INSTALLATION AND MAINTENANCE INSTRUCTIONS FOR LEGEND® LIGHTBAR · INSTALLATION AND MAINTENANCE...

2562246AREV. A 907Printed in U.S.A.

INSTALLATION AND MAINTENANCE INSTRUCTIONS FOR

LEGEND® LIGHTBAR

SAFETY MESSAGE TO INSTALLERS OF FEDERAL SIGNAL LIGHT SYSTEMS

People’s lives depend on your safe instal­lation of our products. It is important to read, understand and follow all instructions shipped with the products. In addition, listed below are some other important safety in­structions and precautions you should follow:

• Toproperlyinstallalightassembly:youmusthaveagoodunderstandingofautomotiveelectricalproceduresandsystems,alongwithproficiencyintheinstallationanduseofsafetywarningequipment.

• Wheninstallingequipmentorwiringinsideairbagequippedvehicles,theinstallerMUSTen-surethattheequipmentorwiringisinstalledONLYinareasrecommendedbythevehiclemanufacturer.Failuretoobservethiswarn-ingwillreducetheeffectivenessoftheairbag,damagetheairbag,orpotentiallydamageordislodgetheequipment,causingseriousinjuryordeathtoyouorothers.

• Whendrillingintoavehiclestructure,besurethatbothsidesofthesurfaceareclearofany-thingthatcouldbedamaged.

• Alightsystemisahighcurrentdevice.Inorderforittofunctionproperly,aseparategroundconnectionmustbemade.Ifpractical,itshouldbeconnectedtothenegativebatteryterminal.Ataminimum,itmaybeattachedtoasolidmetalbodyorchassispartthatwillprovideaneffectivegroundpathaslongasthelightsystemistobeused.

• LocatelightsystemcontrolssotheVEHICLEandCONTROLScanbeoperatedsafelyunderalldrivingconditions.

• ThisproductcontainshighintensityLEDde-vices.Topreventeyedamage,DONOTstareintothelightbeamatcloserange.

• Youshouldfrequentlyinspectthelightsystemtoensurethatitisoperatingproperlyandthatitissecurelyattachedtothevehicle.

• Filetheseinstructionsinasafeplaceandrefertothemwhenmaintainingand/orreinstallingtheproduct.

Failure to follow all safety precautions and instructions may result in property damage, serious injury, or death to you or others.

I. GENERAL.

TheLegendisasinglelevelLEDlightbar,employingROC“BigBoard”technologyandSolarisS2reflectors.Thebaroperatesatanominalinputof13.6VDC(11VDCminimum).ThebasiclightfunctionsoftheunitarecontrolledviatheCAT5serialcommunicationcable.ThecableconnectstoeitheracompatibleFederalSignalSerialcontrolhead,or,aFederalSignalSerialInterfaceModule,8583446.AninternalPCBassembly,withinthelightbar,decodesthecontroldataandperformstherequestedfunction.Withtheinterfacebox,thebarmaybeactivatedbyFederalSignallightbarcontrollers,Signalmastercontrollers,and/orindividuallowcurrentswitches.Thebackboneisanaluminumextrusionandthebasesandtopsaremoldedpolycarbonate.Thebarshavetwenty-one-footpowerandgroundcables,andatwenty-five-footserialcable.MountinghardwareisaConfiguredoption.Refertomountinginstructionssuppliedwithmountinghardware.Thebarshaveanoperatingtemperaturerangeof-30°Cto+65°C.

II. UNPACKING.

AfterunpackingtheLegendlightassembly,inspectitfordamagethatmayhaveoccurredintransit.Iftheunithasbeendamaged,donotattempttoinstalloroperateit.Fileaclaimimmediatelywiththecarrier,statingtheextentofdamage.Carefullycheckallenvelopes,shippinglabels,andtagsbeforeremovingordestroyingthem.

