Code 3 DEFENDER TriCore Installation & Operation Manual
INSTALLATION &
OPERATION
MANUAL
FOR DEFENDER™ TRICORE™
LIGHTBAR
DEFENDER™
LIGHTBAR
WITH TRICORE™ TECHNOLOGY
U.S. Patent Nos. 7,153,015 and 7,300,175
CONTENTS:
Introduction............................................................................................2
Unpacking & Pre-Installation...................................................................3
Installation & Mounting............................................................................3
Wiring Instructions...............................................................................3
Options & Specications......................................................................3-4
Flash Pattern Selection......................................................................4-7
Maintenance.......................................................................................8
Exploded View/Parts List.............................................................................8-9
Troubleshooting...............................................................................10
Notes...............................................................................10-11
Warranty/Returns................................................................................12
For future reference record your lightbar's serial no. here __________________________________________
Read all instructions and warnings before installing and using.
IMPORTANT:
INSTALLER: This manual must be delivered to the end user of this equipment.
1
Introduction
The DEFENDER™ (Patent-Pending) Lightbar 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 Lightbars 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 lightbar also has an extruded internal
frame that is 2X stronger, shock-resistant polycarbonate lenses with an intermolded solar barrier, a modular lens design that enables
almost any lightbar 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 lightbar 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 lightbars 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 lightbar, 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 options (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 lightbar's main cable. Each wire in the cable controls a separate
function of the Central Controller as described in the wire tag.
The DEFENDER provides an ArrowStik function as a standard feature. Connect the appropriate control wires to any control switch
capable of providing +power at approximately 25ma current. As noted in the wire description, connecting both the LEFT Arrow and
RIGHT Arrow wire to +power at the same time enables the Center-Out ArrowStik function.
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. underhood) 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
WARNING!
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.
OPTIONS & SPECIFICATIONS
Many options are available for the DEFENDER. This section is designed to describe the function of the various options.
TRICORE WARNING MODULES
Fusing Considerations
The DEFENDER Lightbar 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 lightbar 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.
3
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. When DIM is engaged, the TriCore light heads will operate in a reduced power mode.
Note: The corner mounted TriCore light heads are excepted from this function and will not dim.
Please contact the factory if more information is needed concerning the dimming mode.
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 lit area. Use of the DIM setting may cause emergency lights to not
WARNING!
comply with applicable emergency warning light standards. Use caution when using the DIM setting to
assure that motorists can clearly see the emergency vehicle.
LED ArrowStik feature
The DEFENDER has a programmable ArrowStik feature integrated into the light bar that operates independently of the other
features. Refer to the ArrowStik Programming section of this manual for detailed information on pattern selection and
operation instruction.
This Product contains high intensity TriCore devices. To prevent eye damage,
WARNING!
DO NOT stare into light beam at close range.
Selecting Flash Patterns
The Pattern Select wire is the BLK/RED wire in the sixteen conductor lightbar control cable and is activated by momentarily touching
the wire to +power.
STEP 1
Power-up the lightbar and select the Level-1 ash mode by applying +power to the GRN/BLK wire in the 16 conductor control cable.
STEP 2
Observe the ashing pattern operation and determine which pattern is in operation for Level-1. Refer to Table 1. 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, until the TriCore light
heads switch ash patterns, and then releasing it. This will step to the next pattern in numbered order as listed in Table 1 for the
selected 3-Level mode. The new pattern is automatically stored each time. Repeat this procedure for Level-2 and Level-3.
Note: All control inputs are +power enabled.
Control Input Function Denitions
Wire Color Function Description
GRN/BLK Level 1 Level 1 Emergency Mode
WHT/BLK Level 2 Level 2 Emergency Mode
RED/BLK Level 3 Level 3 Emergency Mode
ORG/BLK Takedown lights Takedown Lights Steady Burn (overrides Takedown Flash)
BLU/BLK Rear Cut-Off Blacks-Out Rear Facing heads
GRN/WHT Front Cut-Off Blacks-Out Front Facing heads
RED/WHT Right Alley Light Right Alley Steady Burn (overrides Alley Light Flash)
BLK/WHT Left Alley Light Left Alley Steady Burn (overrides Alley Light Flash)
WHT ArrowStik Flash ArrowStik Flash (overrides L1, L2 & L3 for rear of light bar)
BLK/RED** Pattern Select Pattern Select for ArrowStik, L1, L2 & L3, (enables test mode)
BLK Takedown Flash Enables Takedown Lights Wig/Wag Flash
RED* ArrowStik Left Left ArrowStik (overrides L1, L2 & L3 for rear of light bar)
GRN Cruise Lights End heads only (overridden by all other functions)
ORG* ArrowStik Right Right ArrowStik (overrides L1, L2 & L3 for rear of light bar)
BLU Light bar DIM Sets heads to Dim mode
BLU/WHT Alley Light Flash Enables Alley Light Wig/Wag Flash
See "Notes" Next Page
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