INTEGRITYTM Lightbar
Contents
1. SNOILONYLSNI 39IA3Q SNOLLO3NNOO SNINIVIA3H T3NVd HOLIMS 41 INTEGRITY Lightbar Maintaining and Servicing the INTEGRITY Chapter 5 Figure 6 3 Typical connections with a SmartSiren Model 5520005 controller 58795706 3OVJH3LLNI 1 5 LHM Vi Adallva Ach 1 1 1 4 NHu9 Q3H IHAVXIS NHO 9 LL orig 01 ANON SNOILONYLSNI 39IA3Q SNOILOSNNOO 15000255 3509 H31SVWTIVNOIS a3u euo 77 18 NH5 Sindino xnv GOW 13 15000255 SNOLLO3NNOO TVOIdAL INTEGRITY Lightbar 42 Maintaining and Servicing the INTEGRITY Chapter 5 Figure 6 4 Typical connections with a non SignalMaster controller 7871065 S1vO LHM JINON 39V3H3LNI 1 5 Vi M18 oS wee 14 X 18 03H a3u ouo 7 a1 18 1HM a3482. lt NHO St LHMW18 NYD 9uol NH9 9uO OIA 1 980 73A li na HIM 12 V BATTERY n CONNECTIONS PER DEVICE INSTRUCTIONS SIGNALMASTER CONTROLLER REMAINING INTEGRITY LIGHTBAR 290A7487 INTEGRITY Lightbar Maintaining and Servicing the INTEGRITY Chapter 5 Figure 6 2 Typical connections with a Model SW400SS Switch Module internal control 28227062 NOILISOd NMOG 3H L OL SOd HOLIMS did ZMS 3AON OL JAOIN SLVO AH3LIV8 A ia L Or LHM vi 275 Q 14 X18 NH9 a3u ouo r18 1HM aau ria SGOW t Ma 77 SNOILONYLSNI 39IA3Q 2000 SNOLLO3NNOO ONINIVWSY HOLIMS Ei H31SVWTVNSIS 1VNH3LNI SNOLLO3NNOO TWOldAL LHOIH LHWX T8 NH9 H31N39 NH9 1Sv4 LNHVM 1437
3. WARNING detergents solvents and petroleum products can cause crazing cracking of the lightbar lens and reflectors To clean the reflectors use a soft damp cloth To clean the lens use a soft cloth and a solution of water and a mild detergent A WARNING CRAZING CHEMICALS Crazed cracked or faded lenses or reflectors reduce the light output and the effectiveness of the lighting system A lens or reflectors showing this type of aging must be replaced Failure to follow this warning may result in bodily injury or death EQUIPMENT DAMAGE Do not use a pressure washer to clean the lightbar Failure to heed this notice will damage the lightbar To clean the lightbar lens 1 Rinse the lens with lukewarm water to loosen dirt and debris 2 Usea mild detergent lukewarm water and a soft cloth to gently clean the lens To avoid damaging the finish do not use heavy pressure or caustic abrasive or petroleum based cleaners Integrity Lightbar 31 Chapter 5 Maintaining and Servicing the INTEGRITY 3 Rinse and dry the lens with a soft cloth to prevent water spotting 4 remove fine scratches and haze use a soft cloth and a high quality automotive paste cleaner wax that Is non abrasive Removing and Reinstalling the Lightbar Lens The lightbar lens which is the top half of the INTEGRITY housing covers the ROC Reliable Onboard Circuitry PCBs and controller PCB Tool required v 27
4. t ASTU JUST JEU SNOILONYLSNI 39IA3Q SNOLLO3NNOO SNINIVIA3H HOLIMS TX Dex SUNL H3 1SVWTVNOIS NON SNOLLO3NNOO TVOIdAL Ad3Lllva L 43 INTEGRITY Lightbar Wiring the INTEGRITY Lightbar the Vehicle Chapter 4 Figure 6 5 Typical connections with a Model PA640 PA64000 controller 5871 7065 day OF X18 SMV OL cg LHM AOVAYALNI TVIH3S LOH 00079 SNOLLO3NNOO TVOIdA L 08 asnd 3HInO3H S391430 1 QQv NOLLVTIVISNI NMOHS AH3LIV8 A voe 3Sf IXVIN vor v Oc X18 DMV T 81 NnH LOH NOLLINSI 996552 LHS LSNI 33S SNOLLOQHLISNI 391430 SNOLLO3NNOO SNINIVIA3H 000079 0r9 vd day 8 SA0V1d 2 3snd 993 523 23837 DEB Bae Sur ed 298 O44 lI mom INTEGRITY Lightbar 44
5. Lighting Option Current Draw Lamp Technology Reflector Style LED all heads 1 0A in Steady Burn Mode High brightness LED Offset compound curve polished reflector with standard mounting feet Electrical and Temperature Model Electrical Potential Current Draw Operating Temp 50 Flash Rate INTEGRITY44 12 8 11 0A 40 F to 149 F 40 C 50 to 65 C 13 0 A with HotFoot INTEGRITY51 12 8 13 0A 40 F to 149 F 40 C 50 to 65 C 15 0 A with HotFoot Integritym Lightbar CHAPTER 3 Reprogramming the Lightbar A WARNING HEAVY OBJECT Use lifting aids and proper lifting techniques when removing or replacing this product Failure to follow this warning may cause personal injury Carefully unpack the lightbar 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 AM to 5 PM Monday through Friday CT Reprogramming the Lightbar Although the INTEGRITY lightbar is configured and programmed at the factory you may want change default settings and flash patterns before yo
6. 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 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 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
7. F FEDERAL SIGNAL INTEGRITY Lightbar Installation Maintenance and Service Manual 25500063A REV A0 913 Printed in U S A Chapter T Safety 6 Safety Message to Installers and Service Personnel of Warning 6 Safety Messages to Operators of Federal Signal Sound Light 9 Chapter 2 An Overview of the Integrityrw Lightbar 11 LED Lights Colors and Flash Patterns tre eene 11 Electrical SII HTC TT T 11 Controller Options tetra bo 11 Ambient Light Sensor AutoDim Option 11 Product Speciticatiolls 12 Chapter 3 Reprogramming the 13 Reprogramming the Lightbar ssis E E EER E EEEE EEEE EEES 13 Making the Electrical Connections for Reprogramming 14 Identifying Switch and Jumper Settings 15 Selecting Internal SignalMaster Control eene nnne 16 Selecting External SignalMaster 1 enne eene nennen 16 Identifying the Control Wires for Flash Patterns sissisotaa aaen 17 Britern
8. 3 Reprogramming the Lightbar Identifying the Control Wires for Flash Patterns This section describes how to program flash patterns by applying 12 Vdc to the control wires in the 24 pin harness of Serial Interface Module Table 3 2 shows the control wires and their colors The wire s first color is the predominant color and additional colors are stripes Table 3 2 Control wires from the Serial Interface Module Lightbar Controls Wire Color Description MODE 1 Blue Lowest priority MODE 2 Blue White Overrides MODE 1 MODE 3 Black Red Overrides MODES 1 and 2 STEADY BURN Red White One or more LEDs steadily burn when 12 Vdc is applied to the control wire for a MODE and the control wire for STEADY BURN FRONT CUTOFF FRONT ENABLE Green White Turns OFF the FRONT of the lightbar Turns ON the FRONT of the lightbar REAR CUTOFF REAR ENABLE Orange Black Turns OFF the REAR of the lightbar Turns ON the REAR of the lightbar INTERSECTION Blue Black Typically a high activity pattern Overrides all three priority modes FLASH TAKEDOWN ALLEY Red Black Flashes the ALLEY and TAKEDOWN lights in MODES 1 2 or 3 LEFT ALLEY Green Black Turns on LEFT ALLEY lights Overrides the FLASH TAKEDOWN ALLEY lights RIGHT ALLEY Orange Red Turns on RIGHT ALLEY lights Overrides the FLASH TAKEDOWN ALLEY lights TAKEDOWN White Black Provides white li
