Code 3 CODE 360 Installation & Operation Manual
INSTALLATION
& OPERATION
MANUAL
FOR CODE 360
LIGHTBARS
PATENT PENDING
®
®
CODE 360
TRI-LEVEL LIGHT BAR
CONTENTS:
Introduction...................................................................................2-3
Unpacking & Pre-Installation.........................................................4
Installation & Mounting..........................................................4-6
Wiring Instructions.................................................................6-7
Options & Specifications.....................................................7-12
Maintenance...........................................................................12-16
Parts List (Replacement Parts / Exploded View).................17-20
Trouble Shooting.................................................................21-22
Notes....................................................................................22-23
Warranty..............................................................................24
For future reference record your lightbar's serial no. here __________________________________________
IMPORTANT:
Read all instructions and warnings before installing and using.
INSTALLER: This manual must be delivered to the end user of this equipment.
1
Introduction
The Code 360
from Code 3
360 Degrees of Light, the Nth Degree of Protection!
Check out all the exciting features of your new Code 360
√√
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√ 360 degrees of coverage
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√ Outstanding safety features available including:
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√ Corner pods allow forward positioning of:
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Three levels and four rows of lights
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√ Alley lights
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√ ArrowStik
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√ OsciLaser™
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√ T actical T akedowns™
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√ X-Fire upper- and lower-level strobes
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√ X-Sweep dual halogen intersection lights
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®
®
Light Bar
®
√ Available in:
√ All Strobe
√ All Halogen
√ Strobe/Halogen combination
√ Can accommodate up to 10 locations for stationery lights
®
light bar:
Code 360® Quality Assurance means that each light bar has been individually tested and approved
The use of this or any warning device does not ensure that all drivers can or will observe or react to an emergency
warning signal. Never take the right-of-way for granted. It is your responsibility to be sure you can proceed safely
before entering an intersection, driving against traffic, responding at a high rate of speed, or walking on or around
traffic lanes.
The effectiveness of this warning device is highly dependent upon correct mounting and wiring. Read and follow
the manufacturer’s instructions before installing or using this device. The vehicle operator should insure daily that all
!
WARNING!
features of the device operate correctly. In use, the vehicle operator should insure the projection of the warning
signal is not blocked by vehicle components (i.e.: open trunks or compartment doors), people, vehicles, or other
obstructions.
This equipment is intended for use by authorized personnel only. It is the user’s responsibility to understand and
obey all laws regarding emergency warning devices. The user should check all applicable city, state and federal
laws and regulations.
Public Safety Equipment, Inc., assumes no liability for any loss resulting from the use of this warning device.
2
!
WARNING!
Proper installation is vital to the performance of this warning device and the safe operation of the emergency vehicle. It is
important to recognize that the operator of the emergency vehicle is under psychological and physiological stress caused
by the emergency situation. The warning device should be installed in such a manner as to: A) Not reduce the output
performance of the system, B) Place the controls within convenient reach of the operator so that he can operate the
system without losing eye contact with the roadway.
Emergency warning devices often require high electrical voltages and/or currents. Properly protect and use caution
around live electrical connections. Grounding or shorting of electrical connections can cause high current arcing, which
can cause personal injury and/or severe vehicle damage, including fire.
PROPER INSTALLATION COMBINED WITH OPERATOR TRAINING IN THE PROPER USE OF EMERGENCY
WARNING DEVICES IS ESSENTIAL TO INSURE THE SAFETY OF EMERGENCY PERSONNEL AND THE
PUBLIC.
Wiring Instructions (read
Carefully Before Installation)
3
Unpacking & Pre-installation
Carefully remove the light bar and place it on a flat surface, taking care not to scratch the lenses or damage the cable coming out of the
bottom. Examine the unit for transit damage, broken lamps, etc. Report any damage to the carrier and keep the shipping carton.