III. INSTALLATION.

Improper warning system and/or two­way radio system operation may result if a two­way Radio antenna installed on, or within 18­inches of, the lightbar. Before permanent installation of the lightbar or a two­way radio antenna, test the warning system and two­way radio system. DO NOT install a two­way radio antenna on the lightbar.

Some installations may require relocation of the two­way radio antenna to a trunk or fender location.

Warning system failure may result if addi­tional holes are drilled in the lightbar, or if auxiliary devices are installed on the light­bar. DO NOT drill additional holes in the lightbar, or install auxiliary devices on the lightbar.

NOTE

IftheinternalSignalMasteroptionwillbeused,thelightbarshouldbeconfiguredpriortomechani-calmounting.RefertoparagraphG,SignalMasterControls.

A. General.

Beforeproceeding,ensurethatthelightbarhasbeeninstalledonthevehicleroofinaccordancewiththeinstructionspackedwiththemountingkit.

Thelightbariscompletelywiredatthefactoryanddoesnotrequireanyadditionalinternalwiring;two10AWGpowerconductors(redandblack)andtheCAT5communicationcableexitthelightbar.AlltheconductorsnecessaryforcontrolofanyandallbasicandoptionalfunctionsarecontainedintheCAT5cable.ThebasiclightfunctionsoftheunitarecommunicatedviatheCAT5cable.ThecableconnectstoeitheracompatibleFederalSignalSerialcontrolhead,or,aFederalSignalSerialInterfaceModule.

Light system controls must be located so that the VEHICLE and CONTROLS can be oper­ated safely under all driving conditions.

B. Seefigure1.Ensurethatthelinesareadequatelyfusedasshown.Fromthelightbar,routetheCAT5controlcableintothevehicle’scabortrunkneartheeventuallocationofthecompatibleFederalSignalSerialcontrolheadorFSC#8583446InterfaceModule.AninputcableisalsoprovidedwiththeFSC#8583446SerialInterfaceModule.

Reversepolaritymaydamagethelightbarandpreventoperation.Ensurethatcorrectpolarityisobserved.Unitmustbefusedatthesource.

C. Routeandconnecttheseparate10gaugeblackleadtothevehiclebatteryground(-)terminal.

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D. Routeandconnectthe10gaugeredlead,throughthesupplied40Afuse,fusedatthesource,totheBAT+terminal.

E. SignalMaster Option.

TheSignalMasterfunctioniscompletelyconfiguredatthefactoryanddoesnotrequireanyadditionalwiringinsidethelightbar.AllconductorsnecessaryforcontroloftheSignalMasterisviathecompatibleSerialcommunicationcontrolheadortheFSC#8583446SerialInterfaceModule.Forwiringandoperationinstructions,refertotheinstructionsheetpackedwiththeapplicablecontrolheadortheFSCSerialInterfaceModule’sInstructionsheet(partnumber2562248).Thelightbar’sSignalMasteroperationisfactoryconfiguredforusewithaFederalSignalSignalMastercontrollerorSS2000SMseriessiren(EXTERNALconfiguration).

F. Light Bar Controls.

TheLegendS2functionsarecommunicatedviatheCAT5serialcable.BoththeFederalSignalSerialControlHeadandtheSerialInterfaceModulearecapableofprovidingthefollowingcontrolstothelightbar.Forprogrammingoptions,refertotheInstallationManualshippedwiththeInterfaceModuleortheFederalSignalSerialControlHead. 1. MODE1- 2. MODE2–overridesMODE1; 3. MODE3–OverridesMODES1&2; 4. STEADYBURNRED 5. FRONTCUTOFF 6. REARCUTOFF 7. INTERSECTION 8. FLASHHALOGEN 9. LEFTALLEY 10. RIGHTALLEY 11. TAKEDOWN 12. LOWPOWER 13. LIGHTBARTESTPATTERN

G. SignalMaster Controls (INTERNAL configuration).

ToconfigurethelightbarforINTERNALSignalMasteroperation,seefigure2andrefertoparagraphV.6.a,PCBControllerreplacement.Movethejumperfromthe“E”positiontothe“I”position. ThefollowingpatternsareaccessiblewithINTERNALconfiguration:

1. LEFT 2. CENTER 3. RIGHT 4. WARN1 5. WARN2 6. WARN3 7. WARN4 8. FAST

H. Typical Installations.

Fortypicalinstallationswithcommoncontrolsystems,seeinstallationwiringdiagrams1,2,3,and4attheendofthisdocument.

