Manual Rontan - Winglux - Rev 0

WingLux-S Installation, Operation & Programming Instructions

www.rontantech.com MPX.L01.L005-00 - Rev. 0 Page 1

This WingLux-S:

• Designed for multiple vehicle applications.

• Generic manual with specific information relative to the 20XX through the current Dodge Charger model, Chevrolet Impala model and Ford Crown Victoria model.

• Designed and intended to function as an emergency warning light, with take down, alley and directional stick options.

• SMD technology.

• Intended for roof mount application.

• Electrical operating system requirement of 12 volts DC, with a negative ground.

• Operated independently or in conjunction with Rontan light controllers (ICM40®, DSC40®, LC2000®, Intelligent Siren Controller – IS3000, etc.).

• Stores all flash patterns in the light assembly intelligence.

• Plug and play operability and modular design of the light heads facilitate installation, quick color changes, and field upgradeability.

• Vehicle specific. It may require some modifications when used with other models or applications.

• Engineered with Rontan two wire technology capability for ease of installation and quick programming.

Note: All Rontan North America products are SAE compliant and meet Calif. Title 13 standards.



Safety Message

WARNING

Before beginning installation of your lightbar, it is important to read these instructions that are important for the safe/correct installation and operation of this product. Proper installation of this product requires the installer to have a good understanding of automotive electrical systems and procedures. Light system controls must be located so that vehicle and controls can operate safely under all driving conditions. DO NOT install this product or route any wires in the deployment path of your airbag. Refer to the vehicle owner’s manual for the air bag deployment area. Before drilling into a vehicle structure, verify carefully if both sides of the surface are clear of anything that could get damaged. Install grommets into all wire passage holes. DO NOT drill any holes into the lightbar. A light system is a high current device. In order for it to function properly, a good electrical ground connection must be made. This lightbar is intended for use by authorized personnel only. The users have the responsibility to ensure they operate the emergency warning devices in compliance with the applicable laws and regulations. File these instructions in a safe place and refer to them when performing maintenance and/or reinstallation of this product. Failure to follow all safety precautions and instructions may result in damage to the product and vehicle or serious injury to individuals!



1. Specification

• Voltage: 12,8 V +/- 15%

• Electric Current Since the lightbar is customized, the current may vary according to the type of head lights and their colors. To calculate total current, you have to sum the use of the electric current of each head light, as seen below:

Table 1 - Single Color

LIGHT HEAD DESCRIPTION TOTAL # OF LEDs

ILLUSTRATION

MAX. CURRENT BY COLOR (A)

BLUE WHITE AMBER RED GREEN

Focal LED Modules TD & AL OR Prism Solid Lightbar LED Modules 4X1W

4

0.7 0.7 0.35 0.35 0.7

Prism Solid Lightbar LED Modules 4X2D

8

1.05 1.05 0.7 0.7 1.05

Prism Solid Lightbar LED Modules 3X1W

3

0.35 0.35 0.35 0.35 0.35

Reflective Solid LED Modules 3X1 3

0.35 0.35 0.35 0.35 0.35

Reflective Solid LED Modules 6X1 6 0.7 0.7 0.7 0.7 0.7 Reflective Solid LED Modules 9X1 9 1.05 1.05 0.7 0.7 1.05

Reflective Solid LED Modules 12X1 12 1.4 1.4 1.05 1.05 1.4

Table 2 - Dual color

LIGHT HEAD DESCRIPTION

TOTAL # OF

LEDs

ILLUSTRATION

COLOR COMBINATION MAX.

CURRENT (A) BLUE WHITE AMBER RED GREEN

Focal and Wide LED Modules TD & AL COMBO OR Prism Side by Side Lightbar LED Modules 4X2D OR Prism Stacked Lightbar LED Modules 4X2D

8

X X 1.05

X X 0.8

X X 1.05

X X 0.8

X X 1.05

X X 0.7

X X 1.05

Halogen lamp consumption:

• Maximum current (each light - steady burn): 3.3 A



• Maximum current (4 lights - steady burn): 13.2 A

• Medium current (4 lights - flash pattern): 6 A Total lightbar consumption with halogen lamps: Imax (A)= Imax LH(1) + 13.2 Imed (A)= Imax LH(1) x 0.6 + 6 Total lightbar consumption with no halogen lamps: Imax (A) = Imax LH(1) Imed (A)= Imed LH x 0.6

(1) Imax LH represents the maximal current of the light heads as seen in tables 1 and 2.