Standard light bars are built to operate on 12 volt D.C. negative ground (earth) vehicles. If you have an electrical system other than 12
volt D.C. negative ground (earth), and have not ordered a specially wired light bar, contact the factory for instructions.
Test the unit before installation. To test, touch the black wire to a negative ground (earth) and the other wires to +12 volts D.C., in
accordance with the instructions attached to the cable (an automotive battery is preferable for this test). A battery charger may be used, but
please note that some electronic options (flashers, stingrays, etc.) may not operate normally when powered by a battery charger. If
problems occur at this point, contact the factory.
Installation & Mounting
WARNING!
MOUNTING HARDWARE - All mounting hardware is packed in a small box inside the main carton. Four standard kits are available: (1)
Hook-On Type, (1) Tow and Recovery and (2) Permanent Types. These are discussed in detail later. Note: Hook-on mounting for
"gutterless" type vehicles will require a special hook for mounting. Several special application hooks are available. Contact the factory for
details.
!
Utilizing non-factory supplied screws and/or mounting brackets and/or the improper number of
screws may result in loss of warranty coverage on the equipment.
Hook-on Mounting
Begin the installation by attaching the rubber feet to the mounting brackets with 3/8" long Flat Head Screw and Nylock nuts. See
Figure1. Place the light bar upside down on a table or other work surface, being careful not to scratch the lenses. Slide the 5/16"
carriage bolts into the frame. Secure the mounting brackets finger tight so they support the weight of the light bar, but still are
positionable. Now would be a good time to insert the 3 1/2" long carriage bolt through the mounting brackets. If desired, you can also
unbundle the lightbar cable and feed it through the drivers' side mounting bracket. Locate the vehicle on a level surface. Place the
lightbar on the roof of the vehicle. Place a soft pad in the center of the roof to protect the paint. The mounting brackets must be placed
so that the rubber feet are resting on the curved section of the roof, see Figure 2. This is the strongest part of the roof. If necessary
bend the mounting bracket feet to match the contour of roof. Once the light bar is centered, tighten the mounting bracket to the light bar.
Using a tape measure and a level, center the light bar from side to side and locate a position on the roof where the light bar is level.
Black nylon spacers are provided to level lightbar. Place spacer between rubber foot and mounting bracket and use longer flat head
screws provided to secure foot to bracket.
FIGURE 1
5/16" x 3 1/2"lg Carriage Bolt
5/16" Split Lockwasher
5/16" Nut
Bottom of Lightbar
5/16-18 Carriage Bolt
Mounting Bracket
Nylock Nut
Gutter Hook
5/16" Nylock Nut
Rubber Feet
Flat Head Screw
4
Curved Feet on
Curved Portion
Vehicle Gutter
FIGURE 2
Insert the carriage bolts through the holes in the gutter hooks, and into a 5/16" Nylock nut as shown in Figure 1. If a special hook
for a "gutterless" vehicle is used, refer to the instructions for that hook at this time. The carriage bolt provided is sized for the most
common installations, but longer and shorter bolts are available at any hardware store. Tighten the nuts onto the carriage bolts on
both sides evenly keeping the light bar centered and level.
NOTE: Tighten only until the bar is secure (bar does not move when bumped sharply with the heel of the palm). It is NOT
necessary to dimple the roof to obtain a stable attachment. If the light bar "bows" more than 3/16" (determined by placing a
straightedge along the front, bottom part of the frame and measuring downward at the center of the frame), loosen the 5/16" trim nut
sightly.
Vehicle Roof
Permanent Mounting
Typical Mounting: Refer to Figure 3. Place the light bar upside down on a table or other work surface, being careful not to
scratch the lenses. Slide the 5/16" carriage bolts into the frame. Secure the mounting brackets finger tight so they support the
weight of the light bar. Place the unit on the roof of the vehicle. Place a soft pad in the center of the roof to protect the paint.