Figure 1.

290A5656B

LIGHTBAR

FSC SERIAL INTERFACE MODULEPART #8583446 REFERENCEINSTRUCTION SHEET 2562248

SERIAL, CAT5., CONTROL CABLE

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RED 10AWG

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290A5657

EXTERNALSIGNALMASTER CONFIGURATOR

INTERNALSIGNALMASTER CONFIGURATOR

15A FUSES

Figure 2.

IV. OPERATION.

This product contains high output LED de­vices. To prevent permanent eye damage, do not stare into the light beam at close range.

NOTE

Applying12VDCtotheappropriatecontrollineandignitionwireontheSerialInterfaceModulecanactivateallthelightbarfunctions.The10gaugeblackandredpowerleadsmustbecon-nectedtotheirrespectivebatteryterminalsforafunctioncheck.

Afterinstallation,checktheentiresystemtobesurethelightsareflashingproperlyandalllightsystemfunctionsareoperatingproperly.

SAFETY MESSAGE TO OPERATORS

People’s lives depend on your safe use of our products.

Listed below are some important safety in­structions and precautions you should follow:

• Althoughyourwarningsystemisoperatingproperly,itmaynotbecompletelyeffective.Peoplemaynotseeorheedyourwarningsig-nal.Youmustrecognizethisfactandcontinuedrivingcautiously.

• Also,situationsmayoccurwhichobstructyourwarningsignalwhennaturalormanmadeob-jectsarebetweenyourvehicleandothers,suchas:raisingyourhoodortrunklid.Ifthesesitu-ationsoccur,beespeciallycareful.

• ThisproductcontainshighintensityLEDde-vices.Topreventpermanenteyedamage,DONOTstareintothelightbeamatcloserange.

• Atthestartofyourshift,youshouldensurethatthelightissecurelyattachedandoperat-ingproperly.

Failure to follow these safety precautions may result in property damage, serious injury, or death to you, to passengers, or to others.

RETAIN AND REFER TO THIS MESSAGE

V. MAINTENANCE.

Crazing (cracking) of lenses will cause reduced effectiveness of the light. Do not use cleaning agents (which will cause craz­ing) such as strong detergents, solvents, or petroleum products. If crazing of lenses does occur, reliability of light for emergency sig­naling purposes may be reduced until lenses are replaced.

Afterprolongedoperation,theunitgetshotandcancauseburns.Donottouchtheunitwhileorshortlyafterithasbeenoperating.Alwaysallowtheunittocoolbeforehandling.

A. General.

Ordinarycleaningoftheplasticlensescanbeaccomplishedbyusingmildsoapandasoftrag.Shouldfinescratchesorahazeappearonalens,theycanbestberemovedwithaspecialtyplasticcleaner/polishsuchasPlexus®andasoftcloth.Alternatively,non-abrasive,highquality,one-step,automotivepastecleaner/waxmaybeused.

B. Top Removal (see figure 3).

Donotovertightennuts.

RemovethePhillipsheadbarrelnutsthencarefullyremovethetoptoavoiddamagingthelipseal.Verifythatano-ringisundertheheadofeach

290A5658

Figure 3.

