Code 3 DuoBeam II User Manual
INSTALLATION
& OPERATION
MANUAL
DuoBeam II
IMPORTANT:
CONTENTS:
Introduction..... .............................................................................2
Unpacking & Pre-Installation........................................................2
Installation & Mounting.................................................................2
Wiring & Fusing............................................................................4
LED Lighthead Description & Pattern Change.............................5
Parts List......................................................................................8
Dimensions & Specications......................................................11
Maintenance...............................................................................11
Warranty.....................................................................................12
Read all instructions and warnings before installing and using.
This manual must be delivered to the end user of this equipment.
INSTALLER:
1
Introduction
The LED DuoBeam IITM uses state of the art LEDs and optics to provide superior optical output. The rugged
design and long life capabilities make it virtually maintenance free. When properly congured, the Duo-Beam
will exceed SAE Class 1 and California Title 13 requirements.
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
!
Warning!
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 ap-
plicable city, state and federal laws and regulations.
Code 3, Inc., assumes no liability for any loss resulting from the use of this warning device.
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.
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.
The LED DuoBeam IITM is 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) contact the factory.
Installation & Mounting
**For orientation purposes, the DuoBeam was built with the carriage bolt track running from left to right -
(not front to back).
FLUSH MOUNT
Insert carriage bolts into
track. Place spacer over
bolts as shown to the
right. Align bolts with
pre-drilled holes in vehicle's surface. Place lock
washer and nut on bolt
and tighten until snug.
MOUNTING SPACER (S50179)
5/16-18 X 1 1/2" CARRIAGE BOLT (PN 240)
VEHICLE MOUNTING SURFACE
5/16" SPLIT LOCK WASHER (PN 245)
5/16-18 SS HEX NUT (PN 244)
NOTE: Spacer must be used to prevent water from entering the bar.
2
MAGNETIC MOUNT
Insert carriage bolts into
track. Place molded shims
over bolts as shown. Attach
magnetic base over bolts.
Place lock washer and nut
on bolt then tighten until
snug.
MOLDED SHIM (PN 1064)
RB 80 MAGNETIC BASE (PN 499)
5/16" SPLIT WASHER (PN 245)
5/16-18 X 1 1/2" CARRIAGE BOLT (PN 240)
5/16-18 SS HEX NUT (PN 244)
MIRROR MOUNT BRACKET
1. Assemble the brackets, tighten the 3/8 bolt but leave the 7/16 bolt nger tight at this time.
2. Position bracket assembly on top mirror supports, bracket A on rear support and bracket B on front sup-
port. Note: some mirror designs require reversing bracket A and B. Rotate bracket A as necessary to get
the best t. Some additional bending of brackets may be necessary in some cases to achieve a satisfactory t.
3. Attach bracket assembly to mirror supports with U-bolts, position bracket assembly as desired and tighten
U-bolts. The Duo Beam mounting bracket should be parallel to the ground.
7/16" LONG BOLT
T03807 MOUNTING BRACKET
T03804 MOUNTING BRACKET
T07595 MOUNTING BRACKET
T07595 (IMMBH) OR T03802 (MMBH)
MOUNTING BRACKET
!
Warning!
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.
U-BOLT
3/8" LONG BOLT
3
Wiring & Fusing
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 pass-
!
Warning!
One of two cable types will be installed in the DuoBeam:
ing 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 pro-
tected 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.
2 conductor• (1 red & 1 black) - This cable is used when the light heads have an integrated asher
installed. The light heads ash independently. The red conductor should be connected to power
(+12VDC) via a switch or controller of some kind and the black conductor should be connected to
ground.
7 conductor• - This cable is used when there is a central controller installed. All TriCoreTM models
and most multi-color models will employ a CC. These models will require a somewhat more sophisticated method of control (switchbox or siren with lighting controls) as more options are available.
Further explanation can be found starting on Page 6 of this manual.
LED Fusing Considerations
Although the average current draw per LED module is very low, the instantaneous peak current to a module can be higher during low voltage conditions. To avoid prematurely blowing of 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 light bars with many LED modules running off a single fused source. It is always best to have
20-25% head room in calculating for fusing. Please use the values below to calculate fuse values for DuoBeam installation.
For PriZm IITM lightheads:
REF8 - 1.0 x (number of lightheads being fused)
REF12 - 1.5 x (number of lightheads being fused)
Example:
DuoBeam with (4) REF12 lightheads - 4*1.5A = 6A minimum
For TorusTM lightheads:
TRS6 - 1.0 x (number of lightheads being fused)
For TriCoreTM lightheads:
TC6 - 2.0 x (number of lightheads being fused)
4
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