Carson Horn System User Manual

V

A

Carson Manufacturing Co., Inc.

5451 North Rural Street

Indianapolis, IN 46220

Phone: [phone] Fax: [phone]

www.carson-mfg.com

HPK-150

HORN SYSTEM

WITH WATERPROOF AMPLIFIER

HORN SELECT

E
H

I

R

LITE

O
F
F

O
N

CSP-100B

100W 11 OHM

INSTALLATION AND OPERATING

INSTRUCTIONS

Please consult your state/local vehicle codes to ensure compliance with vehicle horn regulations.

Carson is a trademark of Carson Manufacturing Company, Inc.

Sound Hazard - Sound level from horn speaker (>120dBA @ 10 feet) may cause hearing damage.
Do not operate horn without adequate hearing protection for you and anyone in immediate vicinity.
(Ref. OSHA 1910.95 for occupational noise exposure guidelines)

This product is legal in most states.

Page 2 of 8 HPK-150 Installation and Operating Instructions

The HPK-150 is a complete electronic simulated air-horn system. The system includes a water­proof amplifier with matching speaker along with a switch panel. The switch panel allows chang­ing between the vehicle horn and air-horn and includes a switch for emergency lighting. The
amplifier utilizes short circuit, and reverse polarity protection systems for maximum service life. A
power indicator light is provided on the amplifier for diagnostics.

SPECIFICATIONS

Amplifier (HA-150-10 14)

Speaker Load Single 100W 11 ohm

Input Voltage 9 - 16 VDC

Input Current 8 AMPS (14 VDC)

Output Power 105 WATTS RMS MAX. (15 VDC)

Short Circuit Current 50 AMPS (supply circuit must be capable of supplying this for 1 second)

Operating Temp. -22° F to +200°F

Size 4-1/8" Long, 2-1/8" Wide, 1-1/2" High

Weight 1 LB.

Speaker (CSP-100B)

Power Handling 100W

Impedance 11 ohm nominal

Frequency Range 400 Hz to 3500 Hz

Size 6.34” Wide, 5.10” High, 2.36” Deep

Weight 6 LBS.

Switch Panel (SP-200)

Voltage 12VDC

Current 15ADC Max.

Size 3-3/4” Wide, 1-1/4” High, 1-3/4” Deep

GENERAL DESCRIPTION

Due to continuous product improvements, we must reserve the right to change any specifications and information,
contained in this manual at any time without notice.
Carson Manufacturing Co., Inc. makes no warranty of any kind with regard to this manual, including, but not
limited to, the implied warranties of merchantability and fitness for a particular purpose.
Carson Manufacturing Co., Inc. shall not be liable for errors contained herein or for incidental or consequential
damages in connection with the furnishing, performance, or use of this manual.

NOTICE

See www.carson-mfg.com for latest information.

02/05/10 CP5061A

HPK-150 Installation and Operating Instructions Page 3 of 8

Proper installation of the system is essential for years of safe, reliable operation. Please read all

INSTALLATION

instruction before installing the system components. Failure to follow these instructions can
cause serious damage to the components or vehicle and may void warranties.

SAFETY PRECAUTIONS

For the safety of the installer, vehicle operator, passengers and the community please observe
the following safety precautions. Failure to follow all safety precautions and instructions may

result in property damage, injury or death.
Qualifications - The installer must have a firm knowledge of basic electricity, vehicle electrical

systems and emergency equipment.

Sound Hazard - Sound level from horn speaker (>120dBA @ 10 feet) may cause hearing damage.
Do not operate horn without adequate hearing protection for you and anyone in immediate vicinity.
(Ref. OSHA 1910.95 for occupational noise exposure guidelines)

Mounting - Mount the unit for easy access by the vehicle operator. DO NOT mount in air bag
deployment area. Assure clearances before drilling in vehicle.
Wiring - Use wiring capable of handling the current required. Make sure all connections are tight.
Route wiring to prevent wear, overheating and interference with air bag deployment. Install and
check all wiring before connection to vehicle battery.
Testing - Test all horn system functions after installation to assure proper operation. Test vehicle
operation to assure no damage to vehicle.
Keep These Instructions - Keep these instructions in the vehicle or other safe place for future
reference. Advise the vehicle operator of the location.

UNPACKING

Inspect contents for shipping damage. If found alert carrier immediately
Contact supplier immediately if any components are missing.
Contents of box should include the following items:

Qty Item

1 Amplifier Unit (HA-150-10 14)

1 Speaker, 100W 11 ohm (CSP-100B)

1 Switch Panel (SP-200)

4 Screw, Hex #8 Self Drilling (CP4051-XK-12)

6 Terminal, 3/16” Insulated Fem. Q.C. (CP4062-K2545)

1 Instruction Manual (CP5061 This Manual)

.

CP5061A 02/05/10

Page 4 of 8 HPK-150 Installation and Operating Instructions

MOUNTING

Amplifier

The amplifier is waterproof and may be located under hood in the engine compartment or other
areas. Allow clearance for wiring. Inspect behind mounting area for clearance. Use #8 screws
(supplied loose) for mounting.