290A5659PCB GROUND NUT

ADJUSTING SCREW LOCK NUT

Figure 4.

barrelnutandnotstucktothetop.Ifnecessary,useawoodenorplasticpicktoremovetheo-ringfromthetoptopreventtearingtheo-ring.Inspectlipseal(onbase)ando-ringstoinsuretheyarenottorn,brittle,ordamaged.Replaceifnecessary(seereplacementparts).Topreventcross-threadingonreassembly,backthebarrelnutcounterclockwiseuntilanaudibleclickofthethreadsengagingisheard,thentightennormally.

C. Halogen Lamp Adjustment (see figure 4).

Donotovertightenscrews/nuts.

RemovethetopperparagraphV.B.above.Thehalogenlampsareadjustablehorizontally+/-8degreesandvertically+2degrees/-5degrees.

a. Horizontaladjustment:Loosenthelocknutwitha3/8”wrenchwhileholdingtheadjustingscrewwithasmallscrewdriver.Movelampaimtodesiredposition,thencarefullytightenlocknutwiththewrenchwhileholdingadjustingscrewwithscrewdriver.

b. Verticaladjustment:Loosenthelocknutwitha3/8”wrenchwhileholdingtheadjustingscrewwithasmallscrewdriver.Turnadjustingscrewclockwisetolowerpointofaim,counter-clockwisetoraisepointofaim.Oncepositioned,carefullytightenlocknutwithwrenchwhileholdingadjustingscrewwithscrewdriver.

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D. Halogen Lamp Replacement.

A serious injury may result if the lamp is touched when hot. Always allow lamp to cool before removing. Halogen lamps are pressur­ized and if broken can result in flying glass. Always wear gloves and eye protection when handling lamps.

Servicelifeofthelampwillbeshortenediftheglassportionistouched.Iftheglasshasbeenhandled,cleancarefullywithagreasesolvent.

a. Takedownlamps:Seefigures4and5.RemovetopperparagraphV.B.RemovePCBgroundnut,theninvertPCBtoaccesslamp.Seethereplacementpartslistandreplacethedefectivelampwithanexactreplacementonly.Assembleinreverseorder.Donotovertightennuts.

b. Alleylamps:Seefigures4and6.RemovetopperparagraphV.B.RemovePCBgroundnut,theninvertPCBtoaccesslamp.Witha1/16”hexkey,removethelampretainingscrewsandclamps.Slidelampandsocketfromhousingjustfarenoughtograspsocket(itmaybenecessarytounplugconnectortogainadequateslackinleads).Holdingsocketfirmly,unpluglamp.Seethereplacementpartsandreplacethedefectivelampwithanexactreplacementonly.Assembleinreverseorder.Donotovertightenscrewsandnuts.

E. Cleaning Reflector Assemblies.

Useasofttissuetocleanreflectors.Avoidheavypressureandtheuseofcaustic,abrasive,orpetroleum-basecleaners,whichwillscratchordullthesurface.

F. PCB Controller Replacement (see figure 7) and Halogen/LED Head Fuse Access.

1. RemovethepassengersideenddomeperparagraphV.B.,removethePCBgroundnutfromtheendPCB,andinvertPCB,notinggroundleadplacementongroundbracket.

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290A5660

Figure 5.

290A5661

Figure 6.

290A5662

Figure 7.

2. Noteandrecordconnections,thendisconnectwiresandharnesses.

3. CompressthelocktabonthenylonstandoffsandremovecontrollerwithstandoffsfrommainPCB.

4. Compresssecondarylocktabsandremovestandoffsfromcontroller.

5. Assemblyisthereverseofdisassembly.Ensuregroundleadsareinplace.Donotovertightennuts.

G. PCB Replacement (see figures 4 and 7).

1. RemovedomeperparagraphV.B.,removethePCBgroundnut,andinvertPCB.

2. Noteandrecordconnections,thendisconnectwiresandharnesses.

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3. Ifrequired,removecontrollerperparagraphV.F.3.