9. Ib in the sequence shown in Figure 5 1 on page 32 3 Reconnect power to the lightbar Resetting the Controller These instructions explain how to reset the Valor lightbar controller after you install a service replacement board or if the lightheads operate erratically For the Valor lightbar to operate correctly the controller stores information about which LED colors it controls Resetting the lightbar controller may be necessary if you replace the controller board or if the LEDs flash erratically To scan which colors are available at the end of the reset cycle the controller briefly flashes all LEDs simultaneously Be sure to perform the reset cycle on a vehicle with a well charged battery Failure to do so may cause the lightbar to flash or operate incorrectly To reset the controller 1 Remove the barrel nuts and lens from the lightbar See Removing and Reinstalling the Lightbar Lens on page 32 NOTE If you are replacing the controller ensure that power to the lightbar is off then disconnect all connectors to the controller Install the new controller and re connect all cables to the controller board 2 Connecting the main power and ground wires from the lightbar to the battery 3 Apply ignition power to lightbar control head Verify that the POWER ON LED is lit on the Valor controller board 4 Unplug the two ROC board connectors from the controller board see diagram 5 Cycle power to the lightbar by removing
10. SW 2 Switch 3 1A cy BLACKWHITE RED LIGHTBAR TEST down ON in the Serial Interface Module IGNITION IA WHITE IGNITION POWER BLACK GROUND 1 BLACK WHITE GROUND 2 i IGNITION POWER INCLUDES POWER IN THE CRANKING POSITION 290A7461 INTEGRITY Lightbar CHAPTER 5 Maintaining and Servicing the INTEGRITY 4 WARNING SHOCK HAZARD Disconnect ALL power to the lightbar before any maintenance is performed Failure to do so may result in property damage serious injury or death 4 WARNING BURN HAZARD After prolonged operation the unit gets hot and can cause burns Do not touch the unit while or shortly after it has been operating Always allow the unit to cool before handling it WARNING HEAVY OBJECT Use lifting aids and proper lifting techniques when removing or replacing this product Failure to follow this warning may cause personal injury This chapter describes how to maintain and service the INTEGRITY lightbar Establishing a regular maintenance and inspection schedule extends the life of the lightbar and ensures safety For service support or replacement parts contact the Federal Signal Service Department at 1 800 433 9132 7 a m to 5 p m Monday through Friday CT See Table 5 2 on page 37 for replacement parts and part numbers Cleaning the Lightbar Lens CRAZING CLEANING SOLUTIONS The use of cleaning solutions such as strong
11. Torx driver Removing the Lens To remove the lens 1 Disconnect all power to the lightbar at the battery 2 Usea T27 Torx driver to remove the 1 4 20 Torx head barrel nuts securing the lens Figure 5 1 Carefully remove the lens and cover as a unit Avoid damaging the lip seal 3 Verify that an O ring is under the head of each barrel nut and not stuck to the lens Use wooden or plastic pick to carefully remove the O rings from the lens to prevent damaging them 4 Inspect the O rings and the lip seal for deformation brittleness cuts or tears To maintain watertightness replace a questionable O ring or seal 5 Inspect the lens for cracks crazing hairline cracks and other defects Figure 5 1 Locations of the barrel nuts in lens numbers indicate tightening sequence 290A7480 INTEGRITY Lightbar Chapter 5 Maintaining and Servicing the INTEGRITY Reinstalling the Lens To reinstall the lens 1 Reinstall the cover and lens To prevent cross threading the barrel nuts back them counterclockwise until you hear the click of the threads engaging 2 Tighten the barrel nuts to 16 24 in lb in the sequence shown in Figure 5 1 on page 32 Replacing a PCB The INTEGRITY lightbar has two end and two intermediate ROC PCBs as well as a controller PCB Figure 5 2 They are configured at the factory per the
12. WARNING BATTERY EXPLOSION 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 5 Decide where to route the lightbar power and ground wires A WARNING SEAT REMOVAL PRECAUTION If a vehicle seat is temporarily removed verify with the vehicle manufacturer if the seat needs to be recalibrated for proper airbag deployment Failure to follow this warning cause serious injury or death 6 To make wiring easier remove the seats spare tire and pull down the headliner where needed 7 Separate all electronic equipment wiring from two way radio equipment wiring 8 To avoid interference keep two way radio antennas a minimum of 18 in 45 7 cm away from warning equipment 9 Whenever possible run full wire lengths DO NOT splice the wires 10 Do not coil excess wire Leave a drain loop for servicing 11 After drilling holes for wires deburr them smooth sharp edges and insert grommets to protect the wires from chafing 12 When you frame ground the equipment use the manufacturer supplied ground locations in the vehicle IMPORTANT After the installation frequently inspect the lightbar and mounting feet to ensure that all fasteners and brackets are tight Connecting Power to t
13. both the Convergence Network CAT5 connector and the power connector and reconnecting both after at least 5 seconds In response the TX RX LED and the Convergence TX RX LEDS flash ON OFF together The POWER ON LED turns ON 6 Plugthe two ROC board connectors back into their connections 7 Cycle power to the lightbar by removing both the Convergence Network CAT5 connector and the power connector and reconnecting both after at least 5 seconds All LEDs briefly flash once to indicate reset is finished 8 Test and reassemble lightbar INTEGRITY Lightbar Chapter 5 Maintaining and Servicing the INTEGRITY Troubleshooting the Lightbar This section provides troubleshooting assistance for common problems If you have any questions left unanswered call the Federal Signal Service Department at 1 800 433 9132 7 a m to 5 p m Monday through Friday CT Table 5 1 Troubleshooting tips Problem Corrective Action The lightbar does not light v Check that the lightbar s red power line BAT and the black ground power line GND are properly connected to a good fully charged 12 volt battery Check the 40 A fuse Ensure that the ground connection from the lightbar controller to the aluminum extrusion is good Check that the CAT5 cable is connected to the Serial Interface Module J1 and there are no damaged pins in the sockets Try a new CAT5 cable Check the connections on the Serial Interface Module 1
14. customer order NOTICE STATIC SENSITIVE DEVICE This lightbar circuitry can be damaged by electrostatic discharge ESD Follow anti static procedures when servicing this lightbar Figure 5 2 Locations of ROC PCBs 290A7481 Tool required v T27 Torx driver Removing a PCB To remove a PCB 1 2 Disconnect all power to the lightbar Use a T27 Torx driver to remove the 1 4 20 Torx head barrel nuts securing the lens Figure 5 1 on page 32 Carefully remove the lens and cover as a unit Avoid damaging the lip seal Verify that an O ring is under the head of each barrel nut and not stuck to the lens Use a wooden or plastic pick to carefully remove the O rings from the lens to prevent damaging them Inspect the O rings and the lip seal for deformation brittleness cuts or tears To maintain watertightness replace a questionable O ring or seal Note and record the connection to the PCB then lift it and disconnect the harnesses Remove the PCB from the lightbar INTEGRITY Lightbar 33 34 Chapter 5 Maintaining and Servicing the INTEGRITY Reinstalling a ROC PCB To reinstall a PCB 1 Place the new PCB in the same position as the old PCB and reconnect the harnesses 2 Reinstall the lens with the cover To prevent cross threading the barrel nuts back them counter clockwise until you hear the click of the threads engaging then tighten them to 16 24 in