Speaker

The speaker is weather resistant and is intended to be mounted on the outside of the vehicle or
under front hood. Mount the speaker facing forward and as far forward on the vehicle as possible
to minimize sound exposure to occupants. Choose a location that minimizes obstructions in front
of the speaker to maximize forward sound. Attach the speaker to a sturdy part of the vehicle to
prevent vibration and possible damage. Attach the speaker angled slightly toward the road so the
front openings will drain off any fluids. Cover openings of speaker while drilling any holes.

DO NOT get metal shavings inside the speaker.

Switch Panel

Mount the switch panel underneath the vehicle dash board using #8 screws (supplied loose).
Locate the panel away from the driver’s or passenger’s legs. Allow clearance for wiring. Inspect
behind mounting area for clearance. Make all electrical connections before final mounting.

ELECTRICAL CONNECTIONS

Amplifier

Electrical connections to the amplifier are made using butt splices (not supplied). The butt splices
need to be waterproof when unit is mounted under hood or other weather susceptible areas. A
label on the amplifier identifies each lead function. An in-line fuse is provided on the amplifier.
The power supply for the amplifier must be capable of delivering peak currents up to 50 amps for
adequate short circuit protection and reliable operation. Most vehicle horn circuits with relays
provide adequate power on the vehicle horn side of the relay. However do not
both the vehicle horn and this amplifier from one horn relay circuit as this will exceed circuit rating.

NOTE: Permanent disconnection of the vehicle horn is NOT recommended.

Switch Panel

Electrical connections to the switch panel are made using 3/16” quick-connect terminals (supplied
loose).

Wire Size and Termination - The diagram shows the minimum wire size used for each connec­tion, along with recommended lead color. If the wire is longer than 10 ft. use the next larger wire
size. Use only high quality crimp connectors for installation on the vehicle.

provide power to

02/05/10 CP5061A

HPK-150 Installation and Operating Instructions Page 5 of 8

ELECTRICAL CONNECTIONS CONTINUED

NOTE: Permanent disconnection of the vehicle horn is NOT recommended.

LITE

SWITCH

RATED 15A @ 12VDC

HORN SELECT

SWITCH

RATED 15A @ 12VDC

If the “HORN RELAY CIRCUIT” provides -VDC:

Connect “ORG or RED #16G” wire to +VDC supply

and connect “#16G BLK” to “HORN SELECT SWITCH”.

12V

LAMP

OBSERVE

SWITCH TERMINAL

SPACING FOR
ORIENTATION

OBSERVE

SWITCH TERMINAL

SPACING FOR
ORIENTATION

#16G BLK to -VDC

BLK #22G -VDC F OR LAMP

RED +VDC IN

YEL +VDC OUT

SEE

WIRE SIZE TABLE

ORG or RED #16G

ORG or RED #16G

#18G BRN

#18G BRN

GRN #16G

BLU #16G

ADD PROPER FUSE

20A MAX.

Lite

+VDC

Splice

Splice

Recommended

Amps Size
5 - 10 #16G

10 - 15 #14G

Use next larger

if longer than 10 ft.

UNDER HOOD

HORN

RELAY

Splice

Vehicle

Horn

#18G BRN

#18G WHT

Splice

Wire Size

size

HORN

RELAY

CIRCUIT

Break

Connection

CSP-100B
SPEAKER

100W 11 ohm

Match lead colors

coming from amp

Splices

In-line fuseholde r

with 15A

Automotive Type Fuse

FOR UNDER HOOD SPLICES

USE

WATERPROOF

BUTT CONNECTORS

UNDER HOOD

CP5061A 02/05/10

Page 6 of 8 HPK-150 Installation and Operating Instructions

ELECTRICAL CONNECTIONS CONTINUED (NOT USING SWITCH PANEL)

NOTE: Permanent disconnection of the vehicle horn is NOT recommended.

Amplifier Power

Connection E xamples

Assumes Power is +VDC

-VDC instea d, just chang e
to -VDC and Amp NEG in

May be powered with

diagrams.

Momentary

SPST

Switch

To Amp POS

+VDC

HORN RLY

To

Amp POS

+VDC

Added
SPDT
Switch

Vehicle

Horn

Horn

Circuit

Splice

To Amp POS

Vehicle

Horn

+VDC

Added

Relay

Vehicle horn

will also sound

Note:

#16G BLK to -VDC

#16G RED to +VDC

#18G BRN

#18G BRN

Waterproof butt splices

Match lead colors

coming from unit

for under hood install

In-line fuseholder

with 15A

Automotive Type Fuse

OPERATION

Sound Hazard - Sound level from horn speaker (>120dBA @ 10 feet) may cause hearing damage.

Do not operate horn without adequate hearing protection for you and anyone in immediate vicinity.
(Ref. OSHA 1910.95 for occupational noise exposure guidelines)

USING SWITCH PANEL

In an emergency situation, set the HORN SELECT switch to AIR and turn on the LITE switch in
one sweeping motion. When the horn ring on the vehicle is pressed the amplifier and speaker
produce a simulated air horn sound. A power indicator on the amplifier also lights up. The power
indicator is located on the same surface where wires emerge from amplifier.