• Dimensions

2. Installation 2.1. Mounting the hardware Follow the steps bellow to a proper hardware installation: A. Locate and remove the 2 Phillips headed screws from each wire cover on each foot and remove the covers. Save the screws for installation later.



B. Insert the mounting bolts into the groove on the lightbar. Insert the longer bolt first

then the shorter bolt for each side.

C. Place the feet on the mounting bolts as shown and loosely tighten the nuts using a

1/2” wrench. Only use a washer on the taller bolt. Placing a washer on the shorter bolt will prevent the wire cover from seating properly.

D. Measure the distance of each corner from the vehicle ceiling. Use the formula below: Distance (in) = roof [width/2] – 13.5 The inner edge of the feet should be positioned from the center of the lightbar as shown and at the following distances:

Dodge Charger: 12¼ inches Ford Crown Victoria: 12 inches Chevy Impala: 12 inches



E. Before tightening the nuts on the individual feet, align each foot to the lightbar by

placing the edge of the foot parallel to the outer edge of the lightbar as shown.

F. Tighten nuts snugly (50 in-lb).

G. If necessary, use the supplied wedge shaped rubber foot pad in both magfoots to

adjust the angle of the lightbar if it is not level with the roof.



H. Connect the Take Down / Alley connectors on the feet to the mating connectors on the lightbar.

I. Place the wire covers on the feet using the screws removed earlier. Route the wires

through the openings as shown, to avoid pinching them. To insure proper fitment of the covers, the connectors will need to be positioned towards the larger (thicker) end of the cover.

J. Verify the fit of the covers. A properly fitting cover should be flush to the mating

surface to limit debris intrusion and wind noise.



K. While the lightbar is upside down, slide the cylinder nuts into the tab brackets as

shown. Ensure that the grooves in the cylinders engage as depicted.

L. Loosely installing the roof mounting brackets with the long threaded bolts can be

performed at this point or this task can be performed once the lightbar is appropriately positioned on the vehicle roof. Please note that installation at this point will mean that these metal pieces will be hanging loosely when the lightbar is positioned over the vehicle roof dramatically increasing the chances for damaging the vehicle surfaces during installation. Extreme care must be taken on your behalf to avoid vehicular damage.

M. If not previously completed, place the long threaded bolts through the large hole in the roof brackets as shown. Thread the bolt into the cylinder nut previously installed. Make sure that the bolt crossed the cylinder nut all the way though. A flat tipped screwdriver may be needed to properly orient the cylinder nut.



N. Loosely tighten the long threaded bolts to pull the brackets to the roof lip. Drill 7/64

inch pilot holes using the middle and outer 2 bracket holes as guides. Apply sealant (RTV) to the drilled holes. Fasten the brackets to the roof with the six Phillips headed sheet metal screws provided (3 per side). Once the brackets are secure, torque the long threaded bolt to 30 in-lb.

O. When using the supplied rubber grommet, drill a 3/4 inch hole in the roof

approximately as shown for routing the wiring for installation completion.

2.2 Routing the lightbar cable Route the light cable into the wiring shield and towards the firewall to minimize interior intrusion and to optimize wiring. Make sure you do not pinch or crush any wires when running them through the wire shield. The light cable has two power wires (RED and BLACK) and three control wires (GREEN, YELLOW and ORANGE). The end sections of each power wire has plural conductive wires - a terminal set composed by a positive terminal (RED) and a negative terminal (BLACK).



The following are general operation information to aid you in the use of the lightbar:

A) Install a fuse block on the end of the RED wire in the power cable. Use 40A fuse. B) Remove the fuse from the fuse block before connecting the wire to the battery.

Place the fuse back in the fuse block at the end of installation.

C) Connect the RED wire to the POSITIVE terminal on the battery.

D) Connect the BLACK wire to the chassis ground or the NEGATIVE terminal on the battery.

E) Route the control wires towards the controller or switch control panel.

F) Connect the three control wires to the controller or switch control panel.

G) Reinstall the fuse in the block.