15. the black wire and the black white wire are connected to ground GND 2 the white wire is connected to 12 Vdc Check the 1 A fuse 3 aMODE wire has 12 Vdc Check the position of Switch 1 on SW 2 in the Serial Interface Module Figure 3 3 on page 15 If Switch 1 is down ON ensure that the ENABLE control wires green white and orange black have 12 Vdc applied Check the positions of the DIP switches in the Serial Interface Module See Figure 3 3 on page 15 and Table 3 2 on page 17 Check the fuses on the mainbar controller Reset the controller page 34 An LED module does not light Swap the LED board with good board to see if the board is bad Check the connections of the cable that goes from the lightbar controller to the LED ROC board If itis a rear module check the SignalMaster connections Reset the controller page 34 Half of an LED module does not light Replace the ROC board that the LED is on Reset the controller page 34 continued on next page INTEGRITY Lightbar 36 Chapter 5 Maintaining and Servicing the INTEGRITY Table 5 1 Troubleshooting tips continued Problem Corrective Action The lightbar turns off when the Flash Takedown Alley lights turn on Ensure that the vehicle battery is fully charged Check that the lightbar s red power line and black ground power line are properly connected to a good fully charged 12 volt battery Check t
16. 31 Removing and Reinstalling the Lightbar 11 202000000400 000000000000000000000 00000000000 32 Remove he 32 Reinstalling the eet lean 33 Replacing a nsnm iuret Meere rein 33 r 33 Reinstalliig ee Io e E 34 Resetting the Controller 34 Troubleshooting the Lightbar 35 Getting Technical Support and Service nennen enne 37 Ordering Replacement Parts ea e f e a He d e E 37 Returning Product to Federal Signal siesena annae eee eae Ead Ld co 37 Chapter 6 Wiring Schematics 39 Figure 3 1 Electrical connections for reprogramming the lightbar 14 Figure 3 2 Serial Interface Module with cover 15 Figure 3 3 DIP switch settings in Serial Interface Module sme 15 Figure 4 1 Power and cable 23 Figure 4 2 Relay for isolating devices with large filter capacitors 24 Figure 4 3 SignalMaster 331105 c
17. DE 3 overrides MODE 2 and MODE 2 overrides MODE 1 When the lightbar operates in one of these modes the SignalMaster modules keep sequence with the flash pattern You can change default MODE flash patterns by programming each mode with one of 26 patterns in the lightbar s library A typical setup would be MODE 1 REAR LEDs MODE 2 FRONT REAR LEDs MODE 3 Siren SmartSirene or Federal Signal compatible and FRONT REAR LEDs and FLASH TAKEDOWN ALLEY LEDs on the mainbar e MODES and 2 FRONT REAR CUTOFF NOTE If you are reprogramming the lightbar after you have connected a progressive slide switch the programming sequence must be MODE 3 MODE 2 MODE 1 INTERSECTION Mode 3 1 Apply 12 Vdc to the MODE 3 control wire black red from the Serial Interface Module to display the assigned pattern 2 On the Serial Interface Module press and release SW 1 pushbutton until the pattern you want appears on the lightbar 3 Remove 12 Vdc from the MODE 3 control wire Mode 2 1 Apply 12 Vdc to the MODE 2 control wire blue white from the Serial Interface Module to display the assigned pattern 2 On the Serial Interface Module press and release SW 1 pushbutton until the pattern you want appears on the lightbar 3 Remove 12 Vdc from the MODE 2 control wire INTEGRITY Lightbar Chapter 3 Reprogramming the Lightbar Mode 1 1 Apply 12 Vdc to the MODE control wire bl
18. ITE ORANGE ORANGE GREEN VIOLET ORANGE TO J1 ON INTERFACE MODULE NOTE FOLLOW THE CONTROLLER S INSTALLATION INSTRUCTIONS FOR POWER l GROUND AND OTHER YELLOW RED GREEN POSSIBLE FUNCTIONS 290A7451 INTEGRITY Lightbar 27 Chapter 4 Wiring the INTEGRITY Lightbar in the Vehicle Figure 4 4 SmartSiren 5520005 Series controller external SignalMaster control NOTE FOLLOW THE 5520005 SERIES INSTALLATION INSTRUCTIONS FOR OTHER WIRING RED WHT 1 SPA GREEN BRN 2290 GRN BLKWHT 1 GRN 3 TO J1 ON ORANGE GREEN ORN 4 INTERFACE MODULE ORANGE PRP 5 BLUE RED GRA 6 RED GREEN WHITE RED Internal SignalMaster Internal operation uses the lightbar s built in SignalMaster controller to generate directional warning patterns With internal operation an external SignalMaster controller is not needed A standard low current switch box can activate the lightbar s internal SignalMaster controller For the jumper setting in the Serial Interface Module see Selecting Internal SignalMaster Control on page 16 To activate the lightbar s internal SignalMaster controller apply 12 Vdc BAT to the SignalMaster control wires Table 4 2 SignalMaster control wires and warning patterns internal SM control Warning Pattern LEFT Red Rear LEDs flash from right to left 76543211 Control Wires Description with 8 head example CENTER OU
19. Interface Module see Table 3 3 on page 20 For typical installations with common controllers and switch boxes see the wiring schematics in Chapter 6 on page 39 For wiring the controller s functions to the Serial Interface Module s 24 pin cable harness see Table 3 2 on page 17 and the figures starting on page 39 If additional wire is necessary for the harness except ground 22 AWG wire is adequate The ground wires must be extended with 16 AWG or thicker wire Priority Modes 1 2 and 3 To activate a priority mode apply 12 Vdc to a mode control wire Mode 3 black red overrides Mode 2 blue white and Mode 2 overrides Mode 1 blue You can program one of the flash patterns in the lightbar to each Mode input Steady Burn Applying 12 Vdc 4 BAT to the red white control wire turns on the red LED driver side and the blue LED passenger side Steady Burn modules Steady Burn defaults to the HotFoot modules if red blue colors are available otherwise Steady Burn turns on the red blue colors in the lightbar if available In the 44 INTEGRITY red is located in Module 4 and blue in Module 7 In the 51 INTEGRITY red is located in Module 5 and blue in Module 8 Front Cutoff When 12 Vdc is applied to the Front Cutoff control wire green white the selected Mode operation is deactivated to the front of the lightbar Only the rear LEDs function Additionally with Flash Takedown Alley red black active only the alley l
20. T LEDs flash from center out to both sides 312 1 1 2 ai Green Black LEDs flash from left to ri White 2245 Orange Green Ds alternate Orange Two outer LEDs alternate 1 1 212 Blue Red Right four LEDs alternate with left four LEDs 2 2 2 2 Red Green Two outer LEDs flash then the four LEDs between the inner outer LEDs flash White Red Operates the selected pattern 50 percent faster INTEGRITY Lightbar Chapter 4 Wiring the INTEGRITY Lightbar in the Vehicle Figure 4 5 SignalMaster control functions wired to ground for external Serial Interface Module control POWER 12 Vdc J1 CABLE TO SERIAL INTERFACE 1 BLACK RED MODE 3 MODULE O 1A MODE 2 o c BLUEMHITE 0 1A BLUE MODE 1 o c BLU 1 STEADY BURN or SCENE LIGHT LEFT with SW 2 Switch 3 1 BLUE BLACK INTERSECTION down ON in the Serial Interface Module 1 c PED BLACK FLASH TAKEDOWN ALLEY 1 c QBANGE RED RIGHT ALLEY 1 GREENIBLACK LEFT ALLEY 1 Q c TAKEDOWNS 1 c FRONT CUTOFF ENABLE 1 QPANGE BLACK REAR CUTOFF ENABLE 1A 0 0 MHITEIBLACKRED LOW POWER or SCENE LIGHT RIGHT with SW 2 Switch 3 1 OO BLACKWHITEIRED LIGHTBARTEST down in the Serial Interface Mod
