Federal Signal Corporation Reliant Handbuch

25500679

Rev A2 0521

Installation, Maintenance,

and Service Manual

Reliant™Light Bar

Limited Warranty

This product is subject to and covered by a limited warranty, a copy of which can be found at

www.fedsig.com/SSG-Warranty. A copy of this limited warranty can also be obtained by written request to Federal

Signal Corporation, 2645 Federal Signal Drive, University Park, IL 60484, email to [email protected] or call

+1 708-534-3400.

This limited warranty is in lieu of all other warranties, express or implied, contractual or statutory, including, but

not limited to the warranty of merchantability, warranty of ﬁtness for a particular purpose and any warranty against

failure of its essential purpose.

2645 Federal Signal Drive

University Park, Illinois 60484-3167

www.fedsig.com

Customer Support

Police/Fire-EMS: 800-264-3578 • +1 708 534-3400

Work Truck: 800-824-0254 • +1 708 534-3400

Technical Support 800-433-9132 • +1 708 534-3400

All product names or trademarks are properties of their respective owners.

Installation, Maintenance, and Service Manual

Federal Signal www.fedsig.com

Contents

Safety Messages.............................................................................................................................. 5

Safety Message to Installers and Service Personnel of Warning Lights...........................................5

Safety Messages to Operators of Federal Signal Sound/Light Systems ..........................................8

An Overview of the Reliant Light Bar ............................................................................................ 9

LED Lights, Colors, and Flash Patterns......................................................................................................9

Electrical System..............................................................................................................................................9

Controller Options ...........................................................................................................................................9

Product Speciﬁcations....................................................................................................................................9

Reprogramming the Light Bar...................................................................................................... 10

Reprogramming the Light Bar ....................................................................................................................10

SignalMaster®Operation: Internal (Factory Default) or External..................................................10

MODE 1, 2, 3, and INTERSECTION .....................................................................................................10

FRONT and REAR lights: CUTOFF (default) or ENABLE ................................................................. 11

Making the Electrical Connections for Reprogramming................................................................. 11

Wiring the Reliant Light Bar in the Vehicle ................................................................................ 12

Planning the Electrical Installation............................................................................................................. 12

Connecting Power to the Light Bar .......................................................................................................... 13

Low Power ................................................................................................................................................. 15

Maintaining and Servicing the Reliant......................................................................................... 16

Cleaning the Light Bar Lens........................................................................................................................ 16

Replacing a PCB............................................................................................................................................. 17

Troubleshooting the Light Bar.................................................................................................................... 19

Getting Technical Support and Service....................................................................................... 19

Getting Repair Service.................................................................................................................................. 19

Ordering Replacement Parts .....................................................................................................................20

4Reliant™Light Bar

Federal Signal www.fedsig.com

Figures

Figure 1 Electrical connections for reprogramming the light bar...................................................... 11

Figure 2 Cable entry location.................................................................................................................... 13

Figure 3 Relay for isolating devices with large ﬁlter capacitors....................................................... 14

Figure 4 Ground screw ............................................................................................................................... 17

Figure 5 Separated side assemblies....................................................................................................... 17

Figure 6 Locations of ROC PCBs.............................................................................................................. 18

Tables

Table 1 Dimensions........................................................................................................................................9

Table 2 Light speciﬁcations ......................................................................................................................10

Table 3 Electrical and temperature.........................................................................................................10

Table 4 SignalMaster warning patterns (internal SM control)) ....................................................... 15

Table 5 Troubleshooting tips.................................................................................................................... 19

Table 6 Replacement parts ......................................................................................................................20

Safety Messages

Installation, Maintenance, and Service Manual

Federal Signal www.fedsig.com

Safety Messages

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

and servicing the Reliant™light bar. The safety messages presented in this section

and throughout the manual are reminders to exercise extreme care at all times. Read

and understand the safety instructions and keep them close at hand for reference.

To download copies of this manual, go to www.fedsig.com/resource-library or call the

Federal Signal Service Department at 1-800-433-9132, 7  to 5 , Monday through

Friday (CT).

Safety Message to Installers and Service Personnel of Warning Lights

Before Installation or Service

Qualiﬁcations

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

automotive mechanical and electrical procedures and systems, along with proﬁciency

in the installation and service of safety warning equipment. Always refer to the vehicle’s

service manuals when performing equipment installations on a vehicle.

Light Hazards

• In order to be an eective warning device, this product produces bright light that can

be hazardous to your eyesight when viewed at a close range. Do not stare directly

into this lighting product at a close range, or permanent damage to your eyesight may

occur.

• Do not install the light system in an area that would block, impair, or blind the driver’s

vision. Ensure that the light system is mounted in a position that is outside of the

driver’s ﬁeld of vision so the driver can 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 dierent manufacturers

may reduce the warning eectiveness of the lighting system and may damage the

components. 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 o. After disconnecting power to the unit, wait ﬁve minutes before

handling any parts of the strobe system.

• A light system is a high current system. In order for the system to function properly,

a separate negative (-) connection and positive (+) connection must be made. All

negative connections should be connected to the negative battery terminal and a

suitable fuse should be installed on the positive battery terminal connection as close

to the battery as possible. Ensure that all wires and fuses are rated correctly to handle

the device and system amperage requirements.

