Federal Signal Corporation Valor VALR44 Handbuch

2562549

REV. C3 0820

Printed in U.S.A.

Installation, Maintenance,

and Service Manual

Valor®Light Bar

blank page

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 tness 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 Message to Operators of Warning Light Equipment.................................................................8

An Overview of the Valor Light Bar ............................................................................................. 10

LED Lights, Colors, and Flash Patterns.................................................................................................... 10

Modular Connector System ........................................................................................................................10

Controller Options .........................................................................................................................................10

Preparing the Valor for Installation.............................................................................................. 12

Unpacking the Light Bar .............................................................................................................................. 12

Connecting the Valor for Programming................................................................................................... 12

Selecting External SignalMaster Control................................................................................................. 14

Selecting Internal SignalMaster Control (Factory Default).................................................................. 14

Entering Program Mode............................................................................................................................... 15

Exiting Program Mode.................................................................................................................................. 19

Wiring the Valor in the Vehicle .................................................................................................... 20

Planning the Electrical Installation............................................................................................................20

Connecting Power to the Light Bar .......................................................................................................... 21

Installing the Serial Interface Module......................................................................................................22

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

Maintaining and Servicing the Valor............................................................................................ 35

Cleaning the Light Bar Lens....................................................................................................................... 35

Removing and Reinstalling the Light Bar Lens...................................................................................... 36

Replacing a PCB............................................................................................................................................ 37

Disconnecting/Connecting Power and CAT5 at the Light Bar ......................................................... 38

Troubleshooting the Light Bar.................................................................................................................... 41

Quick Testing the Valor with the Light Bar Test.................................................................................... 42

Testing the Steady Burn LEDs (HotFoot Only) ...................................................................................... 43

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

Getting Repair Service................................................................................................................................. 43

Replacement Parts........................................................................................................................................ 44

4Valor®Light Bar

Federal Signal www.fedsig.com

Figures

Figure 1 Serial Interface Module connections for programming ........................................................... 13

Figure 2 Connectors and switches on the Serial Interface Module ..................................................... 17

Figure 3 Relay-isolating devices with large ﬁlter capacitors ................................................................. 23

Figure 4 Wiring block diagram ...................................................................................................................... 24

Figure 5 SignalMaster ﬂash sequences...................................................................................................... 27

Figure 6 SignalMaster control functions wired to 12 Vdc for internal SIM control........................... 28

Figure 7 SignalMaster control functions wired to ground for external SIM control......................... 29

Figure 8 Typical connections with a SignalMaster controller (external control)............................... 30

Figure 9 Typical connections with a SW400SS Switch Module (internal control) ............................ 31

Figure 10 Typical connections with a SmartSiren Model SS2000SM controller.............................. 32

Figure 11 Typical connections with a non-SignalMaster controller....................................................... 33

Figure 12 Typical connections with a PA640 controller.......................................................................... 34

Figure 13 Locations of barrel nuts in light bar cover................................................................................ 36

Figure 14 Location of controller..................................................................................................................... 37

Figure 15 Locations of watertight connectors ........................................................................................... 38

Figure 16 Secondary lock mechanism in the plug and receptacle...................................................... 39

Tables

Table 1 Dimensions ............................................................................................................................................ 11

Table 2 Light Speciﬁcations ............................................................................................................................ 11

Table 3 Electrical and Temperature............................................................................................................... 11

Table 4 SW2 DIP switch settings in the Serial Interface Module.......................................................... 15

Table 5 Control wires from the Serial Interface Module......................................................................... 16

Table 6 Switch settings for Intersection operation .................................................................................. 19

Table 7 SignalMaster control wires and warning patterns ................................................................... 27

Table 8 Troubleshooting tips ......................................................................................................................... 41

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 Valor light bar. 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 a.m. to 5 p.m., Monday through Friday

(CT).

Safety Message to Installers and Service Personnel of Warning Lights

People’s lives depend on your proper installation and servicing of Federal Signal

products. It is important to read and follow all instructions shipped with this product.

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 mechanical and electrical procedures and systems along with

proﬁciency in the installation and service of safety warning equipment. Always

refer to the vehicle service manuals when performing equipment installations on a

vehicle.

Light Hazards

• 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 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 dierent manufacturers

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

the components. You should verify or test your combination to ensure the system

works together and meets federal, state, and local standards or guidelines.

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.

6Valor®Light Bar

Federal Signal www.fedsig.com

Safety Messages

• 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 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. 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 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.

Installation, Maintenance, and Service Manual

Federal Signal www.fedsig.com

Safety Messages

• 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.

• 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 packed with the lighting system for proper electrical

connections, additional precautions, and information.

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

vehicle with a magnetically mounted warning light installed. The light could ﬂy

o 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 light bar 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 light bars tighten the hook-adjustment bolts 10 ft-lb to 11ft-lb. On all

other light bars tighten 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.

• To ensure proper operation, test all vehicle functions, including horn operation,

vehicle safety functions, and vehicle light systems. Ensure that the installation

has not aected the vehicle operation or changed any vehicle safety function or

circuit.

8Valor®Light Bar

Federal Signal www.fedsig.com

Safety Messages

• 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 de-activate 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.

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

installing the product.

Failure to follow these precautions may result in property damage, serious injury, or

death.

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

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

this fact and continue driving cautiously.

• 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.

• 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.

• 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.

• 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.

Installation, Maintenance, and Service Manual

Federal Signal www.fedsig.com

Safety Messages

• It is important that you fully understand how to safely operate this warning system

before use.

• Only operate your vehicle and its light/sound system per 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, you should ensure that the entire warning light system

and the siren system is securely attached and operating properly.

• Suction cup mounting is for temporary applications only. The unit should be

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

changes and sunlight can cause suction 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 o of the vehicle causing injury and

damage.

• Holding power of magnetic mounting systems is dependent upon surface ﬁnish,

surface ﬂatness, and thickness of the steel mounting surface. Therefore, to

promote proper magnetic mounting:

• Mounting surface and magnets must be 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.

10 Valor®Light Bar

Federal Signal www.fedsig.com

An Overview of the Valor®Light Bar

An Overview of the Valor Light Bar

The Valor 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. The light bar is shaped

to provide maximum intersection warning, the most dangerous situation in moving

trac.

LED Lights, Colors, and Flash Patterns

The light bar’s internal microprocessor supplies three priority operational modes

and a library of 27 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. Bright white LED takedown and alley lights that are horizontally adjustable

are also available with the HotFoot™conﬁgured option.

Multi-color heads are available with up to three dierent colored LEDs, eliminating the

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

Individual Valor lightheads can ﬂash between red, blue, amber, or white.

Modular Connector System

The Valor Light Bar has a waterproof (IP67) external connector system for power and

communication to allow removal of the light bar from the vehicle without opening the

light bar or the vehicle hood. The Valor is protected against reversed polarity damage.

The Valor Light Bar may be installed in any vehicle with a 12-volt negative ground

electrical system.

Controller Options

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

cable connects to the Serial Interface Module (Part Number 8583446), the Federal

Signal Six-Button Serial Controller (Part Number 8623133), the Three-Button Serial

Controller (Part Number 8623141), or the SmartSiren Series Platinum System or the

System control head only.

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

Signal light bar controllers, SignalMaster directional-light controllers, or by individual

low-current switch boxes.

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