When the emergency is over, turn off the LITE switch and set the HORN SELECT switch to VEH
in one sweeping motion. When the horn ring is pressed the regular vehicle horn will sound.

NOT USING SWITCH PANEL

As soon as power is applied, the amplifier and speaker produce a simulated air horn sound and
the power indicator lights up. The power indicator is located on the same surface where wires
emerge from amplifier.

02/05/10 CP5061A

HPK-150 Installation and Operating Instructions Page 7 of 8

The complete system consists of the amplifier, speaker, and switch panel components along with

SERVICE

the wiring and electrical connections. A blown fuse on the amplifier does not necessarily
mean the amplifier is bad. If the system stops functioning or exhibits problems, first check that

the wire and electrical connections to each component are OK then check the following.

On the switch panel, check for power into (center terminal) and out of the switch. On the HORN
SELECT switch, check for power while pressing the horn ring. If there is not power into the
switch, check wire for bad connections and check fuses or breakers in the circuit. If there is
power into but not out of the switch, the switch itself may be bad.

While activating the amplifier (with horn ring), look for the power indicator to light up. If it
lights up the amplifier is OK. If not, check the fuse on the amplifier. If the fuse is OK then check
the RED and BLK power input leads for good supply and ground connections. If power into the
amplifier is OK then the amplifier may be bad.

If the fuse on the amplifier is blown, disconnect the speaker leads at the amplifier and replace
the fuse. As before, activate the amplifier and look for the power indicator to light up. If the fuse
blows again then the amplifier may be bad.

If the power indicator on the amplifier lights up, disconnect the leads at the speaker and check
the speaker inputs with an ohm meter. If the reading is less than 1 ohm or reads as open circuit
then the speaker may be bad. If the ohm meter reading is OK then the wiring or connections
between the amplifier and speaker may be faulty.

The following chart shows typical symptoms and possible causes.

PROBLEMS

Symptom Possible Cause Check

No power or
output

Distorted sound Speaker assembly loose

Intermittent tone Connections loose

Power not applied
Connections loose
In-line fuse blown
Loose connection at power source
Bad speaker

Low vehicle voltage

Bad power connection
Circuit breaker in supply connection

Is the power indicator light coming on?
Is an external fuse or circuit breaker used?
Are the negative leads connected to a good ground?

Try another speaker.
Is the speaker bell or tip loose?
Input voltage must be greater than lowest rated voltage.
Are the splice connections tight on the unit?
Is there a loose connection on a power lead?
Is a circuit breaker used with at least a 50A rating?

PARTS and ACCESSORIES

The following parts and accessories are available from Carson Manufacturing Company, Inc.:

Part Description

CP4990-150 Fuse, 15 Amp Mini Automotive (for amplifier)

CP4993 Switch, Lighted Rocker (Lite switch on panel)

CP5044-2 Switch, Red Rocker ON - ON (Horn Select switch on panel)

Accessory Description * - standard accessory supplied with unit

ED1924 Cable, 6-P Lead Assembly 15FT (made w/ 3/16” Q.C. Terminals) (for switch panel)

CP4051-XK-12 * Screw, Hex #8 Self Drilling (for mounting)

CP4062-K2545 * Terminal, 3/16” Insulated Fem. Q.C. (for switch panel)

CP5061 * Manual, HPK-150 Instruction

See www.carson-mfg.com for additional information.

or contact our Service Department at:

E-mail [e-mail] or Phone [phone]

CP5061A 02/05/10

Page 8 of 8 HPK-150 Installation and Operating Instructions

RETURN

If you have any questions concerning this or any other Carson product,
please contact our Technical Service Department at [phone].
Many issues can be handled over the phone. We can also be reached via
e-mail at [e-mail]

If a product must be returned for any reason, please contact our Technical
Service Department to obtain a Returned Merchandise Authorization num­ber (RMA#) before you ship the product to Carson. Please write the RMA#
clearly on the package near the mailing label. Be sure to provide a return
address, contact and phone number, along with a brief description of the
problem.

Carson Manufacturing Company, Inc. warrants this new product to be free from defects
in material and workmanship, under normal use and service, for a period of five (5)
years from the date of delivery to the first user-purchaser.

During this warranty period the obligation of Carson Manufacturing is limited to repairing
or replacing, as Carson Manufacturing may elect, any part or parts of such product
which after examination by Carson Manufacturing is determined to be defective in mate­rial and/or workmanship.

This warranty does not cover labor charges for removal or re-installation of the product.
Fuses and lamps and speakers are not covered under this warranty.

This warranty does not extend to any unit that has been subjected to abuse, misuse,
improper installation or which has not been adequately maintained, nor to units which
have problems related to service or modification at any facility other than the manufac­turer.

THERE ARE NO OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING
BUT NOT LIMITED TO, ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL CARSON MANU­FACTURING COMPANY, INC. BE LIABLE FOR ANY LOSS OF PROFITS OR ANY
INDIRECT OR CONSEQUENTIAL DAMAGES ARISING OUT OF ANY SUCH DEFECT
IN MATERIALS OR WORKMANSHIP.

02/05/10 CP5061A

LIMITED WARRANTY