Safety Messages

6Reliant™Light Bar

Federal Signal www.fedsig.com

• 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 aect 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. 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 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 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 ensure 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 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 veriﬁed

that no shorts exist. If the wiring is shorted to the vehicle body or frame, high current

conductors can cause hazardous sparks, resulting in electrical ﬁres or ﬂying molten

metal.

• DO NOT install equipment or route wiring (or the plug in cord) in the deployment path

of an airbag.

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

seat needs to be recalibrated for proper airbag deployment.

• Before mounting any components, check the manual to verify 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.

Safety Messages

Installation, Maintenance, and Service Manual

Federal Signal www.fedsig.com

• 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, ensure 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.

Ensure that the mounting screws do not cause electrical or mechanical damage to

the vehicle.

• To avoid denting the roof of the vehicle, place the light bar mounting feet as close

to outer edge of the roof as possible.

• Roof damage can occur if the hook adjustment bolts are over-tightened. Torque

the adjustment bolts to 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 aected the vehicle operation or changed any vehicle safety function or circuit.

• Scratched or dull reﬂectors, mirrors, or lenses will reduce the eectiveness 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 deactivate the light system control while driving in a

hazardous situation.

• 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 sta and all operating personnel.

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

damage the light bar.

• File these instructions in a safe place and refer to them when maintaining and/or

reinstalling the product.

Failure to follow all safety precautions and instructions may result in property damage,

serious injury, or death.

Safety Messages

8Reliant™Light Bar

Federal Signal www.fedsig.com

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. Listed below are some other

important safety instructions and precautions you should follow:

• Do not attempt to activate or deactivate the light system control while driving in a

hazardous situation.

• Although your warning system is operating properly, it may not be completely

eective. People may not see or heed your warning signal. You must recognize this

fact and continue to drive cautiously.

• Situations may occur that 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 eective 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 eectiveness 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

eectiveness 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 eective 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.

• 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 o, disconnect the power connector from the control unit and

contact the nearest service center.

• At the start of your shift, ensure that the entire warning light system and the siren

system is securely attached and operating properly.

Failure to follow all safety precautions and instructions may result in property damage,

serious injury, or death.

An Overview of the Reliant Light Bar

Installation, Maintenance, and Service Manual

Federal Signal www.fedsig.com

An Overview of the Reliant Light Bar

The Reliant™light bar is a single-level LED light bar 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 oset, complex reﬂector surfaces for accurate beam-shaping and the highest

optical eciency. The reﬂectors’ overlapping, 360-degree lighting eliminates weak

spots and provides o-axis warning around the light bar.

LED Lights, Colors, and Flash Patterns

The microprocessor inside the light bar supplies three priority operational modes and a

library of ﬂash patterns. To increase the safety of ocers, pedestrians, and motorists, the

light bar has standard front and rear cuto, dimming, and intersection warning.

Multi-color heads are available with up to two dierent colored LEDs, eliminating the loss

of primary warning colors in takedown, alley, and directional warning positions. Individual

Reliant light heads can ﬂash between red, blue, amber, or white.

Electrical System

The Reliant light bar is protected against reversed polarity damage. The Reliant Light

Bar can be installed in any vehicle with a 12-volt negative-ground electrical system.

Controller Options

Flash patterns are controlled through the light bar CAT5 communication cable. The

cable connects to Federal Signal Convergence network controllers or the Serial

Interface Module (Part Number 858303641).

With the Serial Interface Module, the Reliant Light Bar can be activated by Federal

Signal light bar controllers or by individual low-current switch boxes.

Other advanced features of the Reliant light bar include:

• A high degree of reliability through the use of advanced microprocessors and other

integrated circuits.

• High output, long-life LEDs with no bulbs to change.

Product Specications

Operating and technical speciﬁcations for the Reliant™light bar are listed in this section by

model.

Table 1 Dimensions

Size (L x W x H) 47.6 x 11.6 x 1.3 inches (120.9cm x 29.5cm x 3.3cm)

Weight* 20.5 lb (9.3 kg)

*with standard mounting feet

Reprogramming the Light Bar

10 Reliant™Light Bar

Federal Signal www.fedsig.com

Table 2 Light specications

Lighting Option Current Draw Lamp Technology Reector Style

LED (all heads) 1.0 A in Steady-Burn Mode High-brightness LED O󰀨set, compound curve,

polished reector

Table 3 Electrical and temperature

Electrical

Potential

Current Draw

(50 % Flash Rate)

Operating Temp.

12.8 Vdc 13.0 A -40°F to 149°F (-40°C 50 to 65°C)

Reprogramming the Light Bar

HEAVY OBJECT: Use lifting aids and proper lifting techniques when removing or

replacing this product. Failure to heed this warning may cause personal injury.

Carefully unpack the light bar 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 to

5 , Monday through Friday (CT).

Reprogramming the Light Bar

Although the Reliant™light bar is conﬁgured and programmed at the factory, you may

want to change the default settings and ﬂash patterns before installation. Before you

begin, decide if you want to change these default settings.

SignalMaster®Operation: Internal (Factory Default) or External

The internal operation uses the onboard SignalMaster controller in the light bar 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

SignalMaster 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 light bar without looking down. You can select a

pattern for each mode from the light bar’s library of 26 patterns.

• The INTERSECTION ﬂash pattern is typically a high activity pattern that attracts attention

to the vehicle as it approaches an intersection. You can select a pattern from the library

and choose one of three ways to turn on and o 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.

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