21. TY Lightbar in the Vehicle Making the Electrical Connections for Reprogramming To supply power to the lightbar use a fully charged 12 volt automotive battery and follow these steps 1 Place the lightbar on a sturdy flat surface 2 See Figure 3 1 Plug the CATS communication cable 1 from the lightbar into the Serial Interface Module J1 Plug the 24 pin harness 2 into the Serial Interface Module Attach the black ground power line 3 to the negative battery GND terminal Attach the red power line 4 through a 40 A Maxi fuse to the positive battery BAT terminal se m e Attach the white wire 5 from the 24 pin harness through 1 A fuse to the positive battery terminal 7 Attach the black wire and the black white wire 6 from the 24 pin harness to the negative battery GND lug Figure 3 1 Electrical connections for reprogramming the lightbar DRIVER SIDE PASSENGER SIDE FUSE 40 A MAXI POWER LINE RED CATS COM GROUND POWER LINE BLACK SERIAL INTERFACE 12 Vdc MODULE VEHICLE z BATTERY 2 BLACK WIRE BLACK WHITE WIRE WHITE WIRE 24 PIN HARNESS 290A7448 INTEGRITY Lightbar Chapter 3 Reprogramming the Lightbar Identifying Switch and Jumper Settings The jumper for Internal External SignalMaster control and the switches to reprogram flash pat
22. WARNING SHOCK HAZARD Strobe and HID light systems generate high voltages Disconnect power from the system and wait at least 5 minutes before opening the unit Do not apply power to the unit while the unit is open Failure to follow this warning could result in serious injury or death Figure 4 2 Relay for isolating devices with large filter capacitors RELAY CONTROL LEAD STROBE SUPPLY 12 Vdc SIGNAL ACTIVATED 12 Vdc 290A7446 FUSE AMPERAGE DEPENDS ON AMPERAGE OF DEVICES Wiring the Serial Interface Module A WARNING FUSE ELECTRICAL SOURCES Always fuse current voltage sources with a fuse connected near the power source Be sure that the fuse is properly rated to protect the electrical load the wiring and the connectors used in the circuit Failure to follow this notice could result in vehicle or equipment damage This section is an overview of default settings that are activated when connecting LED and Mode control wires to 12 Vdc The basic light functions of the lightbar must be controlled by an installer supplied control head All programming and changes to default settings should be done after quick testing the lightbar and before installation Programming is covered in Programming Priority Modes 1 2 3 and Intersection on page 18 INTEGRITY Lightbar Chapter 4 Wiring the INTEGRITY Lightbar in the Vehicle For a description of the control wires from the Serial
23. d the cable length SignalMaster Connections If SignalMaster operation is not activated by a control head or external controller the SignalMaster LED heads flash with the selected priority mode Mode 1 2 or 3 of operation External SignalMaster The Serial Interface Module is preset for the External SignalMaster option External operation uses the Serial Interface Module to drive each SignalMaster directional warning head independently through an external Federal Signal SignalMaster controller or SS2000SM series siren Figure 4 3 below and Figure 4 4 on page 28 Either device provides an independent ground signal to turn on each head To cross reference external SignalMaster wiring to a Federal Signal controller or the SM2000SM series siren see Table 4 1 Table 4 1 Cross reference for controller leads external Serial Interface Module control 24 Pin Harness from Siena MasreR Wire 2000 Wire the Serial Interface Figure 4 2 Figure 4 3 Module Red White White 1 Green Brown Brown 2 Green Black White Green Green 3 Orange Green Orange Orange 4 Orange Purple Purple 5 Blue Red Gray Gray 6 Red Green Yellow Yellow 7 White Red Blue Blue 8 Wire colors as described in the controller s installation instructions Figure 4 3 SignalMaster 331105 controller external SignalMaster control SIGNALMASTER CONTROLLER 331105 SHOWN 1 RED BROWN GREEN GREEN GREEN BLACK WH
24. e Probram Modes sisenes ea 17 Exiting Program Mode cene deg dis iis idee teg end Leda oc 20 Chapter 4 Wiring the INTEGRITY Lightbar in the Vehicle 21 Planning the Electrical Installation esses eene nnne nnne enne nennen 21 Connecting Power to the Lightbar 22 Installing the Serial Interface Module 23 Wiring the Serial Interface Module rn nennt ennt 24 ah os SP E 25 Steady Burnt HOthoot Only 2 25 25 Rear CNRC 25 RR oK R 25 Flash Takedown Alley esses enne nennen nennen nnne 25 26 Takedown 26 Scene Light Left and Scene Light nemen 26 Low DiNi SER ncaa MA EpL UP IQ GM UD M S d bed 26 Integrity Lightbar Contents MI 26 Master COMMECHONS 27 Chapter 5 Maintaining and Servicing the 2 22 31 ClIeammb the Ligehtbat Lens ee
25. e as a template to scribe four drill position marks at the selected mounting location Mounting centers are 2 00 in x 5 95 in 5 08 cm x 15 11 INTEGRITY Lightbar 23 Chapter 4 Wiring the INTEGRITY Lightbar in the Vehicle DRILLING PRECAUTIONS Before drilling holes check the area into which you plan to drill to ensure you do not damage vehicle components All drilled holes should be de burred and all sharp edges should be smoothed wires going through drilled holes should be protected by a grommet or convolute split loom tubing 2 Drill a mounting hole at each of the four drill position marks sized for the recommended user supplied 8 mounting hardware 3 Secure the Serial Interface Module to the mounting surface with installer supplied 78 hardware 4 Install the CATS serial cable from the lightbar to the J3 output jack of the Serial Interface Module 5 Install the three foot long 24 conductor cable from the lightbar to the 71 input connector of the Serial Interface Module NOTE Powering multiple devices with a common control wire may cause one or more devices to briefly remain functional after signal power is removed For example due to the high input filter capacitance a strobe supply can briefly supply the current required to signal a lightbar function to remain on If necessary use a relay to isolate devices with large filter capacitors Figure 4 2 All components wires are user supplied A