The mounting brackets must be placed so that they are resting on the curved section of the roof, see Figure 4. This is the
strongest part of the roof. Once the light bar is centered, tighten mounting brackets to light bar. Using a tape measure and
a level, center the light bar from side to side and locate a position of the roof where the light bar is level. The shims provided
may be used here to help level the light bar. Also, the tabs on the mounting bracket may be bent at any angle to match the
curvature of the roof (see Figure 4).
5/16-18 Carriage Bolt
Bottom of Lightbar
Mounting Bracket
Customer Supplied Bolt
Rubber Feet
Figure 3
S81912 - Mounting Kit without
Adaptor Bracket
5
Curved Roof
Place Feet on
Curved Portion
Once the light bar is level and centered, mark the holes through the mounting tabs and remove the light bar from the vehicle.
Make sure that the drill will not damage anything when penetrating the roof. Drill the mounting holes and remove any burrs.
Attachment can be made using 1/4" cap screws, toggle bolts, or other fasteners as may be convenient. Use sealant as
necessary to prevent water leakage into the vehicle.
Flat Roof
FIGURE 4
Wiring Instructions
Larger wires and tight connections will provide longer service life for components. For high current wires it is
highly recommended that terminal blocks or soldered connections be used with shrink tubing to protect the
!
WARNING!
connections. Do not use insulation displacement connectors (e.g. 3M® Scotchlock type connectors). Route
wiring using grommets and sealant when passing through compartment walls. Minimize the number of splices to
reduce voltage drop. High ambient temperatures (e.g. underhood) will significantly reduce the current carrying
capacity of wires, fuses, and circuit breakers. Use "SXL" type wire in engine compartment. All wiring should
conform to the minimum wire size and other recommendations of the manufacturer and be protected from moving
parts and hot surfaces. Looms, grommets, cable ties, and similar installation hardware should be used to
anchor and protect all wiring. Fuses or circuit breakers should be located as close to the power takeoff points as
possible and properly sized to protect the wiring and devices. Particular attention should be paid to the location
and method of making electrical connections and splices to protect these points from corrosion and loss of
conductivity. Ground terminations should only be made to substantial chassis components, preferably directly to
the vehicle battery. The user should install a fuse sized to approximately 125% of the maximum Amp capacity in
the supply line to protect against short circuits. For example, a 30 Amp fuse should carry a maximum of 24
Amps. DO NOT USE 1/4" DIAMETER GLASS FUSES AS THEY ARE NOT SUITABLE FOR CONTINUOUS
DUTY IN SIZES ABOVE 15 AMPS. Circuit breakers are very sensitive to high temperatures and will "false trip"
when mounted in hot environments or operated close to their capacity.
Before attempting to connect wiring refer to wire tag attached to the lightbar's main cable. Each wire in the cable controls
a separate lightbar function as described in the wire tag.
The only significant difference between the CODE 360® with optional ArrowStik® and a conventional CODE 360, is the
additional, thinner cable exiting the bottom of the lightbar. The larger cable is the lightbar power cable. Route the wiring
cable into the engine or passenger compartment, taking care to use grommets and to apply sealant around openings to
keep water out. It is advisable to leave an extra loop of cable when installing the light bar to allow for future changes
or reinstallations. Connect the black lead to a solid frame ground (earth), preferably, the (-) or ground (earth) side of the
battery and bring the other wires to the control head or switches. Connect the wires as directed by the wiring
instructions on the cable.
6
Arrowstik® / Narrowstik®
OPTIONAL HALOGEN ARROWSTIK® (7-wire) / L.E.D. NARROWSTIK® (11-wire) WIRING AND CONTROL HEAD INST ALLA TION After installation of the lightbar, route the smaller of the two power cables through the vehicle to the location chosen for the control head. Cut
the cable to length and strip back the outer insulation to expose the seven or eleven colored wires. Strip back 1/8” - 1/4” of colored
insulation from each of the wires in the cable. Connect these wires to the seven position / eleven position terminal plug enclosed in the user
parts bag, according to the diagram on the bottom of the control head.