Note: There are different connections between the lightbar and the controller or switch control panel. The controller can be controlled and programmed in analog or digital mode.



Electrical diagram 1

Note: Refer to the next section for information about operational and programming instructions. 3. Describing the lightbar functions This lightbar provides selectable multiple flash patterns that can be used in all functions: MODE 1-4, AUX 1-4 and EM 1-2. It is possible to have up to 4 steady burning lights active at one time. Below is a brief description of each control function:

MODE 1-4 provides four modes of preprogrammed flash patterns via slide control switch as described below:

• Mode 1 – Alternative corner light heads will be activated. The flashing take down and alley functions will NOT be activated automatically.

• Mode 2 – Most of the light heads will be activated. The flashing take down e alley functions will NOT be activated automatically.

• Mode 3 – All light heads will be activated for an intense warning effect. In mode 3, the flashing take down and alley functions will be activated automatically.

• Mode 4 (additional) - All light heads will be activated for an intense warning effect. In mode 4, the flashing take down and alley functions will be activated automatically.



AUX1 to AUX4: Several alternative preprogrammed flash patterns will be activated. ALLEY-L: LEFT side lights available in LED or halogen light heads. ALLEY-R: RIGHT side lights available in LED or halogen light heads. TAKE DOWN: FRONT lights available in LED or halogen light heads. Steady Burn (SB): Up to 4 LED light heads will be activated simultaneously. CRUISE: Some corner light heads will be activated in low power. Left Directional Stick (DS-L): The REAR light heads (usually amber lights) will be activated and produce a left arrow flashing pattern, instructing traffic to move LEFT. Right Directional Stick (DS-R): The REAR light heads (usually amber lights) will be activated and produce a left arrow flashing pattern, instructing traffic to move RIGHT. Center Directional Stick (DS-C): The REAR light heads (usually amber lights) will be activated and produce a center arrow flashing pattern, instructing traffic to move to either side of the vehicle. HAZARD: Hazard lights (usually amber lights) will be activated in the directional stick function in order to alert other drivers to a problem. EMERG SOS 1: A special preprogrammed flash frequency will activate specifically assigned light heads to be used in a specific situation in order to communicate a distress signal. EMERG SOS 2: A special preprogrammed flash frequency will activate specifically assigned light heads to be used in a specific situation in order to communicate a distress signal. DS1-L to DS8-R: Each input will activate each individual light head (usually amber lights) for directional signal purposes. CUT FRONT: Turn the frontal light heads OFF. CUT REAR: Turn the rear light heads OFF. DIMMER: The low power of the lightbar will be activated to decrease the brightness of LED light heads. BTT (Break /Turn / Tail): Special light heads will be activated in BREAK, TURN and TAIL functions. Available in ICM20 only. 4. Operational & Programming Instructions

4.1 Operating a compatible S-series digital controller in a digital mode



Most of the functions described above will be only activated and set up using a Rontan digital controller (E.g.: Rontan Intelligent Modular Siren - IS3000). Refer to the IS3000 manual for further information. To install the IS3000, proceed as follows:


4.2 Operating an analog controller in a digital mode An analog controller (E.g.: Rontan LC 500) will work with any Rontan ICM (Interface Control Modules) modules. The ICM modules are available in 4 models: ICM 10, 20, 30 and 40. The ICMs convert a 12-Volt input signal to a digital signal which operates the Rontan S-Series products. Activation can occur by constant 12v or Ground (GND). Refer to the ICM manuals for further information. To connect the controller to the ICM, proceed as follows:




4.3 Operating DSC40 in a digital mode

Using the DSC40 with no ICM, ONLY the Directional Stick (DSR, DSL, DSC) and HAZARD functions will be activated. Additionally, EMERGENCY SOS 1 and EMERGENCY SOS 2 can ONLY be used with toggle switches. For further information, refer to the DSC40 manual. To connect the DSC40, proceed as follows:


4.4 Operating in manual mode

To connect the lightbar in manual mode, proceed as follows:




Functions are activated by applying +12V DC to a control wire. The control wire functions are:

• Orange: MODE 4 function. +12V DC Input

• Green: Steady Burn function. +12V DC Input

• Yellow: Flash pattern selection.