26. e control wire for Left green black or Right Alley orange red the appropriate alley LEDs turn on The left and right alley lights override the flash takedown alley lights Takedown Lights When 12 Vdc BAT is applied to the control wire for Takedown white black the takedown LEDs turn on Takedown overrides Flash Takedown Alley and Front Cutoff Scene Light Left and Scene Light Right This function applies only to lightbars with SpectraLuxm Technology INTEGRITY and Vision SLR To use this function with the Serial Interface Module place SW 2 Switch 3 in the Module in the down position ON When 12 Vdc is applied to the control wire for Scene Light Left blue black the left half of the lightbar lights up When 12 Vdc is applied to the control wire for Scene Light Right black white red the right half of the lightbar lights up Intersection and Lightbar Test are unavailable with these options Low Power or Optional AutoDim NOTE Low Power Mode and the optional AutoDim feature are disabled when the lightbar is in MODE 3 or displaying the Intersection flash pattern A WARNING USE THE LOW POWER FUNCTION PROPERLY Enabling the Low Power function in the lightbar causes the light output to fall below current light output standards and guidelines for emergency warning lights Use extreme caution when using this function Ensure that the ambient light conditions are low enough that you are seen and that the reduction of glar
27. e from the lightbar is safer than full light output in the situation Failure to heed this warning may result in serious injury or death to you or others in your vicinity When 12 Vdc BAT is applied to the control wire for Low Power the LEDs are dimmed to approximately 50 percent of their full brightness Low Power is only functional in MODE 1 or MODE 2 Low Power is disabled when switching to another flash pattern including Intersection To use Low Power again disconnect 12 Vdc from the Low Power control wire and reapply 12 Vdc to the Low Power control wire after a change in flash pattern occurs If the lightbar is equipped with AutoDim it will automatically dim at night as long as the controller is not in MODE 3 Once MODE 3 is removed the lightbar will again dim to 50 percent of full brightness NOTE The may take a few minutes to change light intensity after an ambient light change Ignition To connect the Serial Interface Module to the ignition circuit 1 Connect the white wire from the supplied J1 cable harness on the Interface Module to a A fuse 2 Connect the fuse end as close as possible to switched ignition power Power should also be present in the cranking position INTEGRITY Lightbar Chapter 4 Wiring the INTEGRITY Lightbar in the Vehicle 3 Connect the black and black white wire from the 24 pin cable harness on J1 from the Serial Interface Module to battery ground GND Use 16 AWG wire to exten
28. ement parts call the Federal Signal Service Department at 800 433 9132 7 a m to 5 p m Monday through Friday Central Time or contact your nearest distributor Table 5 2 Replacement parts Description Part Number PCB Assembly End Configured Contact Factory PCB Assembly Front Configured Contact Factory PCB Assembly Rear Configured Contact Factory PCB Assembly Controller Configured Contact Factory Nut 1 4 20 Barrel 7065071 Seal Lip Lens 8651116 XX O Ring Lens Nut 7067016 Gasket Lens 8651125 Lens Clear 44 864900254 Lens Clear 51 864900256 Returning a Product to Federal Signal Before returning a product to Federal Signal call 800 264 3578 800 433 9132 or 800 824 0254 to obtain a Returned Merchandise Authorization number RMA number To expedite the process please be prepared with the following information e Your Federal Signal customer or account number e purchase order number under which the items were purchased e The shipping method e The model part number of the product being returned e The quantity of products being returned e Drop ship information as needed INTEGRITY Lightbar 37 38 Chapter 5 Maintaining and Servicing the INTEGRITY e estimate required When you receive your RMA Number e Write the RMA number on the outside of the box of returned items e Reference the RMA number on your paperwork inside of the box e Wr
29. er to the vehicle s service manuals when performing equipment installations on a vehicle Light Hazards 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 e 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 e 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 e 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 five minutes before handling any parts of the strobe system Integrity Lightbar Chapter 1 Safety Messages
30. g 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 firm 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 finish surface flatness and thickness of the steel mounting surface Therefore to promote proper magnetic mounting Integritym Lightbar 10 Chapter 1 Safety Messages The mounting surface and the magnets must be kept clean dry and free of foreign particles that prevent good surface contact v Ensure that mounting surface is flat magnet mounting system should not be used on vehicles with vinyl tops 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 Integrity Lightbar 2 An Overview of the Integrity Lightbar The INTEGRITY lightbar is a single level LED lightbar with Reliable On Board Circuitry and Solarise LED technologies ROC eliminates approximately 85 percent of potential failure points by incorporating a printed circuit board PCB
31. ght to the front Overrides FLASH TAKEDOWN ALLEY lights and FRONT CUTOFF LOW POWER White Black Red Dims the lights approximately 50 percent to prevent blinding approaching drivers LOW POWER is only available in MODES 1 and 2 and is disabled when switched to another flash pattern including MODE 3 and INTERSECTION LIGHTBAR TEST PATTERN Black White Red Flashes the LEDs sequentially and then flashes the TAKEDOWN and ALLEY lights Entering Program Mode To switch the module from Operation Mode to Program Mode 1 Unplug the 24 pin harness from the Serial Interface Module 2 Onthe Serial Interface Module move Switch 6 on SW 2 to the down ON position Figure 3 3 on page 15 INTEGRITY Lightbar 17 18 Chapter 3 Reprogramming the Lightbar 3 Plug the 24 pin harness into the Serial Interface Module NOTE When you press and release the SW 1 pushbutton on the Serial Interface Module to select a pattern the lightbar briefly turns off and then displays the next pattern To cycle backwards to a previous pattern move Switch 5 to ON up position on SW 2 SW 2 DIP Switch Settings in the Serial Interface Module For the location of SW 2 see Figure 3 2 on page 15 Table 3 1 on page 16 lists the DIP switch settings in the Serial Interface Module for programming flash patterns Programming Priority MODES 1 2 3 and INTERSECTION The three modes operate with MODE 3 having the highest priority MO
32. gnalMaster Internal controller Cycle forward through the selection of flash patterns v Cycle backward through the selection of flash patterns v Operation Mode v Program Mode Switch for INTERSECTION operational settings Table 3 3 on page 20 Switch for INTERSECTION operational settings Table 3 3 aR AJOJN Selecting Internal SignalMaster Control To select Internal SignalMaster control 1 Unplug the 24 pin harness from the Serial Interface Module 2 the Interface Module use a 1 4 inch driver to remove the four 28 32 x 1 4 hex head screws and remove the cover On the Interface Module PCB move JP 1 from EXT to INT see Figure 3 3 on page 15 3 4 Reinstall the cover on the Interface Module 5 Move Switch 4 on SW 2 to the down ON position 6 Plug the 24 pin harness into the Serial Interface Module Selecting External SignalMaster Control To return to External SignalMaster control factory default 1 Unplug the 24 pin harness from the Serial Interface Module 2 Onthe Serial Interface Module use a 1 4 inch driver to remove the four 8 32 x 1 4 hex head screws and remove the cover On the Serial Interface Module PCB move JP 1 from INT to EXT Figure 3 3 Reinstall the cover on the Interface Module Move Switch 4 on SW 2 to the up OFF position mc oe Plug the 24 pin harness into the Serial Interface Module INTEGRITY Lightbar Chapter