- Refer to the control head manual packaged with the lightbar for control
head installation and operation instruction.
OPTIONAL STROBE WIRING INSTRUCTIONS - For all configurations the strobe power supply(s) will be
powered by the #14 AWG Red and Red/Black wires in the lightbar main cable. For 2 or 4 head configurations
only the Red or Red/Black wire will be utilized. For 6, 8, 10 and 12 head configurations both wires will be utilized.
These wires will supply DC power to each strobe power supply(s) so all user supplied switches and wiring
connected to the Red and/or Red/Black wires should be rated for a minimum of 10 Amps and fused at a
maximum of 15 Amps, for each wire used. Two additional wires in the main cable (typically Green and Green/
Black) are used to control the flash mode of the power supply. These wires are low current connections at
typically less than 1 Amp. (See lightbar "wire tag" for wire color).
OPTIONS & SPECIFICA TIONS
Many options are available for the LED X 2100. This section is designed to describe the function of the various LED X 2100 options.
LED W ARNING MODULES
L.E.D. Fusing Considerations
Although the average current draw per module is very low, due to the type of circuit used to power each module the instantaneous
peak current to a module can be significantly higher during low voltage conditions. To avoid prematurely blowing ATO style fuses or
tripping breakers it is recommended the following rule-of-thumb be used to size fuses or breakers. This is especially important in
lightbars with many LED modules running off a single fused source wire,
Minimum fuse size calculation:
1.5 x (number of modules being fused)
Example:
Excalibur Lightbar with 2 corner modules (2 per module) and 4 directional modules.
Minimum fuse requirement for single fuse - 1.5 (2+2+4) = 10A minimum
WARNING!
!
This Product contains high intensity LED devices. To prevent eye damage, DO NOT stare into
light beam at close range.
7
Dim Operation
Lightbar LED modules are equipped with a low power "Dimming" mode as standard. Dimming will be controlled by applying
+12V by way of the appropriate wire(color) in the wire harness/wire list. When DIM is engaged the LED's will operate in a
reduced power mode.
For safety purposes, the corner modules in lightbars are not connected to the dimming circuit. This
ensures that when corner modules are turned on, full 360 degree coverage and compliance with
SAE warning light standards is provided.
The DIM control wires( two white wires) located on each of the modules are connected from one module to the
next. To disable the dimming function on a particular module, disconnect the white wires. Then
reconnect the white wire to the white wire on another module that has dimming enabled.
The Dim setting reduces the light output of emergency warning lights reducing the effectiveness of them
!
WARNING!
especially in brightly lit areas. Failure to use adequate light for the circumstances can cause motorists to
fail to see the emergency vehicle and lead to serious personal injury or death. Never use the DIM
setting in a brightly lit area. Use of the DIM setting may cause emergency lights to not comply with
applicable emergency warning light standards. Use caution when using the DIM setting to assure that
motorists can clearly see the emergency vehicle.
Code 3® OPTIX™ 360 DEGREE CORNER MODULES
The Code360™ Lightbar may be equipped with Code 3® OPTIX™ 360 degree corner LED modules that provide a full 360
degree of warning.The optic has been designed to exceed all applicable requirements for 360 degree warning devices in Red,
Blue, and Amber. The new OPTIX corner module is a ( 1" X 6" ) module and uses larger, higher efficiency, TIR optics to produce
an enhanced corner signal over the exisitng ( 1" X 4" ) Code 3 LED X™ corner module. While the OPTIX will become the standard
corner module for most configurations, the LED X corner module will still be available and may be required for some configurations.
Installation and Operation for both modules will be the same. Consult the factory for further information.
Operating Specifications for 360 degree module:
Operating Voltage: 10-16 VDC, Reverse Polarity Protection
Current Draw : Red/Amber - .5A avg @ 12.8 Volts
Blue/White - .8A avg @ 12.8 Volts
Available Colors - Red, Blue, Amber and White
8
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