systems........................................................9

Chapter 2 An Overview of the IntegrityTM Lightbar ................................................................... 11

LED Lights, Colors, and Flash Patterns ......................................................................................................11

Electrical System .........................................................................................................................................11

Controller Options .......................................................................................................................................11

Ambient Light Sensor/AutoDim Option .....................................................................................................11

Product Specications .................................................................................................................................12

Chapter 3 Reprogramming the Lightbar.................................................................................... 13

Reprogramming the Lightbar ......................................................................................................................13

Making the Electrical Connections for Reprogramming .......................................................................14

Switch Settings and Connectors on the Serial Interface Module...........................................................15

Chapter 4 Wiring the INTEGRITY Lightbar in the Vehicle ....................................................... 21

Planning the Electrical Installation..............................................................................................................21

Connecting Power to the Lightbar ..............................................................................................................22

Installing the Serial Interface Module .........................................................................................................23

Wiring the Serial Interface Module .............................................................................................................24

Priority Modes 1, 2, and 3......................................................................................................................24

Steady Burn............................................................................................................................................25

Front Cutoff............................................................................................................................................25

Rear Cutoff.............................................................................................................................................25

Intersection.............................................................................................................................................25

Flash Takedown/Alley............................................................................................................................25

Left and Right Alley Lights....................................................................................................................25

Takedown Lights....................................................................................................................................25

Scene Light, Left and Scene Light, Right..............................................................................................26

Low Power or Optional AutoDim..........................................................................................................26

Ignition ...................................................................................................................................................26

SignalMaster Connections .....................................................................................................................26

Chapter 5 Maintaining and Servicing the INTEGRITY .............................................................. 36

Installing the Filler Strips (Sponge Cords) ..................................................................................................36

Cleaning the Lightbar Lens .........................................................................................................................37

Contents

4Integrity Lightbar

Figures

Figure 3.1 Electrical connections for reprogramming the lightbar ................................................................ 14

Figure 3.2 DIP switch settings in Serial Interface Module ............................................................................ 15

Figure 4.1 Power and cable connections...................................................................................................... 23

Figure 4.2 Relay for isolating devices with large lter capacitors ................................................................. 24

Figure 4.3 SignalMaster 331105 controller (external SignalMaster control) ................................................. 27

Figure 4.4 SmartSiren SS2000SM Series controller (external SignalMaster control) .................................. 28

Figure 4.5 SignalMaster control functions wired to ground for external Serial Interface Module control...... 29

Figure 4.6 SignalMaster control functions wired to 12 Vdc for Internal control............................................. 30

Figure 4.7 Typical connections with a SignalMaster controller (external control) ......................................... 31

Figure 4.8 Typical connections with a Model SW400SS Switch Module (internal control) ........................... 32

Figure 4.9 Typical connections with a SmartSiren Model SS2000SM controller .......................................... 33

Figure 4.10 Typical connections with a non-SignalMaster controller............................................................ 34

Figure 4.11 Typical connections with a Model PA640 (PA64000) controller................................................. 35

Figure 5.1 Locations of the barrel nuts in lens (numbers indicate tightening sequence).............................. 38

Figure 5.2 Locations of ROC PCBs.............................................................................................................. 38

Removing and Reinstalling the Lightbar Lens ............................................................................................37

Removing the Lens ................................................................................................................................37

Reinstalling the Lens..............................................................................................................................38

Replacing a PCB..........................................................................................................................................38

Removing a PCB....................................................................................................................................39

Reinstalling a ROC PCB........................................................................................................................39

Resetting the Controller...............................................................................................................................39

Troubleshooting the Lightbar ......................................................................................................................41

Getting Technical Support and Service .......................................................................................................43

Ordering Replacement Parts ........................................................................................................................43

Returning a Product to Federal Signal.........................................................................................................43

Contents

Integrity Lightbar

Tables

Table 3.1 SW-2 DIP Switch Settings............................................................................................................. 15

Table 3.2 Control wires from the Serial Interface Module ............................................................................. 16

Table 3.3 Switch settings for INTERSECTION operation ............................................................................. 19

Table 4.1 Cross reference for controller leads (external Serial Interface Module control) ............................ 27