33. he Lightbar NOTE Plan the location of the wire routing hole in the vehicle roof so that the power and communication cables do not have tight bends and have some slack to allow disconnection on removal A WARNING BATTERY EXPLOSION 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 A WARNING BATTERY EXPLOSION 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 REVERSE POLARITY MISWIRING Reverse polarity or incorrect voltage may damage the light To avoid damage to the light ensure that the battery voltage is the same as the voltage rating of the light and that the correct polarity is observed If you are connecting to a cigarette lighter plug or 12 V outlet connect the positive wire to the center terminal and connect the negative wire to the outer terminal INTEGRITY Lightbar Chapter 4 Wiring the INTEGRITY Lightbar in the Vehicle To make the power connections 1 Ensure that the lines are adequately fused as shown in F
34. he red power line and the black ground power line CGND connections in the lightbar and vehicle Reset the controller page 34 The lightbar has a delayed response to being shut off Ensure that the connections on the Serial Interface Module are kept separate from strobe supplies Check all the ground connections especially on the Serial Interface Module Reset the controller page 34 A Flash Takedown Alley light stays on with ignition power applied Ensure there is no voltage on the corresponding control wire To see if the ROC board is bad swap it with a similar board Swap the cables on the lightbar controller outputs with a known good output If the problem moves to another halogen light send the lightbar controller to Federal Signal for repair Reset the controller page 34 Takedown alley lights work but Flash Takedown Alley lights do not work Ensure that 12 Vdc is applied to the takedown and alley red black control wire Check the 12 Vdc power and negative ground connections to the lightbar to ensure there is enough current Reset the controller page 34 Only one takedown light turns on Check the connections from the lightbar controller to the ROC boards and ensure they are in the proper locations Reset the controller page 34 SignalMaster LEDs do not light Check the jumper and switch settings on the Serial Interface Module Ensure they are both set for the co
35. ights turn on Rear Cutoff When 12 Vdc is applied to the Rear Cutoff control wire orange black the selected Mode operation is deactivated to the rear of the lightbar Only the front LEDs flash NOTE The operational settings for Front Cutoff and Rear Cutoff are not independent The default setting is for 12 Vdc BAT to be applied for the lightbar s front and rear lightheads to turn them off Cutoff To change the default setting to turn on these LEDs when 12 Vdc is applied Enable see Front Rear Enable or Cutoff on page 20 Intersection When 12 Vdc is applied to the Intersection control wire blue black and a Mode control wire it turns on the Intersection pattern When 12 Vdc is removed the lightbar returns to its previous state SW 2 Switch 3 must be in the up ON position in the Serial Interface Module See Scene Light Left and Scene Light Right on page 26 NOTE With the flexibility of the SmartSiren Platinum System both the Intersection and the Scene Light Left option are available in Vision SLR and INTEGRITY lightbars without the need to choose one or the other Flash Takedown Alley When 12 Vdc BAT is applied to the Flash Takedown Alley control wire red black and MODE control wire the takedown and alley lights flash INTEGRITY Lightbar 25 26 Chapter 4 Wiring the INTEGRITY Lightbar in the Vehicle Left and Right Alley Lights When 12 Vdc BAT is applied to th
36. igure 3 1 Figure 4 1 Power and cable connections DRIVER SIDE FUSE 40 A MAXI POWER LINE RED 5 COM CABLE GRAY NEG GROUND POWER LINE BLACK SERIAL INTERFACE 12 Vdc MODULE BATTERY L IGNITION FUSE 1 A BLACK WHITE WIRE WHITE WIRE 24 PIN HARNESS 29 2 From the lightbar route the CATS control cable into the vehicle cab or trunk near the eventual location of the Serial Interface Module An input cable is also provided with the Interface Module 3 Route and connect the black lead from the lightbar to the vehicle battery s ground GND terminal 4 Route and connect the red lead from the lightbar through the supplied 40 A Maxi fuse holder at the source which is the positive battery terminal BAT Installing the Serial Interface Module UNIT REQUIRES VENTILATION The Serial Interface Module needs to radiate heat Do not install it in an area where it cannot dissipate heat into the air Do not mount it near a heater duct _ NOTICE NOTICE UNIT REQUIRES SHELTER FROM WEATHER The Serial Interface Module is NOT x waterproof It must be mounted in a location that is sheltered from rain snow standing water etc IMPORTANT The Serial Interface Module must be installed within 36 in 91 cm of the lightbar controller To mount and wire the Serial Interface Module 1 Usethe Serial Interface Modul
37. in one assembly to substantially reduce the number of electrical connections Solaris S2 LED modules use offset complex reflector surfaces for accurate beam shaping and the highest optical efficiency The reflectors overlapping 360 degree lighting eliminates weak spots and provides off axis warning around the lightbar LED Lights Colors and Flash Patterns The microprocessor inside the lightbar supplies three priority operational modes and a library of 27 flash patterns To increase the safety of officers pedestrians and motorists the lightbar has standard front and rear cutoff dimming and intersection warning Bright white LED takedown and alley lights that are horizontally adjustable are also available with the HotFootm configured option Multi color heads are available with up to three different colored LEDs eliminating the loss of primary warning colors in takedown alley and directional warning positions Individual INTEGRITY lightheads can flash between red blue amber or white Electrical System The INTEGRITY lightbar is protected against reversed polarity damage The INTEGRITY Lightbar can be installed in any vehicle with a 12 volt negative ground electrical system Controller Options Flash patterns are controlled through the lightbar CAT5 communication cable The cable connects to Federal Signal Convergence network controllers the Serial Interface Module Part Number 8583446 or the Federal Signal Six Button Serial Contro
