Code 3 Defender User Manual
INSTALLATION &
OPERATION
MANUAL
for DEFENDER® LIGHT BARS
DEFENDER®
LIGHT BAR WITH
TRICORE® AND TRICORE®TC2 TECHNOLOGY
U.S. Patent Nos. 7,153,015 and 7,300,175 - Other Patents Pending
CONTENTS:
Introduction............................................................................................2
Unpacking & Pre-Installation...................................................................3
Installation & Mounting............................................................................3
Wiring Instructions...............................................................................3
Options & Specications......................................................................3-4
Flash Pattern Selection......................................................................4-8
Maintenance.......................................................................................9
Exploded View/Parts List.............................................................................9-10
Troubleshooting...............................................................................11
Notes...............................................................................11
Warranty/Returns................................................................................12
For future reference record your light bar'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 DEFENDER® (Patent-Pending) Light bar Features the truly unique, TriCore® (Patent-Pending) Technology which constitutes a quantum leap
forward in signal brightness far exceeding the intensity and quality of any system. Unlike traditional LED Light bars that drop off at key angles, TriCore maintains it's astonishing visibility a full 360 degrees. TriCore is also designed so that brightness won't fade. Watt for Watt, TriCore is the most
efcient emergency warning light ever made.
The DEFENDER is approximately 2.2" high, yet delivers 360° of unobstructed warning signal. The low prole and aerodynamic lines reduce air drag,
which results in fuel savings and stability at high speeds. The DEFENDER light bar also has an extruded internal frame that is 2X stronger, shockresistant polycarbonate lenses with an intermolded solar barrier, a modular lens design that enables almost any light bar length which can be created
from 3 lens lengths, and warning signals that exceed SAE standards.
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 trafc, responding at a high rate of speed, or
walking on or around trafc 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 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.
Code 3, Inc., assumes no liability for any loss resulting from the use of this warning device.
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 re.
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)
2
Unpacking & Pre-Installation
Carefully remove the light bar and place it on a at 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 the 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 note that some electronic op-
tions (ashers, etc.) may not operate normally when powered by a battery charger. If problems occur at this point, contact the factory.
Utilizing non-factory supplied screws and/or mounting brackets and/or the improper number of
screws or modifying the supplied parts may result in loss of warranty coverage on the equipment.
WARNING!
Installation & Mounting
MOUNTING HARDWARE - Mounting hardware is usually packed in a small box inside the main carton although some mounting kits may be shipped
separately. Refer to the Installation Manual included in the mounting kit for mounting instructions. 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.
Wiring Instructions
Before attempting to connect wiring, refer to wire tag attached to the light bar's main cable. Each wire in the cable controls a separate function of the
Central Controller as described in the wire tag.
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
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. under hood) will signicantly 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
WARNING!
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.
Options & Specications
Fusing Considerations
The DEFENDER Light bar should be installed with an external fuse or circuit breaker in the RED lead of the two conductor 10 AWG power cable.
The recommended external fuse size for the light bar is 30A. The internal circuitry of the Central Controller is reverse polarity protected. Each
TriCore output on the Central Controller board is protected against over current and over heating with automatically resetting output devices.
Dim Operation
The DEFENDER® features a low power "Dimming" mode. Dimming will be controlled by applying +12V by way of the appropriate wire (Blue) in the
wire harness/wire list. Dimming can also be controlled by an optional photo cell. When DIM is engaged, the TriCore® light heads will operate in a
reduced power mode. Note: For light bars with software T116XXV5 or lower, T117XXV5 or lower and T118XXV1 or lower, the corner mounted
light heads are excepted from this function and will not Dim.
The Dim setting reduces the light output of emergency warning lights reducing the effectiveness of them 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
WARNING!
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.
3
WARNING!
This Product contains high intensity TriCore devices. To prevent eye damage,
DO NOT stare into light beam at close range.
Selecting Flash Patterns
Use the following instructions for lightbars without programmable light head pairs.
Note: If you have purchased a light bar with programmable light head pairs,
For lightbars with all single color light heads, please see supplement T16406 (800Series Software).
For lightbars with any multi-color light heads, please see supplement T54006 (950Series Software).
STEP 1
The Pattern Select wire is the BLK/RED wire in the sixteen conductor light bar control cable and is activated by momentarily touching the wire to
+power. Select the desired 3-Level mode to program by applying +power to the appropriate wire in the 16 conductor cable.
Make sure +12v is only applied to the function you are trying to program - otherwise program function will not operate.
There are seven possible 3-Level modes (see Table 1). The factory default is different for each of the 3 -Level modes. The standard progressive
switch will use the Level-1, Level-2 and Level-3 modes. The defaults for Level-1, Level-2 (L1 + L2) and Level-3 (L1 + L2 + L3) are identied in Table
1A. When using individual switches, make sure to select patterns for all switch combinations.
TABLE 1: 3-LEVEL MODES OF OPERATION
MODE NUMBER WIRES ACTIVATED
L1 GRN/BLK (LEVEL-1)
L2 WHT/BLK
L1 + L2 GRN/BLK & WHT/BLK (LEVEL-2)
L3 RED/BLK
L1 + L3 GRN/BLK & RED/BLK
L2 + L3 WHT/BLK & RED/BLK
L1 + L2 + L3 GRN/BLK, WHT/BLK, & RED/BLK (LEVEL-3)
STEP 2
Observe the ashing pattern operation and determine which pattern is in operation for Level-1. Refer to Table 1A. This table shows the available
ash patterns. Note: the Factory Default is different and identied in the table for each of the ash mode Levels (L1, L2, L3). Once the ash pattern
has been determined, proceed to Step 3
.
STEP 3
Scroll to the next ash pattern by momentarily holding the Pattern Select wire (BLK/RED) to +power for ~1 sec. The light bar will stop ashing when
the wire is connected to +power. Release the wire and the next pattern as listed in Table 1A will begin to ash. The new pattern is automatically
stored each time. Repeat this procedure for each of the seven possible 3-level modes.
NOTE: To restore the Factory Default Emergency Warning Flash Patterns (see Table 1A), hold the pattern select wire to +power for ~four
(4) seconds.
SEE FLASH PATTERN SELECTION NOTES ON FOLLOWING PAGES
4
Loading...