Table 4.2 SignalMaster control wires and warning patterns (internal SM control)) ...................................... 28

Table 5.1 Troubleshooting tips ...................................................................................................................... 41

Table 5.2 Replacement parts ........................................................................................................................ 43

6Integrity Lightbar

CHAPTER 1

Safety Messages

For your safety, read and understand this manual thoroughly before installing, operating, and servicing

the INTEGRITY lightbar. The safety messages presented in this chapter and throughout the manual are

reminders to exercise extreme care at all times. In addition, read and understand the safety instructions and

keep it close at hand for reference. To download copies of this 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 Lights

Before Installation or Service

Qualications

• To properly install or service this equipment, you must have a good understanding of automotive

mechanical and electrical procedures and systems, along with prociency in the installation and service

of safety warning equipment. Always refer to the vehicle’s service manuals when performing equipment

installations on a vehicle.

Light Hazards

• 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.

• 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 eld of vision, so the driver

can maintain safe vehicle operation.

• Federal Signal power supplies and light heads are designed to work together as a system. Combining

light heads and a power supply from different manufacturers may reduce the warning effectiveness of

the lighting system and may damage the components. You should verify or test your combination to

make sure the system works together 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 ve minutes before handling any parts of the strobe system.

Chapter 1: Safety Messages

Integrity Lightbar

• 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

effect vehicle 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 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 ying glass.

Always wear gloves and eye protection when handling these components.

• Do not mount a radio antenna within 18 inches 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 elds.

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 this or any other electrical device while it is connected to its power source.

Exposure to liquid while the product is connected to the power source may result in an electrical shock

and personal injury and may short circuit and damage the product.

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 rst 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.

• 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 veried 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 res or ying 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.

• 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.

Chapter 1: Safety Messages

8Integrity Lightbar

• 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.

• Because vehicle roof construction and driving conditions vary, do not drive a vehicle with a

magnetically mounted warning light installed. The light could y 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 outer edge of the

roof as possible.

• Roof damage can occur if the hook adjustment bolts are over-tightened. On Arjent® lightbars tighten

the adjustment bolts 10 ft-lb to 11 ft-lb. On all other lightbar models torque the adjustment bolts

6 ft-lb to 7 ft-lb. Install keeper plates.

• 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.

• If a seat is temporarily removed, verify with the vehicle manufacturer if the seat needs to be

recalibrated for proper airbag deployment.

• 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 reectors, mirrors or lenses will reduce the effectiveness of the lighting system.

Avoid heavy pressure and use of caustic or petroleum based products when cleaning the lighting

system. Replace any optical components that may have been scratched or crazed during system

installation.

• 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.

• Do not use a pressure washer to clean the lightbar. Failure to heed this notice will damage the lightbar.

• 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.

Chapter 1: Safety Messages

Integrity Lightbar

Safety Messages to Operators of Federal Signal Sound/Light Systems

People’s lives depend on your safe operation of Federal Signal products. It is important to read and follow all

instructions shipped with the products. In addition, listed below are some other 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 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.

• The effectiveness of an interior mounted warning light depends on the clarity, the tinting, and the angle

of the glass it is being placed behind. Tinting, dirt defects, and steeply angled glass reduce the light

output of the warning light. This may reduce the effectiveness of the light as a warning signal. If your

vehicle has dirty, tinted, or steeply angled glass, use extra caution when driving your vehicle or blocking

the right of way with your vehicle.

• 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 the 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. Window-mounted warning lights should be

removed from the window and stored securely when not in use. Temperature changes and sunlight can

cause suction cups to lose holding power. Periodically check the unit to be sure the suction cups have

a rm grip on the mounting surface. An improperly secured light could fall off of the vehicle causing

injury and damage.

• The holding power of magnetic mounting systems is dependent upon surface nish, surface atness, and

thickness of the steel mounting surface. Therefore, to promote proper magnetic mounting:

Chapter 1: Safety Messages

10 Integrity Lightbar

✔

The mounting surface and the magnets must be kept clean, dry, and free of foreign particles that

prevent good surface contact.

✔

Ensure that mounting surface is at.

✔

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 all safety precautions and instructions may result in property damage, serious injury,

or death.

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