4. Assemblyisthereverseofdisassembly.Ensuregroundleadsareinplace.Donotovertightennuts.

H. Fuse Replacement (see figure 2).

Four15AfusesareonthePCBController.AccessthefusesperparagraphV.G.1.

I. Base Replacement (see figure 8).

1. RemovetopperparagraphV.B.,andPCBsperparagraphV.G.1.andV.G.2.

2. Removegroundbracketnut,groundbracketwithlockwasher,baseretainerscrew,and(cableentrysideonly)cableholddownclamp.

3. Ifthebarisonthevehicle:Slidebasefromextrusion,catchingthecarriageboltsastheyarefreedfromthechannels. Ifthebarisoffthevehicle:Invertbaronclothorcardboardtopreventscratchingthetops,thenslidebasefromextrusion.Carriageboltscanthenberemovedfrombase.

290A5663

Figure 8.

4. Removeventplugsand/orgrommetfrombase.

5. Besurenewbasehasnewendgasketandlipseal.

Ifthebarisonthevehicle,proceedasfollows:

Startbaseontoextrusion,insertthefirsttwocarriagebolts(long)intotheirrespectivewells,thenholdtheboltsupwhileslidingthebasefurtherontotheextrusion.Ifdesired,thetopbarrelnutsmaybetemporarilyinstalledtoholdtheboltsinposition.Repeatwiththegroundcarriagebolt(short),slidingthebaseonjustfarenoughtotrapthebolt,thenrepeatwiththetworemaininglongcarriagebolts.

Ifthebarisoffthevehicle,proceedasfollows:

WiththebarstillinvertedfromparagraphV.H.3.,startbaseontoextrusion,thendropthecarriageboltsintotheirrespectivewells(thegroundboltistheshortone).Slidethebaseontotheextrusion

6. Applyendpressuretobasetogetaflushfitbetweenthebasesbeforeinstallingbaseretainerscrew.Remainingassemblyisthereverseofdisassembly.Ensureastarwashergoesontothegroundscrewpriortoinstallingthegroundbracketandthatallgroundleadsareinplace.Donotovertightennuts.

J. Lip Seal Replacement (see figure 9).

RemovetopperparagraphV.B.Notethejointpositionoftheseal,thenremoveoldlipseal.Installthesealwiththefinsangleddownwardasshown,positioningthejointinthesamepositionasoriginal(slightlyoff-centeralongthestraightsurfacewherethebasesmate).Theedgeofthesealshouldbeflushwiththetopsurface.

290A5664

Figure 9.

VI. REPLACEMENT PARTS.

Description PartNo.

PCBAssembly,End(Configured) ContactFactoryPCBAssembly,Intermediate(Configured) ContactFactoryPCBAssembly,Center(Configured) ContactFactoryPCBAssembly,Controller 2005429-1234PCBAssembly,Controller, 2005429-124SteadyBurnRedDS(CA)PCBAssembly,Controller, 2005429-234SteadyBurnRedDS&PS(CA)Lamp,HalogenAlley,35W,MR-11 8107241Lamp,HalogenTakedown,50W,GH-8Bi-Pin8107169Fuse,Mini,15Amp 148181-06Fuse,Maxi,40Amp 148182-01Seal,Lip,Clear(5.5ftperendsection; 8583020-01 3.5ftpercentersection)Gasket,End 8653110O-Ring,DomeNut 7067016Base,End 8653100Top,End,Clear 8653101Top,End,Amber 8653101-02Top,End,Blue 8653101-03Top,End,Red 8653101-04Base,Center 8653102Top,Center,Clear 8653103Top,Center,Black 8653103-01Top,Center,Amber 8653103-02Top,Center,Blue 8653103-03Top,Center,Red 8653103-04

Manufacturedby: FederalSignalCorporation EmergencyProductsGroup 2645FederalSignalDrive UniversityPark,Illinois60466 1-800-433-9132

Copyright 2007 Federal Signal Corporation

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VII. INSTALLATION WIRING DIAGRAMS.

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