38. ion 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 Integrity Lightbar Chapter 1 Safety Messages Safety Messages to Operators of Federal Signal Sound Light Systems 4 WARNING 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 effective sirens and horns produce loud sounds that may cause in certain
39. ite the RMA number down so that you can easily check on status of the returned equipment Send all material with the issued RMA Number to Federal Signal Corporation 2645 Federal Signal Drive University Park IL 60484 3167 Attn Service Department INTEGRITY Lightbar Chapter 5 Maintaining and Servicing the INTEGRITY CHAPTER 6 Wiring Schematics This chapter has schematics showing the INTEGRITY lightbar with typical connections to these controllers e SignalMaster controller external control e SW400SS Switch Module internal control e SmartSiren Model SS2000SM Non SignalMaster e PA640 INTEGRITY Lightbar 39 40 Chapter 5 Maintaining Servicing the INTEGRITY Figure 6 1 Typical connections with a SignalMaster controller external control 2 SERIAL INTERFACE e i lt e lt 2 E P 2 Ge 50 e 9 e o z o0 2 LY ZO lt gt lt E 5 X lt m9 m 2 5 5 2 5 E 2 83 CL 9 a3u ouo E C TI lav mnan E f 5 2 a m ul uz 2 Lil n d 330 a3unna on a 2129 3GOW gt
40. ller With the Serial Interface Module the INTEGRITY Lightbar can be activated by Federal Signal lightbar controllers SignalMaster directional light controllers or by individual low current switch boxes Ambient Light Sensor AutoDim Option The INTEGRITY lightbar can be ordered with an optional ambient light sensor The sensors that detect the ambient light and automatically dim flashing lights during nighttime are located on the ROC boards at each end of the lightbar If used with a controller that has a dedicated dim button the user has the option to temporarily override the dimming AutoDim is disabled in MODE 3 and is enabled when MODE 3 is removed Integrity Lightbar 11 Chapter 2 An Overview of the Integrity Lightbar Other advanced features of the INTEGRITY lightbar include Ahigh degree of reliability through the use of advanced microprocessors and other integrated circuits e One piece seamless construction that eliminates leaking bulkhead gaskets High output long life LEDs with no bulbs to change Product Specifications Operating and technical specifications for the INTEGRITY lightbar are listed in this section by model Dimensions Model INTEGRITY44 INTEGRITY51 Length 43 7 in 111 0 cm 51 8 in 130 3 cm Height 1 96 in 5 0 cm 1 96 in 5 0 cm Width 9 7 in 246 4 cm 9 7 in 246 4 cm Weight 21 5 Ib 9 8 kg 24 5 10 11 1 kg with standard mounting feet Light Specifications
41. n the INTERSECTION flash pattern for eight seconds To change from HIGH to TAP II or 8 SECOND TIMEOUT 1 Unplug the 24 pin harness from the Serial Interface Module 2 On the Serial Interface Module set Switch 7 and Switch 8 on SW 2 to select a method of operation Figure 3 3 on page 15 and Table 3 3 on page 20 Each setting is independent of the other 3 Plug the 24 pin harness into the Serial Interface Module INTEGRITY Lightbar 19 Chapter 3 Reprogramming the Lightbar Table 3 3 Switch settings for INTERSECTION operation Operational Settings SW7 8 HIGH maintained OFF up OFF up BAT push on push off ON down OFF up 8 SECOND TIMEOUT activated by BAT OFF up ON down Front Rear Enable or Cutoff The operational setting for FRONT REAR ENABLE or CUTOFF must be programmed after MODE and INTERSECTION The default setting is for CUTOFF in which the FRONT or REAR LEDs turn off when 12 Vdc BAT is applied to their control wires Table 3 2 on page 17 In contrast FRONT REAR ENABLE turns on these LED modules when BAT is applied to their control wires Both FRONT and REAR share the same operational setting and are not independent To program the lightbar for FRONT REAR ENABLE or CUTOFF 1 Unplug the 24 pin harness from the Serial Interface Module 2 See Figure 3 3 on page 15 On the Serial Interface Module move Switch 1 on SW 2 to a the down on position for Fro
42. nt Rear Enable b the up off position for Front Rear Cutoff 3 Plug the 24 pin harness into the Serial Interface Module NOTE When set to ENABLE 12 Vdc must be applied to MODE control wire and the FRONT and or REAR ENABLE control wire for the lightbar to operate In a typical installation if you want only the REAR LED modules to flash in MODE 1 set the operation for ENABLE Connect the green white and blue white control wires to the MODE 2 connection and the orange black and blue control wires to the MODE 1 connection Exiting Program Mode When you are finished switch the Serial Interface Module from Operation Mode to Program Mode 1 Unplug the 24 pin harness from the Serial Interface Module 2 Onthe Serial Interface Module move SW 2 Switch 6 to the up OFF position 3 Plug the 24 pin harness into the Serial Interface Module INTEGRITY Lightbar 4 Wiring the INTEGRITY Lightbar in the Vehicle Before proceeding ensure that the lightbar has been installed on the vehicle roof in accordance with the instructions included with the mounting kit Depending on the type of vehicle and mounting system feature there are two options available for installing the lightbar to the roof of the vehicle hook on mounting or permanent mounting NOTICE INSTALLATION PRECAUTION Do not mount a radio antenna within 18 inches of the lighting system Placing the antenna too close to the lighting system could cau
43. nterface Module 17 Table 3 3 Switch settings for INTERSECTION operation enne 20 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 5 1 5 T 35 Table 5 2 Replacement parts INTEGRITY Lightbar 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 WARNING Before Installation or Service Qualifications e 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 ref
44. 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 ofthe 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 Integritym Lightbar Chapter 1 Safety Messages 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 fly 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 o
45. ontroller 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 29 Figure 5 1 Locations of the barrel nuts in lens numbers indicate tightening sequence 32 Figure 5 2 Locations of ROG PCBS niece teer tte 33 Figure 6 1 Typical connections with a SignalMaster controller external Control 40 Figure 6 2 Typical connections with a Model SW400SS Switch Module internal control 41 Figure 6 3 Typical connections with a SmartSiren Model 5520005 42 Figure 6 4 Typical connections with a non SignalMaster 43 Figure 6 5 Typical connections with a Model PA640 PA64000 44 INTEGRITY Lightbar Contents Tables Table 3 1 SW 2 DIP Switch Settings erepti tem 16 Table 3 2 Control wires from the Serial I