Switching the flash patterns (cycle forward though available patterns)

WIRE FUNCTION ACTION RESULT

GREEN Stead Burn Must be open

ORANGE Flash Must be tied to +12V

YELLOW PRG Open + (+12V) + Open _||_ >>> cycle to next flash pattern

Note:

• The first pattern is blank (all light heads off). Switching the steady burn lights WIRE FUNCTION ACTION RESULT

GREEN Stead Burn Must be tied to +12V

ORANGE Flash Must be open

YELLOW PRG Open + (+12V) + Open _||_ >>> cycle to next light head



Notes:

• The end of the flash pattern is signified with a “blank” flash pattern (all light heads off).

• It is possible to have up to 4 preprogrammed steady burning lights active at one time. However, only one steady burn light will be activated when the above procedure is conducted. It is possible to reactivate the 4 preprogrammed steady burning lights using a Rontan digital controller.

• Some WingLux models do not include the steady burn function in certain light heads.



Different applications require different functions. Use the table below for further information of all the functions available for each operational mode:

Digital

Controller in Digital

Mode

Analog Controller in Digital Mode using

Interface Control Master DSC40 in

Digital Mode

Manual Mode ICM40

ICM30

ICM20

ICM10

Mode 1 to 4 Only mode 4

AUX1 to AUX4

ALLEY-L/R / TD

SB

CRUISE

DS-L / C / R

(1)

(1)

HAZARD

(1)

(1)

EMERG SOS 1/2

(1)

(1)

DS1L to DS8-R

CUT FRONT

CUT REAR

DIMMER

BTT

Note: (1) When a DSC40 is connected to an ICM (Electrical diagram 3).

Operational

Mode

Feature



5. Maintenance To conduct basic maintenance instructions, some automotive electrical knowledge is necessary.

Figure 1 – Basic diagram of the lightbar

5.1 Changing a light head

For light head replacement, proceed as follows:

A) Before working on the light, disconnect the lightbar from power source or remove the internal fuse.

B) Remove the dome clips that hold the lightbar dome. Insert a screwdriver at each corner and pull the dome off gently.

C) Disconnect the 4-pin connector from the light head.

D) Remove the two Phillips headed screws. E) Unplug the defective light and plug the new light head into the lightbar and

reconnect the 4-pin connector.



F) Reconnect the lightbar to power source or replace the internal fuse. G) Performing Polling: You must perform the polling procedure (using an ICM

device) or just using the wires. Otherwise, the lightbar will not activate the flash patterns properly. For further information, go to section 5.3.

H) After performing the polling procedure, place the dome back on the lightbar base

and secure it using the dome clips removed earlier.

Note:

This lightbar has different electronic board types. The first electronic board is the motherboard (MBLD). It is located on the first light head, and connected to the external electrical harness. In case the motherboard needs to be replaced, call technical assistance for the motherboard model specific to your lightbar.



5.2 Changing a halogen take down or alley light



Magfoot ITEM QTY DESCRIPTION

1 1 Magfoot Base plate

2 2 Rubber foot Pad

3 2 M8 DIN 125 A2 S/S flat washer

4 2 5/16-18 Stainless steel nylon insert lock Nuts

5 1 5/16-18 x 2” Stainless steel tap bolt or 5/16-18 x 4” Extended stainless steel tap bolt

6 1 Roof mounting bracket

7 2 5/16-18 x 3/4” Stainless steel tap bolt

8 1 Cylinder nut

9 1 Magfoot assembly Cover

10 2 Cover Screws

11 3 Zip-ties

Assembly light ITEM QTY DESCRIPTION

A 1 Light Cap B 1 Rubber seal

C 1 Halogen Lamp (MR 11- 12V / 35W) D 1 MR 11 alignment bracket

E 1 Ceramic plug F 1 Rubber O-ring

G 1 Socket H 1 Rubber grommet

For external halogen lamp replacement, proceed as follows:

A) Before working on the light, disconnect the lightbar from power source or remove the internal fuse.

B) Remove the light cap by turning counterclockwise to release.

Note: Confirm if the rubber seal is on the lamp or the outside edge of the cap. Replace the rubber seal if it is stretched, worn thin anywhere, or has a hole torn in it.

C) Gently slide the light out of the socket.



