Code 3 MX 7000 User Manual
INSTALLATION
MX 7000
TM
& OPERATION
MANUAL
MX7000®
LIGHT BAR
Patent Number
5,091,828
D326,621
Contents:
®
DUAL LEVEL
LIGHT BAR
Introduction..........................................................................2
Unpacking & Pre-Installation ............................................... 3
Installation & Mounting........................................................ 3
Hook-on Mounting.............................................................4
Permanent Mounting.........................................................5
Wiring Instructions..........................................................6-7
Options & Specifications ................................................8-14
Maintenance.................................................................15-19
Parts List (Replacement Parts / Exploded View)..........19-24
D-Tech Rotator.............................................................25-26
Trouble Shooting..........................................................27-28
Notes............................................................................29-31
Warranty............................................................................32
Read all instructions and warnings before installing and using.
IMPORTANT:
INSTALLER: This manual must be delivered to the end user of this equipment.
Introduction
The MX 7000® Light Bar is a dual-level light bar that is less than 6" high, yet delivers unobstructed 360° warning and
more signal power and versatility than any other light bar of its size.
The low profile and aerodynamic lines of the MX reduce air drag, which results in fuel savings and stability at high
speeds. This light bar has a strong extruded internal frame, shock-resistant polycarbonate lenses, and warning signals that
exceed SAE standards.
The MX is designed on a modular basis, which means that the light bar can be customized to meet any requirements.
Because of its dual-level design, the MX has room for an incredible number of these options: standard or high speed
rotators, StingRay
lower corners, and up to 12 locations for special purpose stationary lights in the lower deck. While we do not recommend
a light installed in every location, the design of the MX 7000 offers the ultimate flexibility in the location of warning and
auxiliary lights.
!
WARNING!
TM
oscillating signals, an OsciLaserTM in the top deck, alley lights and intersection or Pursuit Lights in the
The use of this or any warning device does not insure 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 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.
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.
2
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 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 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!
!
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.
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 are available. Contact the
factory for details.
SIREN SPEAKERS
(Single Speaker Installation in 43", 47", 52" & 58"
Light bars) Speaker Installation is advised at this
point while the speaker section is easily accessible.
To install a speaker, first remove the two (2) hexhead screws, (4 screws on 58 1/4" bars) from the
bottom of the perforated side of the speaker cover.
The cover is hinged at the back--pull the front of the
cover up and over the lenses to remove it. Figure 1
shows the speaker cover opened and location holes
for installing a Code 3 "LP" speaker. If other than a
Code 3® "LP" speaker is used, two possibilities
exist for speaker installation. An "LPSPKR"
conversion kit is available from the factory to
mount an existing speaker in an MX7000TM.
Otherwise, holes must be drilled for installation.
The center speaker deck is 1/8" thick aluminum and
may be drilled almost anywhere. Before drilling,
however, it is imperative to remove the speaker
deck so as not to damage any components below.
All holes in this area not used must be sealed with
some type of water resistant caulking so that
components below are protected from the
elements. Re-install the speaker deck, then mount
the speaker and connect the leads to the terminal
block. Non "LP" speaker bells must be trimmed to
match the speaker cover contour.
Replace the cover.
Figure 1
Figure 2
3
(Dual Speaker Installation in 52" & 58 1/4" Light bars) Using the same procedure as above, install the speakers using the
mounting holes in Figure 2 (For a Code 3 "LP" speaker). When using the two speakers , follow the manufacturer's
instructions for correct phasing of speakers.
Hook-on Mounting
Begin the installation by attaching the rubber feet to the mounting brackets using the black 1/4" carriage bolts and 1/4" nuts
provided. See Figure 3 (Do not install shims at this time).
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. Locate the vehicle on a level surface.
Place the light bar 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 4. This is the
strongest part of the 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.
Figure 3
Figure 4
4
The shims provided may be used here to help level the light bar, see Figure 3. Also, the tabs on the mounting brackets may be
bent at any angle to match the curvature of the roof.
Select the appropriate length cap screw and insert through the holes in the gutter hook and mounting bracket, and into a
lockwasher and acorn nut as shown in Figure 3. If a special hook for a "gutterless" vehicle is used, refer to the instructions for
that hook at this time. The stainless steel cap screws supplied are sized for the most common installations, but longer and
shorter bolts are available at any hardware store.
Tighten the cap screws 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.
Re-Installation: When moving a light bar from one vehicle to another, we suggest that new rubber feet be used. These are
standard hardware items, and can usually be found at any hardware store, or can be ordered from the factory.
The special hooks are stainless steel and should be saved and reused. Mounting kit parts are available to permit remounting
on vehicles of different design or make. Consult your local dealer or Code 3, Inc. for detailed information.
Permanent Mounting
Typical Mounting: Refer to Figure 5. 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 6. 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 6).
Figure 5
5
Figure 6
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.
Wiring Instructions
!
WARNING!
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.
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 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.
The only significant difference between the MX 7000® with optional ArrowStik® and a conventional MX 7000, 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 heads 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 ALLATION - After inst allation 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.
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 to the control head or switch (as
directed by the wiring instructions on the cable). Next, calculate the light bar power draw. Table 1 consists of an equation
and data for quick calculating of light bar load. Run a power wire from the control head to the (+) or positive side of the
battery, the alternator, or to the stud on the battery side of the starter solenoid. Use Table 2 for reference.