46. rrect operation See Figure 3 3 on page 15 and Table 3 2 on page 17 Ensure that Switch 4 on SW 2 is in the correct position for the Selected operation on the Serial Interface Module and ignition power was removed and reapplied Check the connections at the SignalMaster controller If the controller is a model 5520005 ensure that the connector has power and the ground is connected to pins 10 and 11 on the SignalMaster plug Reset the controller page 34 INTEGRITY Lightbar Chapter 5 Maintaining and Servicing the INTEGRITY Getting Technical Support and Service Federal Signal Corporation will service your equipment or provide technical assistance with any problems that cannot be handled locally Any product returned to Federal Signal for service inspection or repair must be accompanied by a Return Material Authorization number The RMA number can be obtained from your local distributor or Federal Signal Please provide a brief explanation of the service requested or the nature of the malfunction Contact your local dealer distributor for replacement parts availability or contact the Federal Signal Service Department 7 a m to 5 p m Monday through Friday Central Time at Service Department Federal Signal Corporation 2645 Federal Signal Drive University Park IL 60484 3167 800 433 9132 phone 800 343 9706 fax Ordering Replacement Parts This section contains a partial list of replacement parts To order replac
47. se 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 Planning the Electrical Installation The lightbar is completely wired at the factory and does not require any additional internal wiring the conductors necessary for control of any and all basic and optional functions are contained the 5 cable The basic light functions of the INTEGRITY must be controlled by a installer supplied control head To prevent damage to the lightbar and vehicle and ensure that all equipment operates properly carefully plan where to mount and wire the lightbar and controlling equipment 1 Verify that the lightbar and mounting hardware fit the vehicle 2 Determine where to mount the lightbar on the vehicle 3 Determine where to mount the controlling equipment a Trunk or remote location b Console A WARNING AIRBAG DEPLOYMENT Do not install equipment or route wiring in the deployment path of an airbag Failure to observe this warning will reduce the effectiveness of the airbag or potentially dislodge the equipment causing serious injury or death 4 Decide where to route wiring around airbag areas Integritym Lightbar 21 22 Chapter 4 Wiring the INTEGRITY Lightbar in the Vehicle A
48. 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 mountin
49. terns are on the PCB in the Serial Interface Module The switches SW 1 and SW 2 are accessible through openings in the housing To access the SignalMaster jumper remove the cover from the Interface Module Figure 3 2 Be sure to reattach the cover when you are finished Figure 3 2 Serial Interface Module with cover attached TO ACCESS THE JUMPER FOR INTERNAL EXTERNAL SIGNALMASTER CONTROL REMOVED THE HOUSING COVER 8 32 x 1 4 HEX HEAD SCREWS 4 290A7449 Figure 3 3 DIP switch settings in Serial Interface Module BACK OF SERIAL INTERFACE MODULE d Qs cas SW 1 PUSHBUTTON SERIAL INTERFACE MODULE PCB SW 2 DIP SWITCH 200 oe SETTINGS 1 THROUGH 8 N amp N N N 5 E J j N gt 2 7 INTEGRITY Lightbar 15 16 Chapter 3 Reprogramming the Lightbar Table 3 1 SW 2 DIP Switch Settings SW 2 Switch Setting Switch Up Down Number OFF ON Function 1 v FRONT REAR LEDs cut off turn off when 12 Vdc is applied their control wires Table 3 2 on page 17 FRONT REAR LEDs enable turn on when 12 Vdc is applied to their control wires Keep in OFF position Keep in OFF position SignalMaster External controller Si
50. 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 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
51. u install the lightbar Before you begin decide if you want to change these default settings SignalMaster Operation External default or Internal Internal operation uses the on board SignalMaster controller in the lightbar 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 through 3 are most often selected by a progressive slide switch which enables the driver to turn on the lightbar without looking down You can select a pattern for each mode from the lightbar 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 off 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 FRONT and REAR lights CUTOFF default or ENABLE Set these options after you change the default settings for MODE and INTERSECTION flash patterns CUTOFF turns OFF the front or rear LEDs when 12 Vdc is applied to the FRONT or REAR light control wire ENABLE turns ON the front or rear LEDs when 12 Vdc is applied Integrity Lightbar 13 Chapter 4 Wiring the INTEGRI
52. ue from the Serial Interface Module to display the assigned pattern 2 On the Serial Interface Module press and release SW 1 pushbutton until the pattern you want appears on the lightbar 3 Remove 12 Vdc from the MODE 1 control wire Intersection The INTERSECTION flash pattern overrides all three priority modes when activated To select a new pattern you must apply 12 Vdc to the control wire for either MODE 2 or 3 Table 3 2 on page 17 and the blue black control wire for INTERSECTION NOTE This procedure only programs the INTERSECTION pattern It does not assign the pattern to a MODE 1 Apply 12 Vdc to a control wire for either MODE 1 2 or 3 and the control wire for INTERSECTION from the Serial Interface Module 2 On the Serial Interface Module press and release SW 1 pushbutton until the pattern you want appears on the lightbar 3 Remove 12 Vdc from the MODE and INTERSECTION control wires Intersection Operational Settings Select one of three options to turn on the INTERSECTION pattern HIGH with BAT power maintained default the lightbar displays the INTERSECTION pattern until power is removed push on push off the INTERSECTION flash pattern is turned on and off by pressing a momentary contact switch such as a horn button Momentary 12 Vdc turns on the pattern a second momentary 12 Vdc signal turns it off e 8 SECOND TIMEOUT activated by BAT momentary 12 Vdc turns o
53. ule L RED 1 LEFT L GREEN 2 E GREEN BLACK WHITE L ORANGE GREEN 4 ANYSIGNALMASTER CONTROLLER L ORANGE 5 E BLUE RED 6 O L RED GREEN 7 1 _ WHITE RED 8 RIGHT O O IGNITION d NI WHITE IGNITION POWER BLACK GROUND 1 BLACK WHITE GROUND 2 IGNITION POWER INCLUDES POWER IN THE CRANKING POSITION 290A Figure 4 6 SignalMaster control functions wired to 12 Vdc for Internal control INTEGRITY Lightbar Chapter 4 Wiring the INTEGRITY Lightbar in the Vehicle 30 POWER 12 Vdc J1 CABLE TO SERIAL INTERFACE 1A BLACK RED MODE 3 MODULE Oo 1A BLUEMVHITE MODE 2 BLUE MODE 1 ME 1A A RED WHITE STEADY BURN or SCENE LIGHT LEFT with SW 2 Switch 3 1A BLUE BLACK INTERSECTION down ON in the Serial Interface Module 1A RED BLACK FLASH TAKEDOWN ALLEY Cy RIGHT ALLEY 1 Q o GREENIBLACK LEFT ALLEY 1A 5 WHITE BLACK TAKEDOWN omer TN Q o GREENWHITE FRONT CUTOFF ENABLE TA 5 ORANGE BLACK REAR CUTOFF ENABLE Q OBANGE BLACK __ RED LEFT 1 GREEN CENTER INT GREEN BLACK WHITE RIGHT orev ORANGE GREEN WARN 1 1A 5 WARN 2 1A BLUE RED WARN 3 I 1A A RED GREEN WARN 4 1A WHITE RED FAST E 1A WEITEIBLACK RED LOW POWER or SCENE LIGHT RIGHT with
54. uter 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 Ib to 11 ft Ib On all other lightbar models torque the adjustment bolts 6 ft Ib to 7 ft Ib 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 reflectors 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 installat
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