D) Hold the ceramic plug tightly and pull the light carefully.

P.S.: Pull the light from the ceramic plug with a moderate tug of the hand to prevent rupturing the wires.

Incorrect Correct

E) After unplugging the old light from the ceramic plug, pull the MR 11 alignment

bracket off the defective light and place it on the new lamp. Connect the new lamp into the ceramic plug.

F) Position the new light into the socket.

P.S.: Notice that the light will NOT fit the socket completely.

G) Position the new lamp into the socket. Depress and rotate the light clockwise until

the locking pins of the MR 11 alignment bracket align with the 2 internal holes of the socket.

H) Position the rubber seal on the outside edge of the cap and the outer o-ring over the end cover.

I) Make sure the rubber seal and outer o-ring are positioned properly to prevent water and dirt from entering inside the lamp. Turn the cap clockwise.

J) Confirm if the outer o-ring and rubber seal are positioned properly. In case the outer o-ring is exposed, remove the cap and place it back on. Ensure the rubber seal is positioned symmetrically.



Correct

K) Reconnect the lightbar to power source or replace the internal fuses. Note: It is NOT necessary to perform pooling after take down/alley light replacement.

5.3 Polling Polling is an important procedure to ensure the lightbar operation. When replacing an LED board or module in a Rontan S-Series product, you must perform a Polling upon installation to allow the lightbar to recognize and include the new application.

In this process, all the LED lights receive a sequential number. Additionally, the motherboard identifies information such as:

a) Total LED light heads b) Presence of takedown/alley lights

This process also verifies if the control wires were connected correctly, and not switched.

Polling can be performed with all the compatible Rontan S-series controllers. Refer to each controller manual for instructions. Manual Polling Function:

Polling has basically 3 steps:

First Step – Identifying the light heads and light sequence

This first step is used to identify internal communication problems that may occur in the lightbars. The connection between the motherboard and the light heads occurs in sequence (MB > 1°LH > 2ºLH > 3ºLH > 4ºLH >…). For example, information will get to

WIRE COLOR FUNCTION ACTION RESULT

GREEN Stead Burn Must be tied to +12V

ORANGE Flash Must be tied to +12V

YELLOW PRG Open + (+12V) + Open _||_ Start 1ª Step-Identification

YELLOW PRG Open + (+12V) + Open _||_ Start 2ª Step -Show Connection Mode

YELLOW PRG Open + (+12V) + Open _||_ Start 3ª step - Show firmware version

YELLOW PRG Open + (+12V) + Open _||_ Stop all process



the third light head after going through the first and second light head and so on. It is very important to verify the correct light sequence of the LED light heads.

When the manual polling process is initialized, the first light head will be activated for approximately 1 sec. Each individual light head will flash sequentially. If TD and alley lights are included in the lightbar, they will be also activated sequentially. Once the last light head is reached, the next pattern will cycle back to light head #1. This cycle will be repeated 10 times. Once the operation of the lightbar is verified, simply tap the YELLOW wire into the RED wire and proceed to the next step.

How to verify the problems in the light heads:

• The communication between the motherboard and the light heads is CORRECT if the lights flash sequentially.

• The communication between the motherboard and the light heads is INCORRECT if the lights flash rapidly and simultaneously, or if the communication does not run through one of light heads, which means that the communication problem occurred between the last active light and the following inactivate light. The error may have occurred because of an electronic defect or an interrupted internal electrical harness.

Second Step – Verifying firmware version

The first light head of the lightbar will flash in order to specify the firmware version on the MB. E.g.: Version 1.8 (V1.8):

☼▫▫▫▫☼▫☼▫☼▫☼▫☼▫☼▫☼▫☼▫▫▫▫

Third Step – Verifying the activation mode

Similar to Step 2, the first light head of the lightbar will flash in order to specify the activation mode of the lightbar. E.g.: Activation Mode (Mode 6):

☼▫☼▫☼▫☼▫☼▫☼▫▫▫▫

Description:

☼= Short Flash ☼= Long Flash

▫ = Short Interval ▫▫▫▫ = Long Interval



6 Warranty message

For warranty information regarding this product, please visit: www.rontantech.com/eng/warranty

Documents

Manual Rontan - Winglux - Rev 0