Speaker Wires: If the light bar has a speaker
section, the blue wires go to the siren amplifier
and are to be connected in accordance with the
siren manufacturer's instructions. Test the unit for
proper operation. Caution - Operating a siren
with a live speaker can inflict hearing damage-always use hearing protection.
Table 2
RECOMMENDED SWITCH CONTROL MINIMUM WIRE SIZES
Based on 15-Foot Wire Run
Amp Draw Min. Wire Size
Below 8 #16 AWG
9-13 #14 AWG
14-21 #12 AWG
22-36 #10 AWG
37-56 #8 AWG
Table 1
Total Watts in Light bar Divided by 12 Volts Equals Amperage
Draw or: Watts / 12 Volts = Amp Draw
Bulb Type Location Wattage AmpDraw
1156 Stationary/ 28 2.33
S795 Standard Rotating 50 4.17
H-1 Rotating Lamps 55 4.58
H-5 High-Speed Rot. 100 8.33
194 D.O.T. Lamps 3 .25
211-2 ArrowStik
573 ArrowStik 25 2.08
Flashing Lights
Lamps
Alley Lights
Intersection Lights
Stationary/Flashing
Lights
Lamps
®
12 1
7
Options & Specifications
Many options are available for the MX 7000. This section is designed to describe the function of, and
maintenance for, the various MX 7000 options.
STINGRAYTM - The StingRay is a modified rotator which produces a patented three-mode signal that (1)
oscillates to the rear, (2) rotates conventionally, and (3) oscillates to the front. Lamp and reflector
maintenance is the same as for a typical rotating lamp.
INTERSECTION LIGHTS - A high intensity 120° oscillator, located in the lower outboard corner of the light
bar. Maintenance of these units is much the same as for a typical rotator. The lamps used here are the
bayonet type. Two mounting screws hold the assembly in place. Note: Never install a black worm gear
on the 120° Intersection Light.
PURSUIT LIGHTS - Same as intersections lights except sweep angle is only 70°.
ALLEY LIGHTS - Located in the lower section of the light bar at each end, to provide light to the side of
the vehicle. The lamps used are a bayonet type and the unit is held down with 2 #8 X 5/8" screws. (An
additional screw in a curved slot controls the aim of the alley light in light bars that do not incorporate an
ArrowStik. Simply loosen this screw, adjust the aim and tighten. (This screw does not need to be
loosened when the whole unit is removed.)
HIGH SPEED ROTATOR - A rotator that produces twice as many flashes as a conventional assembly.
The only significant difference between this unit and a normal assembly is that a faster motor is used.
Maintenance is the same as for a typical rotator.
STATIONARY LAMPS/TAKEDOWN LIGHTS - A stationary reflector assembly used for flashing,
takedown, and/or work light applications. These are located in the lower section of the light bar. Lamps in
these units are bayonet type and the units are mounted with two screws.
LED WARNING 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:
MX700™ 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.
8
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
!
WARNING!
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
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 MX7000® 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
9
Master/Slave Operation
Each 360 degree corner module consists of a "master" and a "slave" driver circuit board, 360 degree optics and LED light
engines along with a single integrated heatsink bracket.
The "master" circuit board (rear position) must always be powered for the "slave"(front position) to flash. The "master" is always
located in the rear position of the module. The lightbar is wired to allow running only the rear facing LED on each module by
removing power to the front facing "slave" module. This gives a "front-cutoff" function. The flash pattern for each corner pair
can be selected by shorting together the 2-pin header J1, on the "master" , momentarily and releasing. The module is set-up
for "Cycleflash" as a standard. Holding down the 2-pin header for 5 sec., or longer, and releasing will return the pattern to
Cycleflash. The following chart describes the available patterns and order;
360 Degree Module Flash Pattern - Table 3
See Figure 22
Flash Pattern Description
Cycle Flash Cycles through various patterns @ 70 fpm
Five Flash Five Pulses per flash @ 70 fpm
Quad Flash Four Pulses per flash @ 70 fpm
NFPA Four Pulses, 70% Duty Cycle @ 75 fpm
Triple Flash Three Pulses per flash @ 70 fpm
Quad Pop Flash Four Pulses per flash (3 equal, 1 extended) @ 70 fpm
Both heads will be in the mode selected. Both heads will flash together unless in Front Cut-off mode.
LED DIRECTIONAL MODULES
In addition to the 360 warning modules the lightbar may be equipped with a number of single head
directional warning LED modules. These modules are available in either the existing LED X™ ( 1" X 4" ) or the new Code 3®
OPTIX™ ( 1" X 6" ) and LC-LED directional modules in stationary and flashing versions ( see figure 8). The stationary versions
can be flashed by connecting the module(s) to any flasher that does not require ground through the load (example: Code 3®
700 series relay flasher). The flashing modules will have "Cycleflash" as the standard pattern. The OPTIX and LEDX flash
pattern can be changed by shorting the 2-pin header, J1 as shown in Figure 22, momentarily then releasing. Table 4 shows
the available patterns and the order when stepping through patterns. The module can be reset to "Cycleflash" by shorting the
header for greater than 5 sec. and releasing.
Operating Specifications for directional module:
Operating Voltage: 10-16 VDC, Reverse Polarity Protection
Current Draw : Flashing Module
Red/Amber - .25A avg @ 12.8 Volts
Blue/White - .4A avg @ 12.8 Volts
Steady Burn Module
Red/Amber - .5A avg @ 12.8 Volts
Blue/White - .8A avg @ 12.8 Volts
Available Colors - Red , Blue, Amber, and White
10
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